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C28 Manual 05.18.09 F English
C28 Manual 05.18.09 F English
Instruction Manual
IMPORTANT INFORMATION
Information in this document is subject to change without notice and does not represent a commitment on the part of
Cincinnati Test Systems, Inc. No part of the manual and/or software may be reproduced or transmitted in any form or
by any means, electronic or mechanical, including photocopying, recording, or information storage and retrieval
systems, for any purpose, other than the purchasers personal use, without the express permission of Cincinnati Test
Systems, Inc.
No patent liability is assumed with respect to the use of the information contained herein. While every precaution has
been taken in the preparation of this book, Cincinnati Test Systems, Inc. assumes no responsibility for errors or
omissions.
Because of the variety of uses for this equipment and because of the differences between this solid-state equipment and
electromechanical equipment, the user of and those responsible for applying this equipment must satisfy themselves as
to the acceptability of each application and use of the equipment. In no event will Cincinnati Test Systems be
responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
The illustrations, charts, and layout examples shown in this manual are intended solely to illustrate the text of this
manual. Because of the many variables and requirements associated with any particular installation, Cincinnati Test
Systems cannot assume responsibility or liability for actual use based upon the illustrative uses and applications.
!
CAUTION - When you see this warning symbol on the product, refer to the instruction manual for information before
proceeding.
CAUTION - To avoid personal injury due to electric shock, disconnect all power services before servicing.
If this instrument is not used according to the instructions of this manual, the protection provided by this equipment'
design may be compromised.
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION ...............................................................................1-1
QUICK START .....................................................................................................................1-1
INSTRUMENT FEATURES.................................................................................................1-4
UNPACKING ........................................................................................................................1-5
VERIFICATION OF PROPER INSTRUMENT SPECIFICATION ....................................1-6
INSTALLATION ..................................................................................................................1-7
MOUNTING CONSIDERATIONS ......................................................................................1-8
PLUMBING RECOMMENDATIONS ...............................................................................1-10
PNEUMATIC CONNECTIONS .........................................................................................1-11
ELECTRICAL CONNECTIONS ........................................................................................1-12
INPUT/OUTPUT TERMINAL TABLE .............................................................................1-16
ADDITIONAL ACCESSORIES .........................................................................................1-17
CHAPTER 2 INSTRUMENT OVERVIEW ...............................................................2-1
POWER ON ...........................................................................................................................2-1
OPERATOR DISPLAYS ......................................................................................................2-2
DISPLAY AND FUNCTION PANELS ................................................................................2-2
NAVIGATION KEYS ...........................................................................................................2-4
DISPLAY PANEL .................................................................................................................2-6
MONITOR .............................................................................................................................2-8
PART CONFIG ...................................................................................................................2-10
INSTR CONFIG ..................................................................................................................2-11
TEST DATA ........................................................................................................................2-12
SELF TEST ..........................................................................................................................2-12
HELP....................................................................................................................................2-13
FUNCTION PANEL ...........................................................................................................2-14
HOLD ..................................................................................................................................2-14
CHANGE PART ..................................................................................................................2-14
AUTO SETUP .....................................................................................................................2-14
AUTO CALIB .....................................................................................................................2-15
START .................................................................................................................................2-15
STOP ....................................................................................................................................2-15
CHAPTER 3 AUTO SETUP and AUTO CAL.........................................................3-1
TURN ON POWER ...............................................................................................................3-1
AUTO SETUP .......................................................................................................................3-2
AUTO CAL ...........................................................................................................................3-6
CHAPTER 4 INSTRUMENT CONFIGURATION AND COMMUNICATION............4-1
INSTRUMENT SETUP ROUTINE ......................................................................................4-1
MANIFOLD TYPE AND TRANSDUCER SELECT ..........................................................4-2
COMMUNICATIONS ..........................................................................................................4-4
SERIAL COMMUNICATION ..............................................................................................4-4
TCP/IP COMMUNICATIONS ...........................................................................................4-12
USB FLASH FIRMWARE UPDATE .................................................................................4-15
EMAIL COMMUNICATION .............................................................................................4-17
MISCELLANEOUS INSTRUMENT SETTINGS .............................................................4-18
VERSION ............................................................................................................................4-19
Rev 11/18/08
SECURITY ..........................................................................................................................4-19
CHAPTER 5 PART CONFIGURATION .................................................................5-1
REVIEW OR CHANGE PART TEST PARAMETERS.......................................................5-1
TEST TYPE ...........................................................................................................................5-3
TEST TIMERS ......................................................................................................................5-4
TEST PRESSURES ...............................................................................................................5-5
TEST PARAMETERS...........................................................................................................5-6
CALIBRATION PARAMETERS .........................................................................................5-9
MISCELLANEOUS ............................................................................................................5-10
COPY PART PROGRAMS ................................................................................... 5-11
AUTO RUN ........................................................................................................... 5-11
UNITS OF MEASUREMENT ............................................................................................5-12
DIGITAL INPUT AND OUTPUT CONFIGURATION ....................................................5-14
DIGITAL INPUT CONFIGURATION ...............................................................................5-15
PART PROGRAM LINKING ............................................................................... 5-17
DIGITAL OUTPUT CONFIGURATION ...........................................................................5-18
TIMING CHARTS ................................................................................................ 5-22
TOOLING CONFIGURATION ..........................................................................................5-23
CHAPTER 6 PRINCIPLES OF OPERATION .........................................................6-1
INSTRUMENT CONFIGURATIONS ..................................................................................6-1
PRESSURE DECAY TESTING ...........................................................................................6-1
CHAPTER 7 SELF TEST .......................................................................................7-1
VERIFY OR ADJUST PRESSURE TRANSDUCER CALIBRATION ..............................7-1
ADJUST MECHANICAL REGULATOR SETTING ..........................................................7-2
SELF TEST THE INSTRUMENT FOR LEAKS .................................................................7-4
CALIBRATION VERIFICATION (Open Leak Std) ............................................................7-6
CHAPTER 8 COMMUNICATIONS INTERFACE ...................................................8-1
COMMUNICATION SETUP AND EXECUTION ..............................................................8-1
SENDING INFORMATION ONE-WAY VIA COMMANDS THROUGH SENTINEL
C28 .........................................................................................................................................8-6
REQUESTING INFORMATION TO BE SENT USING TWO-WAY
COMMUNICATION .............................................................................................................8-6
CHAPTER 9 DOWNLOADED REPORTS ..............................................................9-1
INSTRUMENT CONFIGURATION ....................................................................................9-1
STATION CONFIGURATION.............................................................................................9-2
PRESSURE STREAMING ...................................................................................................9-2
TERMINAL TEST RESULTS OUTPUT AFTER EACH TEST .........................................9-5
FIXED WIDTH TEST RESULTS OUTPUT AFTER EACH TEST ....................................9-5
PART RESULTS ONLY AFTER EACH TEST ...................................................................9-6
FIRST 2 TEST RESULTS .....................................................................................................9-6
ALL RESULT INFORMATION ...........................................................................................9-7
STATION COUNTERS ........................................................................................................9-7
CHAPTER 10 TEST DATA .................................................................................... 10-1
COUNTER INFORMATION ..............................................................................................10-1
TEST RESULTS ..................................................................................................................10-2
STATISTICAL INFORMATION .......................................................................................10-3
Rev 11/18/08
CHAPTER 11 DIGITAL INPUTS AND OUTPUTS ................................................. 11-1
UNIVERSAL DIGITAL INPUT FUNCTIONS .................................................................11-1
PART PROGRAM SPECIFIC DIGITAL INPUTS ............................................................11-4
DIGITAL OUTPUT FUNCTIONS .....................................................................................11-6
CHAPTER 12 PREVENTIVE MAINTENANCE ...................................................... 12-1
PERIODIC MAINTENANCE .............................................................................................12-1
UPLOADING PROGRAM FIRMWARE ...........................................................................12-1
CALIBRATED LEAK STANDARD CERTIFICATION...................................................12-2
SPARE PARTS....................................................................................................................12-3
SERVICES ...........................................................................................................................12-4
CHAPTER 13 TEST MESSAGES .......................................................................... 13-1
CALIBRATION ROUTINE MESSAGES ..........................................................................13-1
SELF TEST MESSAGES ....................................................................................................13-2
TRANSDUCER ERRORS ..................................................................................................13-3
PART PROGRAM ERRORS ..............................................................................................13-3
PART PRESENCE ..............................................................................................................13-3
TOOLING ERRORS ...........................................................................................................13-4
TEST AND ERROR MESSAGES ......................................................................................13-5
CHAPTER 14 SPECIFICATIONS .......................................................................... 14-1
CHAPTER 15 OPTIMIZING THE TEST PERFORMANCE..................................... 15-1
CHAPTER 16 WARRANTY-SENTINEL INSTRUMENTS ...................................... 16-1
CHAPTER 17 GLOSSARY .................................................................................... 17-1
CHAPTER 18 INDEX ............................................................................................. 18-1
Rev 11/18/08
CHAPTER 1 INTRODUCTION
CHAPTER 1 INTRODUCTION
You made an excellent decision to buy this instrument! You now own the new Sentinel C28 high
performance, leak test instrument. This instrument incorporates the latest in high-resolution
analog-to-digital conversion, signal processing, Automatic Setup, 32-bit microprocessor
technology, Automatic Calibration, Quik fill-and-Test capability, easy-operator interface, and
comprehensive communication. The economics and compact packaging of these new instruments
make them ideal and affordable solutions to many assembly verification applications. The
convenient communication capabilities including TCP/IP (Ethernet) and RS232 make the
communication interface of these instruments into the factory information system easier with no
extra engineering time.
QUICK START
Step One:
Mount Instrument
Position the instrument above the part test fixture to minimize dirt and moisture
exhausting through the instrument.
Locate the instrument close to the test fixture to minimize test volume.
Mount the wall-mount instrument to framing or a panel using the four internal bolt
channels.(same bolt pattern as the Sentinel C-20 instrument). Allow sufficient clearance
to the enclosure for the supply connections and test ports and access to the inside for
maintenance.
Step Two:
Connect Supply Air (250-psig max for under 200 psi tests)
The air supply input connections are for test supply pressure (or vacuum) and pilot air
pressure. Connect an independent 65-110 psig supply to the pilot supply port.
Good leak tests and long instrument life depend on a clean, dry air supply. If you did not
purchase in-line air filters with your instrument, be sure to install 5.0 and 0.3-micron
filters at the input supply manifold. (See pages 1-10 and 1-11 for more information.)
Internal test regulators control the test pressure or vacuum, but it is also recommended to
regulate the air supply to the instrument at 10 psi greater than the highest test pressure for
optimal performance.
Step Three:
Power up Instrument
An electrical power cord is attached to the top, right side of the Sentinel C28 wall-
mounted enclosure.
Check the instrument label on the right side of the instrument to verify the Supply
Voltage for the instrument.
For 120 VAC, 50-60 Hz instruments plug the power cord into a standard 3-prong wall
socket (in the US and Canada). See pages 1-12 and 1-13 for more details.
For 220 VAC (50-60Hz) instruments this power cord has no three-prong plug on the end
so wire directly to power source using Line (black), neutral (white) and ground (green).
See page 11-12 for more details.
For 24VDC instruments this power cord has no three-prong plug on the end so wire
directly to power source using +V (white), V (black) and ground (green). See page 11-
13 for more details.
Operate the power switch on the top center of the wall-mounted enclosure to turn on the
Sentinel C28 instrument. (The power switch is a rocker style switch. The On and Off
markings on the power switch are marked as "I" and "O" respectively.)
Step Four:
Setup wiring via extension I/O cable from external I/O connector located on top of the enclosure
in the back left corner for 24 VDC or 120 VAC (50-60 Hz). Check the instrument label on the
right side of the instrument to verify the correct I/O Voltage. There is a resistor across the 24
VDC pins for 24 VDC I/O or a resistor across the 120 VAC pins for 120 VAC. Also there are
three capacitors on the circuit board above the output relays for 120VAC instruments. See Figure
150 for details.
Study the digital input and output requirements and assign to the available 6 inputs and 3
outputs. (See pages 1-14 through 1-16 for more details).
Step Five:
Auto Setup
Follow the operator prompted routine to set up the instrument to perform a basic leak test on the
test part. Auto Setup will automatically determine the best test sequence to meet the required
maximum cycle time for pressure decay leak rate tests only. Auto Setup does not function for
Pressure drop, Rate of change, or Occlusion tests. It does not establish the I/O functions.
Press AUTO SETUP on the Function panel
Press the EDIT key and use the up or down arrow keys to select the desired Test Type
to perform the desired test like 1P-Press Decay. Then press ENTER
Press the down arrow key, EDIT, and then enter the desired part number using the
up/down and left/right arrow keys for Apply to Part # (select part number 01-32).
Press ENTER and AUTO SETUP or right arrow to advance to the next screen.
Using the same method, edit the appropriate units of measurement for test pressure, leak
rate, pressure loss during test cycle, and timers. Press ENTER and AUTO SETUP or
right arrow key. (Take note of the differences for setting vacuum values when using psig
vs psiv pressure units see page 2-9.)
Edit the Desired Cycle Time (maximum total cycle time), Target Pressure (specified test
pressure), Leak Std Value (for leak standard mounted on test manifold), Leak Std
Pressure (Pressure at which leak standard was calibrated), Hi Lim Leak (high limit reject
point for test), and Cal method.
Edit Start AutoSetup for Yes and push ENTER.
Follow the instructions on the screen. The process will give you an opportunity to adjust
the manual regulator pressure to match the Target pressure by pressing ENTER to OK
this next step
Step Six:
Set Test Pressure
Connect the plug (Self Test Plug) attached to the chain on the bottom of the instrument
into the port on bottom right side. Adjust the regulator so the Instrument pressure
equals the desired Target test Pressure.
Step Seven:
Connect your test part
Use high quality tubing, swaged fittings, and the supplied Quick Connect fitting to
interconnect a Master (Non-leaking) part to the instrument.
Connect the Quick Connect fitting to Leak Test Port located on the bottom right side of
the wall mounted instrument.
Step Eight:
Proceed with the AutoSetup Routine:
The instrument will conduct an automatic tuning process on a master part for pressure
decay tests by performing a sequence of tests to determine the appropriate timer values
within the Desired Cycle Time.
The AUTO Setup will automatically set the optimal pre-fill, fill, stabilization, test,
exhaust, and relax times; Leak Std flow and pressure; and Target pressure and Min and
Max Test Pressure into the selected Part # to achieve the best possible test on the tested
part within the Desired Cycle Time.
At the completion of the Auto Setup routine the display will prompt for an Auto Calib
routine.
Step Nine:
AutoCal
The instrument will automatically determine the pressure loss to leak rate relationship for the test
part based on the timer values set by the Auto Setup routine.
Agree to perform the AUTO CALIB function.
At the completion of a successful Auto Cal routine, the instrument display will indicate a
calculated PF (Performance Factor). In general, values greater than 35 and up to 99
indicate an acceptable calibration for reasonably repeatable testing. What value results in
an acceptably repeatable test is very application dependent and does not apply to all parts.
Further testing is required to determine if these parameters will result in acceptable
repeatability. Higher values (which require longer Desired Cycle Time) will generally
predict more repeatable performance.
The instrument is ready for testing upon completion of AUTO CALIB routine.
Setup within Part Configuration any additional test parameters like Tooling Control,
Digital Input functions, and Digital Output functions.
INSTRUMENT FEATURES
Test status lights (In Test, accept, reject)
480 x 272 pixel graphic display
Display panel Power on-off switch
Functions panel
Source
air/vacuum and
pilot air ports
Exhaust muffler
Regulator adjustment knob Test port quick connect fittings RS232 port (9 pin)
UNPACKING
Carefully remove the instrument from the shipping carton. Locate the quick connect fitting
supplied with the instrument. The fitting is provided for your test line connection. Open the
instrument and inspect for damage before progressing any further. Make certain that all cables
are securely attached to the appropriate connectors.
Before installing the instrument verify that the instrument supplied matches the application
specification. On the right side of the wall-mounted enclosure is an identification label with
the catalog number of the instrument. Below is a breakdown of the catalog number.
Enclosure Construction
(i.e. 1 W 3 B E)
Pneumatic Connection
(1) NPTF
Instrument Mounting Option
(W) Wall
Power supply
(1) 120 VAC (2) 24 VDC (3) 240 VAC
Digital I/O
(A) Six Inputs/Three Outputs 120 VAC
(B) Six Inputs/Three Outputs 24 VDC
Keypad Language
(C) Chinese
(E) English
INSTALLATION
The Sentinel C28 leak test instrument is a modular, flexible instrument designed to operate in a
factory environment or in a clean room. To operate trouble-free, it requires:
Because this is a precision instrument, it is preferable to locate this instrument at least 15 feet
away from high electromagnetic energy devices (induction heat treat equipment and welders)
whenever possible. In addition, plants having poor quality electrical power or ground systems
should consider using isolation transformers on the power drops.
In addition, the wiring for the digital inputs and outputs must be isolated and protected from
electrical noise.
MOUNTING CONSIDERATIONS
The Sentinel C28 instruments provide the best test results when located as close as possible to the
test parts. This will minimize the volume in the test pneumatics thereby reducing the total test
time requirements. Mount the Sentinel instrument above the test part to minimize the amount of
dirt and moisture that might migrate back into the instrument during the exhaust cycle.
Mount the wall-mounted, Nema 12 enclosure to a frame or panel. Insert the mounting bolts
through the four channels located on each interior corner of the enclosure. The bolt pattern for
the Sentinel C-28 enclosure matches the mounting bolt pattern of the Sentinel C-20 enclosure.
Select a mounting location that gives access to the bottom, top, left, and front of the enclosure.
Do not forget to allow room for the door swing. See Figures 5 for the mounting dimensions for
the unit supplied.
Test Port
Left Side View Test Port Fitting
Self Test Cap
and Holder Allow 4 (102 mm) clearance
for installation of test line and
7.087 (180.1mm) hand clearance
Mechanical
Bottom view Regulator Knob
Rear View for Mounting Dimensions
PLUMBING RECOMMENDATIONS
This leak test instrument needs clean, dry air in order to provide trouble-free operation. Good
plumbing practices will greatly enhance the quality of the test air.
Regulate the air supply for the test pressure circuits to at least 10 psi greater than the maximum
test pressure at all times while testing. For optimal test results, install an external regulator to
maintain a steady 10 psi greater pressure to the instrument.
For vacuum tests, connect a vacuum source to one of the inlet ports located on the left side of the
enclosure identified for vacuum. The vacuum source must be greater than the vacuum required
for the leak test.
A separate air supply to the pilot port must be between 65 to 110 psig at all times for the
instrument to operate properly.
Sentinel C28
Test Pressure/
Vacuum
Pilot
5.0 Micron 0.3 Micron Pressure
Coalescing Coalescing 65 psi
Shutoff
Filter Filter
Valve
Drip
Leg
Automatic
Drain SENTINEL-FILTER SET-SMALL
SENTINEL-FILTER SET-MEDIUM
SENTINEL-FILTER SET-LARGE
(Small<300cc Part, Large>3000 cc Part
PNEUMATIC CONNECTIONS
There is one test air (vacuum) supply inlet port (S1) and one pilot-air inlet port on the left side of
the Sentinel C28 enclosure. The supply inlet port is 1/4" FNPT and the pilot-air port is 1/8"
FNPT. After mounting or locating the instrument, connect the inlet air or vacuum supply to the
inlet port shown in Figure 7. To reduce future maintenance requirements use the recommended
plumbing detailed in Figure 6 Plant Plumbing Recommendations and utilize the 0.3 and 5.0-
micron coalescing filters. Be certain to replace the filter elements at least quarterly as preventive
maintenance.
The pneumatic test manifold connects to the exhaust manifold internally according on the
pressure/vacuum requirements. The pilot air uses 1/8" yellow tubing. The pressure supply line is
1/4" or 3/8" green tubing. Vacuum supply line is 1/4" or 3/8" green tubing. Exhaust line is 1/4"
or 3/8" clear tubing. Internal tubing between the test station regulator and the manifold
connection is either 1/4" or 3/8" red tubing. 3/8" tubing is used for the supply interconnection
and exhaust connection for the high flow manifold.
Supply Connections
Pilot
Supply port 1
Exhaust muffler
Exhaust air
Figure 8 View of air (vacuum) supply and exhaust pneumatic connections for Sentinel C28
instrument located on the left inside of the enclosure
Located out the bottom of the enclosure is the quick-connect test port fitting. Use flexible tubing
to connect to the mating male quick connect fitting (supplied with the instrument) via the 1/4"
NPT connection. Use enough flexible tubing to allow easy connect and disconnect action on the
test port. It is recommended to use Parker 1/4" or 1/8" 2000 lbs tubing with Parker CPI or
Swagelok fittings to provide rugged flexibility and eliminate any volumetric change within the
tubing during test. Properly tighten these fittings to assure leak-free connections. Typical push-
lock fittings are not appropriate for test lines because they can leak. They are acceptable
for use on the supply side of the test manifold only.
The quick connect SELF TEST plug attached to the bottom of the enclosure is supplied so the
operator can manually disconnect the test line and easily attach the quick connect plug for the
SELF TEST function. The SELF TEST function is a standard feature to make it easy to verify
the instrument's internal leak integrity.
Do not tighten the female quick connect fitting into the pneumatic block. Tightening
the fitting may crack the pneumatic block and void the warranty.
Regulator knob
Test port
ELECTRICAL CONNECTIONS
WARNING: DISCONNECT POWER BEFORE OPENING ENCLOSURE TO WORK
ON ELECTRONICS.
The electrical supply connections for 120 VAC or 240 VAC (50-60 HZ) or 24 VDC are made
through a pre-wired electrical cable supplied with each instrument. The AC Line (black) or DC
V+(white) wire is terminated to the power switch. The AC Neutral (white) or DC V- (black)
wire is terminated to the power supply terminal or power terminal of circuit board. The ground
wire (green) is terminated to the grounding stud located in the upper left corner of the enclosure.
The separately powered digital input/outputs are pre-wired to a connector on the top of the
instrument enclosure. The external supplied 120 VAC or 24 VDC power for the inputs and
outputs are wired to ION (neutral or common) and IOH (hot) on the ST1 terminal of the main
circuit board. For the 120 VAC digital I/O circuit board, there are three red mobs located to the
right of the I/O fuse. See Figure 10 below. For the 24 VDC digital I/O circuit board, there are no
mobs in this position.
Figure 10 Power input 24VDC, digital input/output, and test valve terminals
Figure 11 120/220 VAC to 24VDC Power supply (AC powered instruments only)
There is a connector for the digital input/outputs and a power cord for the source power on the top
of the enclosure. The power On/Off switch is located in the center back on the top of the
enclosure.
Access hole
Figure 12 Power supply cable, power switch, digital I/O connector and access hole
The input/output interface wiring connections for the Sentinel C28 are made via the connector on
the top of the instrument enclosure. This connector includes 6 inputs, 3 outputs, voltage source,
and common. An optional I/O cable interfaces this connector to the input/output devices and I/O
power supply. Before wiring this input and output cable, define and layout all the inputs and
outputs required by all the tests planned for this instrument. Make sure that there are sufficient
inputs (6) and outputs (3) for the test requirements. See definitions for the inputs and outputs in
Chapter 5, Part Configuration and Chapter 11, Digital Inputs and Outputs. The power supply for
the Inputs and Outputs is independent of the instrument power. A separate 120 VAC or 24
VDC supply needs to be wired to the I/O interface cable for the inputs and outputs. Check
the instrument label on the right side of the instrument to verify the voltage for the digital
I/O and instrument supply power. Also check the controller board to verify the presence
(for 120 VAC I/O) or absence (24 VDC I/O) for three red mobs (see Figure 10 above).
The available input functions are listed below. Review the list and check the inputs
required. Make sure that only 6 inputs are checked.
The available output functions are listed below. Review the list and check the outputs
required. Make sure that only 3 outputs are checked.
Outputs (ST3)
Pin1 OT1 Tan------------------Pin U---- -------Pin U--------------Tan
Pin 2 OT2 Green---------------Pin J----- --------Pin J---------------Green
Pin 3 OT3 Brown--------------Pin A---- -------Pin A--------------Brown
The input and output terminals on the circuit board are pre-wired to the I/O connector mounted on
the top of the enclosure in the back right corner. See Figure 14 for pin designations for the 6
inputs, 3 outputs, common, and power. Use the diagram to wire the required inputs and outputs.
Note the terminal numbers and functions for each input and output. The use of these inputs and
outputs are programmed within each part program. This gives excellent flexibility to the use of
this instrument for a variety of applications. Within the Part Config menus (Tooling, Inputs, and
Outputs) individually select the functions of the pre-wired inputs and outputs required by each
part program. The inputs and outputs apply to either all or selected part programs based on their
functionality and how each part is programmed. See the setup procedure of the input and output
terminals in the Chapter 5, Part Configuration section, Inputs, Outputs, and Tooling screens. The
programming of the input and output functions in the Part Configuration menu must match the
wiring connections of the installation. For additional information about interfacing to remote
devices and/or a PLC, please refer to Chapter 5 and Chapter 11.
Refer to Part Configuration (see pages 5-14 to 5-23), digital input and output screens, to assign
the use of the input and output functions per the wiring terminations to the individual part
programs. Record the wiring of each terminal for reference when programming the inputs and
outputs in the Part Configuration section discussed in Chapter 5.
Terminal Inputs terminals There are six inputs and three outputs wired
to the multi-pin connector mounted on the top
1 ______________________________________
of the instrument. These I/O terminals are
2 ______________________________________
specified as either 24VDC or 120 VAC. On
3 _______________________________________
the lower right corner of the circuit board, a
4 resistor is soldered on either the 24 VDC or
_______________________________________
5 120 VAC pins. This defines the voltage of
_______________________________________
the source for the I/O. Refer to Part
6 _______________________________________
Configuration (Chapter 5) for the setup of the
input and output terminals. The power
Output terminals supply for the Inputs and Outputs is
1 independent of the instrument power.
_______________________________________
2 Wire a separate 120 VAC or 24 VDC
_______________________________________
supply via the power and common leads of
3 _______________________________________
the I/O connector.
Log the wiring for inputs and outputs for use during PART CONFIGURATION, Chapter
5, page 5-14 and 5-23.
ADDITIONAL ACCESSORIES
Helpful accessories that are available to provide additional capabilities to the instrument include:
Pressure/vacuum gage
(calibrate or check
pressure readings)
POWER ON
After mounting the instrument, assuring proper electrical connections, and checking the air and/or
vacuum connections, you are ready to power up the instrument. The on-off switch is located on
the top of the instrument in the front center for the wall-mounted enclosure.
After the Sentinel C28 instrument completes its internal checks and displays the Power-on screen
for about 3 seconds, the display advances to the Monitor screen. The contents of the Monitor
screen vary depending upon the configuration of the Sentinel instrument. The following display
is representative:
From the initial Monitor screen, view other screens by using the keys on the display panel.
For more information about setting up the Sentinel system, see CHAPTER 4, INSTRUMENT
CONFIGURATION, and CHAPTER 5, PART CONFIGURATION.
OPERATOR DISPLAYS
The Sentinel C28 Control Panel accesses the features of the firmware. For an example of a
typical test result display, see Figure 17 below.
The Sentinel C28 user selects the information to display or functions to perform by pressing one
of the keys in the Display or Function panels located below the LCD Display.
Indicator
Settable
of screen
parameters
with arrow
position
indicating within
selected function
variable.
Indicator of
position
Potential system within
error messages available
Current active variables of
Open Leak Security lock part program current
Std Symbol or unlocked active
screen(s)
Figure 19 Typical display format
Editing Keys
NAVIGATION KEYS
UP and DOWN arrow buttons move the display pointer up or down the screen to select a new
parameter for change. When in the edit mode, these keys scroll through available Yes or No
choices or option selections. When in the edit mode for a numeric character string like a timer,
pressure, or leak value, the up and down arrow keys sequence through the numeric character
library for each character.
1234567890
For an alphanumeric character string like a part name, email address, or instrument name, the
up and down arrow keys sequence through the alphanumeric character library for each character.
After a momentary delay between keystrokes the curser automatically advances to the right for
the next new character in the numeric or alphanumeric variable being entered.
The Left and Right arrow buttons advance the selection of the functions within one of the
Display or Functions menus. When editing an alphanumeric display, these keys move the
position curser left or right within the line of characters being edited. Also when in the edit
mode, these keys scroll through available Yes or No choices or option selections.
EDIT
EDIT selects the information line indicated by the pointer on the display for change. After
pushing EDIT, the UP / DOWN and LEFT/RIGHT keys are used to choose new variables. Push
Edit key after making changes to save the highlighted variables and move down to the next row
where there are additional items to change or select.
(Pushing EDIT may initiate the password display if security is set and the value is editable.
Enter the correct password using the Up/Down and Left/Right keys and then push ENTER..)
ENTER
ENTER key stores the changes made to test parameters, Yes or No toggled choices, or
programmed choices into memory and escapes the edit mode. In order to leave a Display
screen and store the parameters as they appear on the screen, you must push ENTER.
You cannot escape a screen to another display function while in the edit mode.
EXIT
EXIT returns the highlighted line back to its original setting and escapes the edit mode. If
changes were made on the highlighted line, those changes are lost.
Moving from one display function to another and changing values or settings.
To sequence through the displays of information within each area, push the desired Display panel
key repeatedly. To change a parameter, push the EDIT key until the pointer is next to the item to
change. After making the change push EDIT to save the new information and advance to another
parameter on that screen or advance to the next screen within the function set. Push ENTER to
store the changed data on the edited line and exit the edit mode. The EXIT button will return the
edited line back to its original value and exit the edit mode. Push the Display panel key or left or
right arrow keys to go back or forward through the variable screens indicated on the top row of
the screen. If these keys are pushed while in the Edit mode, the instrument will not advance to
the next screen until Enter or Exit is pushed. If it does change screens, changes to the highlighted
line will not be saved.
To review parameters in another "Display" function, simply press the key for the display function
with the desired parameter. You must be out of the Edit mode to change Display screens. If in
the edit mode when the Display key is pushed, the highlighted line will return back to its original
setting and the instrument exits the edit mode. The Display key will need to be pushed again. To
exit any display function, push the MONITOR key.
All functions or parameters for Part Configuration, Monitor, and Test Data are specific to the
selected part program. The selected part program number appears in the lower right corner of
each screen.
DISPLAY PANEL
The DISPLAY Panel is laid out to give the operator convenient access to review or change the
test information stored in the instrument or verify instrument performance. (Access to change the
stored information can be protected by a security password.) The selection of what information is
to be protected by password is programmed within the INSTR CONFIG function, security.
The instruments test manifold, transducers, and regulators are setup for general
operation at Cincinnati Test Systems before shipment. To change the setup, refer to the
appropriate chapters:
MONITOR
MONITOR key displays the active status of the part test or test results and the functioning of the
digital inputs and outputs.
The monitor displays the following information during test and upon completion of test:
Part Name and part program number
Bar graph of pressure or pressure loss verses limits
Test sequence
Remaining test sequence time
Test pressure during fill and stabilization sequences
Test Pressure and Pressure Loss or Rate of loss values during test cycle
Calculated leak rate or rate of loss after test
Corrected Pressure loss after test
Pass/Fail test result and test type for each test
Accept/Reject part result at the completion of tests
Vacuum pressure settings and values are entered and displayed as positive vacuum pressure
values (psiv) or negative pressure values (psig) measured from atmospheric pressure. Therefore,
2.0 psiv or 2.0 psig represents a vacuum setting of 12.7 psia (Atmospheric pressure is 14.7 psi
absolute so 14.7 psia minus 2.0 psiv is 12.7 psia). The bar display shown in Figure 23 Monitor
display will extend to the right as vacuum is applied to the part. If the part under test has a leak
or loses vacuum, the bar graph will retreat to the left.
Positive pressure tests (psig) will be displayed similarly. The bar display shown in Figure 23,
will extend to the right as the test pressure increases. If the part under test has a leak or losses
pressure, the bar graph will retreat to the left.
Both pressure and vacuum tests will display positive numbers for loss when the pressure units
during test are set for psig and the vacuum test units are set for psiv.
The bar graph displays the actual pressure (or vacuum) during the fill and stabilization cycle
verses the Min and Max pressure limits. This gives a quick visual indication of how the charge
and stabilization cycles are performing verses the pressure limits.
Min Max
During the test segment, the bar graph displays the pressure loss or pressure loss/time verses the
Lo Lim and Hi Lim set points. The Lo Lim set point is on the right side and the Hi Lim is on
the left side. This arrangement applies to pressure decay, Pressure loss, or Pressure loss/time
tests. For Occlusion tests, the Low Limit Pressure is also displayed on the right and High Limit
Pressure on the left. For Occlusion tests Low Limit Pressure represents low back pressure or
the high flow limit and the High Limit Pressure represents high back pressure or the low flow
limit. The test evaluation setting is always set as FPF as indicated below. Only the results
between the high and low limits are accepted or passed.
Hi Lim Lo Lim
F P F
View the Digital Inputs by pressing the MONITOR key twice. Pressing the Monitor key again
will access the Digital Output screen.
Digital Input, Monitor screen is a typical display for the Digital Inputs and Digital Outputs.
The available 6 inputs or 3 outputs are displayed with terminal numbers only. The plus sign (+)
appears to the left of the terminal number when that digital output is activated or an input signal
goes high. These displays make it easy to view the function of the instrument for troubleshooting
purposes. When interfacing the instrument with a PLC or tooling control, the instrument can step
through the test sequence using the HOLD button to interrupt the sequence at various stages of
the test to verify that the digital inputs and outputs are activating appropriately.
PART CONFIG
PART CONFIG key accesses the following information on the selected part program:
Test type select from available test methods.
Timers set and review timers for test cycle
Pressure values set and review target pressure setting
Test Parameters set and review leak test and leak standard specifications
Part test calibration parameters review part calibration parameters
Miscellaneous functions set/ review part name, AutoCal method, and Auto Run feature
Units of measurement set/review measurement units of time, pressure, and leak rate for
part testing
Digital Input/Output terminal configuration set/review inputs and outputs used by part
program
Tooling Control set/review how tooling control operates for testing
INSTR CONFIG
INSTR CONFIG key provides access to instrument setup and communication functions.
USB Flash Update request firmware update with flash (thumb) drive
Miscellaneous set instrument name and review serial number, set and review instrument
time and date settings
Security set and review security configuration
Screen Saver setup set and review method for screen saver
Firmware version documentation review instrument firmware versions
TEST DATA
See Chapter 10, TEST DATA, for the details about the Test Data information.
SELF TEST
HELP
HELP key displays definitions of the parameters on the screen. Push the HELP key while in
PART CONFIG, INST CONFIG, TEST DATA, SELF TEST, and AUTO SETUP screens to get
an explanation of the variables.
The following is a representative example of a Help screen. In this case, the INSTR CONFIG
key was pressed and then the HELP key. If more information is available, use the down arrow to
scroll down to the remaining information on the next screen. Press the EXIT or HELP key to
escape the Help screen.
HELP
Manifold Type: Defines the hardware
pneumatic configurations and valve
arrangements installed within the
instrument.
6
Figure
P01
30 Help screen for Instrument Configuration
FUNCTION PANEL
HOLD
HOLD function manually pauses the test sequence at any step of the test process. Pressing the
key will pause the test sequence. Pressing the key again allows the test sequencing to continue.
(This function can be activated by a digital input.)
CHANGE PART
CHANGE PART key selects a stored part test program from the 32 available while in the
Monitor, Instrument Configuration, Part Configuration, and Test Data displays. There are several
ways to select the desired part program.
1. Push and hold Change Part key until prompt appears. Use up or down arrow keys to
sequence the ones digit and the left and right arrow keys to sequence the tens digit to the
desired part number and then push ENTER key.
2. Push the Change Part key repeatedly to sequence through the defined number of part
programs stored and available for selection (max 32).
Binary digital inputs or any of the communication options like RS232 or TCP/IP can also be used
to select the active part program.
AUTO SETUP
Auto Setup is a unique, fast, and easy way to perform the initial setup of a part program for a
new test part. Before using the Part Configuration menus, configure a new program using Auto
Setup. This routine will prompt the operator to input the very basic information needed to
initialize a part program (Test type, part number, desired cycle time, test pressure, reject rate, leak
standard flow rate and calibration pressure, and units of measurement). After prompting the
operator to manually set the mechanical regulator to the Target pressure, this setup routine will
start sequential tests to automatically determine the optimal timers to test the part within the
desired cycle time. At the completion of these tests the instrument sets up the specified part
number with the optimized test parameters (pre-fill, fill, stabilization, test, exhaust and relax
timers; min, max, and target test pressures; and hi lim, lo lim and leak standard values) that
provide the best possible test results within the desired cycle time limit. It then prompts for the
Auto Calib routine described briefly below. The Auto Setup routine is available for direct
pressure decay test types only. See Chapter 3 for details about the Auto Setup routine.
AUTO CALIB
AUTO CALIB automatically sequences through a calibration routine to establish the accept
and reject pressure (vacuum) loss values for the established part parameters. The tests are
conducted using a master test part in conjunction with the integral calibrated leak standard(s)
supplied in the instrument pneumatics or an external leak standard. (This function can be
activated by a digital input.)
START
START initiates a test sequence. (This function can be activated by a digital input.)
STOP
STOP interrupts the test sequence and resets for a new test. (This function can be activated by a
digital input.)
TURN ON POWER
Use the power switch located on the top to turn on the power to the instrument.
The instrument software goes through a startup procedure that checks the RAM memory,
input/output modules, operator display, transducer zero, and calibration status. During this time
the Sentinel C28 initialization screen appears.
When the Sentinel C28 system completes its self-check, it displays the Monitor screen.
After verifying the instruments proper configuration with the correct pneumatic manifold as
described on pages 1-6 through 1-7, check the Hardware configuration for the instrument by
pushing the INSTR CONFIG key.
The letters in the Test-Manifold Type (i.e. PA in the above example) should match the Pneumatic
Manifold code letters in the catalog number shown on page 1-6. Also check the Transducer Type
to assure that it matches the pressure transducer mounted on the manifold. If all agrees, exit the
Instrument Configuration screen.
AUTO SETUP
The easiest way to setup an instrument without considering digital input and output interface with
external devices is by using the Auto Setup routine. Auto Setup will only function for a single
test sequence of direct pressure decay. The Auto Setup routine resets the Input and Output
functions for a part program to the default. Therefore, Auto Setup must be performed with the
part manually sealed. After completing the Auto Setup routine, configure the instrument for
interface to external inputs and outputs reviewed in Chapter 5, Inputs and Outputs.
The Auto Setup routine is a unique process developed by Cincinnati Test Systems for the Sentinel
C28 instrument that makes the initial setup of the instrument to a new test part quick, easy and
efficient. The process will determine the best time sequence to test a part within the limits of a
desired maximum cycle time. If the desired maximum cycle time is set too short, the final test
will not produce repeatable results. Any leak test needs a certain amount of cycle time to achieve
sufficient resolution and repeatability that are dependent on the part volume, leak rate, test
pressure, and part characteristics. The Auto Setup routine will set the best possible test cycle
within the maximum cycle time specified for the test.
The Auto Setup routine is not functional for Pressure Loss (Drop), Pressure loss/time, or
Occlusion tests.
Press the EDIT button and use the UP and DOWN arrow keys to edit the Test Type to the
desired method for testing the new part. The available test types are limited by the pneumatic
manifold supplied. Next press the EDIT key to save the Test Type selection and move down to
assign the new part program number (01 to 99) and press ENTER. Push the Auto Setup or right
arrow key to advance to the Units screen.
Review and edit (using the EDIT, up and down arrows, and ENTER keys) the desired units of
measurement for test pressure, leak rate units, time, and pressure loss. Push the Auto Setup or
right arrow key to advance to the Test screen.
Enter the basic test information shown on the screen to setup the test.
Description
Desired This is the total desired time to complete the test on the part excluding tooling
Cycle Time motion. The Auto Setup will determine the best possible sequence of testing
within this maximum cycle time. But this optimized setup can not produce
acceptable resolution and repeatability if the total time is too short for the part
volume, leak rate, test pressure, and part construction. Utilize all the available
time in the manufacturing process to conduct this test. When acceptable
results are achieved, you may be able to repeat the process and reduce the total
cycle time.
Target This is the specified test pressure for the part. Auto Setup will preset the Min
Pressure pressure at 80% and Max pressure at 120%.
Leak Std This is leak rate value on the calibrated leak standard mounted on the
Value* pneumatic manifold or alternative standard used.
Leak Std This is the pressure value on the calibrated leak standard where it was
Pressure* calibrated.
High Limit This is the specified leak rate for the part. Auto Setup will preset the Low
Leak Limit Leak at 20% of the High Limit Leak. It will also set the Test
Evaluation to FPF. FPF means Fail > Hi Lim > Pass > Lo Lim > Fail.
These values and settings can be changed after completing the Auto Setup and
Auto Cal processes.
Cal This defines whether one or two parts are used in the calibration procedure. It
Method also specifies if the Leak Standard is located internally on the manifold where
the Calibration Valve will automatically activate in the calibration procedure
or located externally where it will be added to the process by the operator or
system control.
Start This starts the Auto Setup procedure
AutoSetup
*The Auto Setup routine will calculate an estimated flow value for the leak standard to
represent its flow at the Target Pressure if it is different than the Leak Std Pressure. For
optimal accuracy it is preferable to use a leak standard with a leak rate that is close to
the reject or high limit rate calibrated at the target pressure.
The first step is to set the mechanical regulator. Push ENTER key to confirm the interest to
No OK CANCEL OK
Figure 39 Auto Setup screens to adjust regulator and insert self test cap
Follow the screen instructions and replace the test line connection with the Self Test cap in the
test port and push the ENTER key. The instrument will display the current mechanical regulator
setting. Adjust the regulator so that the Instrument Pressure equals the Target Pressure for the
test.
After setting the regulator, remove the self test cap and reconnect the test line and master part to
the test port. After acknowledging that the test line is connected by pushing the ENTER key in
the test line connected screen, the Auto Setup routine continues with a sequence of tests on a
master part to determine the optimal settings for pre-fill, fill, stabilization, test, exhaust, and relax
within the time constraint of the Desired Max Cycle Time. These tests include adding the
internal calibrated leak standard to one of the tests. At the completion of the testing cycles, the
optimized calculation screen below appears.
To accept the optimized cycle values, push ENTER key. These new values will overwrite any
timer, pressure, and leak rate values previously stored for the selected part program number. To
overwrite the old values, push the ENTER key again. This completes the Auto Setup routine.
YES NO
To finalize the setup of the part program to test parts, an Auto Calibration is required. Push the
ENTER key to confirm the initiation of the Auto Cal routine.
The Auto Setup routine enters the following parameters (depending on the Test Type selected) in
the target part program. Preview these parameters in the Part Configuration routine.
Figure 43 Values set by Auto Setup routine into the designated part program
AUTO CAL
The Sentinel C28 instrument has a unique calibration procedure that simplifies calibration and
assures greater accuracy. Access this routine by one of three ways:
As the default procedure Auto Cal uses the Standard Leak mounted on the internal pneumatics as
a known leak to determine the leak rate to pressure loss relationship for the test. This procedure
tests a master (no leak) part in the test fixture using the timers and pressures established for the
part program. The timers are set by one of several ways:
The procedure automatically tests the master (non-leaking) part twice with the Relax timer delay
between tests. Within each part program Auto Cal can be configured to use one of four methods:
START CANCEL
After loading the master no-leak part into the fixture and connecting the test part to the
instrument, push the START key to initiate the test procedure.
The system will make an initial test of the Master (no-leak) part to measure the pressure loss
associated with a non-leaking part. This should represent the typical offset associated with testing
parts within the environment of the test system. The pressure loss value is saved as the Master
Part Loss.
The system will conduct a second test on a Master part with a known calibrated leak standard
included in the test.
dPmeas and Fmeas represent the measured pressure loss during each test. Leak Rate represents the
calculated test result displayed after each test.
Upon the successful completion of the Auto Calib routine, the display will show the calculated
Performance Factor for the calibration. The performance factor is an estimate of the quality of
the calibration. It combines the ratio of the Hi Lim result to the Master part result, the test
pressure, and difference between the Hi Lim result and the Master part result to scale its
anticipated performance. This value ranges from 0 to 99. It is generally desirable to have a
Performance Factor of 35 to 99. The actual acceptable Performance Factor can vary depending
on the desired Gage R&R performance of the test. Generally, longer timers will produce higher
Performance Factors. If the Performance Factor value is low, go back to Auto Setup and increase
the Desired Max Cycle time or go into Part Configuration and increase the timers for the test
(review Chapters 5).
Several conditions must be met during the Auto Calibration procedure for the instrument to
accept and store the calibration results. If the procedure does not meet these conditions, error
messages are displayed at the completion of tests.
If the Auto Cal routine is successfully completed, Auto-Cal Passed will be displayed.
Master Part Loss > Master +Leak Loss Test of Master Part with Leak Std included was
less than the Master Part. This generally
indicates that the part pressure is not stabilized
enough therefore requiring longer stabilization
time and there is not enough test time to create
a difference between accept and reject parts.
Also the relax timer should be longer.
Master + Leak Loss > Max Master +Leak One of the tests during Auto Cal had greater
Loss losses than the preset Max Master + Leak Loss
{This value is set by the operator}. This means
that there is leakage in the Master part or
fixture that is unacceptable, the Leak Std
Isolation valve did not open, or the Leak
Standard is clogged.
Performance Factor < Min Perf Factor Calculated Performance Factor is less than
preset Min Performance Factor {this value is
set by operator} indicating insufficient times in
Test and other timers or clogged leak standard.
The INSTR CONFIG key on the Display panel accesses the setup and operation of the universal
instrument functions. The universal instrument operations include Hardware and Firmware
Identification, Communication, Instrument Identification, and Security. The basic
configuration functions are:
Instrument Configuration functions are reviewable at any time. The hardware parameters
within Instrument Configuration are not editable while the instrument is testing.
Push INST CONFIG to advance to the next screen within a tab or the next tab indicated
across the top of the INST CONFIG screen.
Also use the right and left arrow keys to advance or retreat through the INST CONFIG
tabs identified across the top of the INST CONFIG screen.
Push MONITOR, PART CONFIG, TEST DATA, or any other key to escape INSTR
CONFIG.
You must exit the edit mode before switching to any other instrument function. Pressing
any Display or Function key while in the edit mode will not escape at edit mode. The
Exit or Enter key must be pushed first.
Push the HELP key while on any screen (not in Edit mode) to receive a brief
description of each variable. You must EXIT the edit mode to view the Help displays.
The stored instrument configuration settings are programmable remotely via RS232 or
TCP/IP by entering software access code commands via an internet connection.
Press the INSTR CONFIG key to see the INSTRUMENT SETUP Hardware items like Manifold
Types, Transducer Type and Regulator Type.
Figure 47 Hardware configuration screen for the manifold, transducer and regulator
Manifold Type
There are three manifold configurations available for the Sentinel C28 instrument. The
instrument will be configured for the manifold supplied at shipment. The available manifolds are
listed in Figure 48 on page 4-3. This Manifold Type is factory set and not editable in the field.
Number of Parts The Sentinel C28 can store up to 32 unique part programs. When using a
limited number of programs, the number of available programs can be limited by editing the
Number of Parts to the number of active programs. This limits the part programs available for
selection via the keypad or via remote selection. You can select a part program in a number of
ways.
Binary input
- Set up required number of digital inputs to select the part program numbers.
One input (part program 1)
Two inputs (up to 3 programs)
Three inputs (up to 7 programs)
Four inputs (up to 15 programs)
Five inputs (up to 31 programs)
Manifold Type
The configurations of the available manifolds for flow capacity, transducers, regulators, leak
standards, extra test features and available test types are listed below.
The selection of Test Types (shown in Figure 48) is set within each part program using Part
Configuration or Auto Setup.
There are several different transducers available in the Sentinel C28 instrument
depending on the manifold defined above. The instrument will be configured for the
transducer supplied at shipment. The transducers available are:
The Sentinel C28 offers several choices for regulators depending on the options supplied. The
mechanical regulators are precision, relieving vacuum or pressure regulators selected with a range
that exceeds the maximum pressure range of the pressure transducer. It is not necessary to
program the range of the mechanical regulators because the operator manually adjusts them. The
Hardware set up for the regulator provides the following options. Check to assure that this setting
matches the equipment supplied.
COMMUNICATIONS
SERIAL COMMUNICATION
The Sentinel C28 instrument has one port for serial communication located on the front OF THE
operator panel (external D connector).
Press the INSTR CONFIG key to see the INSTRUMENT SETUP Serial Communications
screens
The Sentinel C28 has one RS232 port. Port 1 is the nine-pin D connector located on the front
panel below the Display keypad. See Figure 52 below. This terminal needs an RS232 null cable
(crossover cable with the two send and receive wires crossed over) for direct connection to a
laptop or PDA.
RS232 connector
The RS232 Port Config parameters independently select the data rate and the Flow Control
mechanism for the RS232 port. The allowed choices for the RS232 Config are:
When selecting Sentry Output for Interface, there are no Configuration options.
RS232 Port 1 Function
There are sets of reports that are available via the RS232 serial ports to a PDA, PLC, computer or
printer.
Figure 57 Sample of Test Only output for a pressure decay leak rate test.
Streaming data
Every 0.01 seconds the Streaming Data option sends a string of hexcode that contains complete
data about the test at that time. The data includes station number, part number, phase of the test,
elapsed time, decrementing time within phase, pressure reading, and pressure loss values.
See page 9-2 through 9-4 for the coding of this data stream.
The test result outputs are pre-formatted or customize with Fixed Width and/or space delimited
text files. The following data is saved for each test result. Depending on the test type (pressure
drop, pressure rate of change, occlusion, or pressure decay leak rate,), the data saved will vary
somewhat. Below are examples of the three standard Fixed Width data outputs for a pressure
decay leak rate test
Figure 61 Table of Variables for output to any of the initial 8 data fields
ALR Absolute Leak Rate MQ Master Part Quik Loss PMQ Master Part Quik
Pressure
EDC Environmental. Drift PF Performance Factor PQ Predicted Leak Rate
Correction Offset
LL Master+Leak Loss PL Pressure Loss Pt Test Pressure
LQ Master+Leak Quik Loss PLQ Master+Leak QuikPress QF Quik Test Flow
LQF Master+Leak Quik Flow PLR Pressure Loss Reading QL Quik Test Loss
LR Leak Rate PM Master Part Pressure QP Quik Test Pressure
ML Master Part Loss PML Master+Leak Pressure RL Loss Rate
Code Description
P Test passed
F Test failed
E Test error
N Test skipped
L Test Completed AutoCal Leak Standard
M Test Completed AutoCal Master
Press the INSTR CONFIG once more to see the TCP/IP Setup screen.
Instrument IP Address
Instruments IP address on the factory network set manually or assigned by DHCP server.
Mail Server IP
Mail server IP address This information should be setup by Management Information Personnel
within company if there is an intent to use the email function of the instrument.
Gateway\Router
Set the Gateway/ router address. This information should be setup by Management Information
Personnel within company if default values do not apply to factory network.
Subnet Mask
Set the Subnet Mask address. This information should be setup by Management Information
Personnel within company if default values do not apply to factory network.
There is one TCP/IP port that can be set up to communicate with a data Terminal (i.e. computer),
or Fixed Width Out device. Depending on the Interface selected, there are different screen
options available for the Function and Output options.
The Sentry Output sets up direct communication to a computer with Sentry PCS software that
has the capability to request specific data for transfer. There are no output options.
There are several reports available via the TCP/IP (Ethernet) port. Below is a list of the available
reports via the TCP/IP port. See Chapter 9 for samples of the different reports.
When selecting Sentry Output for Interface, there are no Function options.
TCP/IP 1 Output
Terminal
When selecting Terminal Interface, the Output options are No Output or Test Only.
Custom
See Figure 61 and the Actual test data options shown on page 4-10 for available formats for
custom outputs.
Sentry
When selecting Sentry for Interface, there are no Output options.
There is a USB mass storage connection inside of the Sentinel C28 instrument door. See Figure
71 below.
USB port
Connect a USB flash drive to the receptacle inside the Sentinel C28 instrument. This flash drive
must be formatted to FAT32. DO NOT REMOVE THE FLASH CHIP WHEN THE LIGHT IS
BLINKING BECAUSE IT IS PROCESSING INFORMATION.
Update Firmware
When selecting Yes to update firmware, the instrument screen will display the firmware versions
stored on the USB drive. Move the cursor to the latest version and push the ENTER key.
FILE
>C28 UPDATE 174.137
The instrument will download the new firmware into the onboard memory of the instrument
automatically. For more complete instructions refer to pages 12-1 and 12-2 for how to format
the flash chip to FAT32 and download firmware files for instrument updates.
Drive Control
This function deactivates any writing to the flash drive for safe removal.
User id
When the operator wants to send an email of instrument information to an email address, a user
id must be entered. This can be up to a 19-character alphanumeric string. The user companys
IT department must establish a user id and password.
Email password
When the operator wants to send an email to an email address, the user must enter a password
in addition to the user id above. This can be up to a 19-character alphanumeric string.
From Addr: Instruments email address
Email address for the Instrument may be up to 39 characters long. The From Addr: is the
instruments email address.
Email Function:
There are several report outputs available to email. The available reports are:
Select Description
Parameter
Instrument Setup Information for communication, Firmware, Instrument name, time, date,
Config and security
Station Config Information about the manifold, transducer, and regulator
Part Config Part setup parameters for all part programs
Autosetup info Initial parameters provided in the AutoSetup routine
All part results All the test results for the active part program in the instrument memory
All results All the test results in the instrument memory
Last 1000 1000 most recent test results
Last 100 100 most recent test results
Last 20 20 most recent test results
Station Counters information
Counters
Figure 74 Email Function Reports
Instrument Name
Enter up to 19 alphanumeric characters. The name appears on email messages from the
instrument.
Serial Number
Cincinnati Test Systems assigns this unique serial number to the instrument for reference and
service issues. The Serial Number is set before shipping the Sentinel C28 instrument. The user
can not change the Serial Number. Use this number as a reference for the instrument when
calling CTS for service or operations questions. This number should also appear on the
instrument label located on the right side of the instrument.
Time
The current time is stored with each test result as HH:MM:SS (24 hour clock). This instrument
does not recognize Daylight Savings Time so the time must be reset manually when this event
happens.
Date
The current date is stored with each test result as MM\DD\YY
Each major electronic component in the instrument has its serial number and software version
recorded for future reference for maintenance or service issues. If a service issue arises, record
these numbers when calling CTS for assistance.
SECURITY
Record all changes to the original factory settings. It is important to know these values when
troubleshooting.
No allows changing test part parameters by pressing Change Part button without security
protection.
No allows changing test part parameters by pressing Part Config button and Edit without
security protection.
No allows changing instrument and station parameters by pressing Instr Config and Edit
buttons without security protection.
To initially enter a password the beginning password of 2424 must be used. After a new
password is entered, the beginning password is deleted. The password can be changed at any
point in the future. It requires the password to change it. Enter the new password value using
alphanumeric keys and press the ENTER button. Password can be upto 20 numeric characters.
The part configuration function has the setup and test parameters that are part program specific.
These parameters include the test type, timers, pressure values and units, leak parameters and
units, test optimization settings, test evaluation criteria, calibration method, and tooling control
functions. There are 32 part programs available. Each part program is independent of the others
except for some universal input and output functions. These parameters are accessible via several
sequentially addressed screens. Below is a summary of the variables on each screen. Chapter 6
has a complete description for most of the parameters and methods to optimize the test.
Use the Up or Down arrow keys to position the pointer next to the item to be edited.
Push the EDIT key and the variable information for the selected field will be
highlighted for editing.
For pre-set options use the Up and Down or Left and Right arrow keys to scroll
through the choices
For variable parameters like Part name, timers, pressures, etc. use the Up/Down and
Left/Right arrow keys to sequence through letters and numbers to select the desired
number or letter for each character. After a slight delay between pushing keys the
curser will automatically move to the right for the next character. Use the right and
left arrow keys to move the cursor forward or back on a line.
Press PART CONFIG to advance to the next screen within a tab or the next tab
indicated across the top of the PART CONFIG screen.
Also use the right and left arrow keys to advance or retreat through the PART CONFIG
tabs identified across the top of the PART CONFIG screen.
Push MONITOR, INST CONFIG, TEST DATA, or any other key to escape PART
CONFIG.
Press the HELP key while on any screen (not in Edit mode) to receive a brief description of
each variable. You must EXIT the edit mode to view the Help displays
The stored part parameters are programmable remotely via RS232 or TCP/IP by entering
software access code commands via an internet connection. There is memory for up to 32 part
programs.
Select programmed part parameters via the Functions keypads CHANGE PART key, binary
coded digital inputs, or RS232.
Review or change any test parameter by pressing the PART CONFIG button. A password may
be required to change the parameters. All of the unique part program parameters for each part
program are displayed via several screens. The table below summarizes the location of the
parameters, which are organized by test timers, test pressure values, test parameters, calibration
parameters, Misc settings, units of measurement, digital inputs and outputs, and tooling control.
Test type Cal. Parameters (for pressure decay leak rate only)
Select Test Type Performance Factor
Timers Master Part Press
Pre-fill Timer Master+Leak Press
Fill Timer Master Part Loss
Stabilize Timer Master+Leak Loss
Test Timer Corr. Leak Std Flow
Exhaust Timer Miscellaneous
Relax Timer Part Name
Pressures Cal Method
Target Pressure Copy to Target Part
Copy Part Program
Test parameters TST:PDC Autorun Method
Low Limit Leak (or Loss or Rate) Autorun Cycle Count
High Limit Leak (or Loss or Rate) Autorun Enable
Low Limit Pressure Units
High Limit Pressure Time Unit
Max Master(+Leak) Loss Pressure Unit
Min Master Loss Pressure Unit
Min Perform Factor P/T Unit
Leak Std Cal Flow Flow Unit
Leak Std Cal Press Digital Inputs
Quik Test Enable Assign input terminals
Quik Test Timer Digital Outputs
Quik Test LL Band Assign output terminals
Quik Test HL Band
EDC Enabled
EDC Percentage Not all parameters are available for each test
EDC Quantity type.
TEST TYPE
Press the PART CONFIG button in the Display section of the keypad. The Test Type parameter
is the first parameter displayed for review and edit.
Each part program can be independently setup to perform any of the Test Types available within
the Manifold-Firmware supplied. Press the INST CONFIG key to review the Manifold Type
supplied. Review the table below to see the Test Types available.
TEST TIMERS
Press the PART CONFIG or right arrow key. The timer parameters will display for review or
edit.
Test Type Code Test Type Test Type Code Test Type
PLO Pressure Loss or Drop DPT Pressure Rate of Change
PLR Pressure Decay Leak Rate OCC Occlusion
The Sentinel C28 displays the Test Type codes in Figure 82 after each test in the Monitor display
and stores them with each test result.
The different test type setups and tooling control configurations have different timer
requirements. Table 83 below describes the timer functions and the test types that use them.
Exhaust Time to relieve or vent part pressure before signaling the end of A S S S
test. Need time to prevent blowing out debris or fixture seals.
May be set to zero when part program used within Parent Program
to allow program linking without relieving part pressure.
Relax Timer used during Auto Cal, Auto Setup, and Auto Run routines A S S S
as a precise delay between tests to allow the part to recover to
repeatable virgin state. Usually short relax times result in
decreasing pressure losses (flows) in successive tests.
Tooling When tooling control is specified, there can be one tooling retract O O O O
Retract timer for tooling motion.
A Timers calculated and set by Auto Setup routine.
O Timers used if tooling control activated
S Timers set by operator (Auto Setup not available for these test types.)
Blank Not applicable to the test
There are digital outputs, selectable within the Output tab (discussed later in this chapter) that go
high during the pre-fill, fill, stabilize, test, exhaust, and relax timers.
TEST PRESSURES
Target Pressure Target Pressure is the specified test pressure for the part. For vacuum test
pressures enter as positive values if psiv was selected as the pressure unit. Enter as a negative
if psig was selected as the pressure unit. (i.e. A test pressure 9.7 psia would entered as 5 psiv
or -5 psig.)
All pressure loss, leak standard values, and calculated leak rates are corrected to the
Target Pressure.
Enter vacuum test pressures same as discussed above.
This value is entered during Auto Setup.
Minimum Test Pressure Minimum test pressure is not a displayed value. It is automatically
set at 90% of Target pressure or Target pressure 0.5 psig, whichever is a greater deviation
from the Target Pressure. This pressure value must be reached before the pre-fill timer elapses
and must be maintained through fill and stabilization timers or the testing cycle will end as a
severe leak. The Auto Setup routine will also set the Minimum Test Pressure at 90% of the
Target Pressure or -0.5 psig. This pressure value is not editable.
Maximum Test Pressure Maximum test pressure is not a displayed value. It is automatically
set to 110% of Target pressure or Target pressure + 0.5 psig, whichever is greater deviation
from the Target Pressure. Actual pressures during fill and stabilize must remain less than the
Maximum Test Pressure to successfully complete the test. If the pressure goes above the
Maximum Test Pressure, the testing cycle will end as a Malfunction. Auto Setup routine will
set the Maximum Test Pressure at 110% of Target Pressure or +0.5 psig. This pressure value
is not editable.
Target Pressure Window Target Pressure Window is not a displayed value. This is a
plus/minus 50% window set about the Target Pressure that must be maintained during the Test
segment of the testing cycle. It generates a Malfunction output if the actual pressure falls
outside this window during test. This percentage value is not editable.
TEST PARAMETERS
Test parameters are values specifying limits or set points for the test as well as the leak
standard value to calibrate the instrument, Quik Test options, limits to validate the calibration,
and Environmental Drift correction options. There are different Test Parameters depending the
Test Type. The instrument will only display the parameters that are appropriate for the Test
Type. The table below describes the parameters and Test Types in which they are active.
Parameters with an M denote values that are entered as part of Auto Setup. Parameters with
an A denote values that Auto Setup automatically sets. O denotes parameters that are
optional for the test and are setup after completing Auto Setup and Auto Cal if this function is
used. These values can be changed, after Auto Cal routine is completed, without having to re-
calibrate the instrument. S denotes values entered by the operator because Auto Setup is not
an option. F denotes fixed values that are not editable.
EDC (Environmental Drift Correction) adjustment or offset is the allowed band around the
Master Part curve due to fluctuations in process temperature or test volume. This compensation
band is calculated as a percentage of the difference between "Master Part Loss and "Hi Limit"
parameters. The function calculates the environment drift based on a moving average of the EDC
Quantity of test results that are within the percent band around the "Master Part " pressure curve.
The test result must be an accept that is above the Lo Lim value. EDC Percentage value can be
set at: Off, 10%, 25%, 50%, 90%. The Auto Setup routine sets the EDC On with a 10% band
for a quantity of 30 units. EDC resets to zero when power is cycled on, there is no activity for
one hour, an Auto Cal is performed, or the Lo Limit or Hi Limit values are changed.
Test Evaluation
Test results are compared against two set points for pass or fail status. There are three areas for
evaluation of results: above high limit, between limits, and below low limit. This parameter is
not editable. This fixed evaluation criteria is:
For typical leak test applications, the high limit value is the reject leak rate. Therefore, the
flow rates (pressure drop or pressure loss rates) above the high limit are designated as Fail. The
low limit value is typically set at zero or at a negative value that is 10 to 30% of the high limit
value (or reject rate) below zero. (i.e. If the high limit or reject rate is 10 sccm, then the low
limit value would typically be set at -1 to -3 sccm.). The area between the limits is designated
as Pass. The low limit value can alarm the operator by failing tests if the measured pressure
loss or flow readings are significantly less than the master calibration part or average
production part. This condition may occur due to temperature changes in the part, environment,
or fill air or if the part volume changes significantly due to tubing or part blockage. The area
below the low limit is set as Fail to fail tests with significantly low or negative leak rate values.
The fixed set up for the Sentinel C28 is FPF.
FAIL>high>PASS>low>FAIL (FPF - Pass if between high and low limits)
For the Occlusion (blockage) test, the High Limit Pressure value represents the high limit for
back pressure resulting from a restrictive flow path allowing a minimum flow rate through the
part. The Low Limit Pressure represents the low limit for back pressure resulting from a less
restrictive flow path allowing a maximum flow rate through the part. The set up is
FAIL>high>PASS>low>FAIL.(FPF Pass if flow greater than Low Limit Pressure but less
than Hi Limit Pressure).
For typical flow applications, the test verifies that acceptable flow occurs between a low and
high flow limit. The typical set up would be FAIL>high>PASS>low>FAIL (FPF Pass if
between limits).
CALIBRATION PARAMETERS
MISCELLANEOUS
Part Name:
Enter user desired 12-digit alphanumeric name of part. This part name is displayed in the upper
right corner of each screen in Monitor and Part Configuration.
Cal method
The Sentinel C28 instruments can perform the auto calibration routine in one of four ways. The
method depends on where the leak standard is located and whether one or two parts will be tested
during the calibration sequence. The choices are:
Select Description Explanation
Parameter
One Part Automatic test Automatically tests same Master part twice using calibrated
Int. LS cycling using Leak leak standard mounted on the internal pneumatic block.
Std in manifold With integral tooling control, tooling does not retract
between tests.
One Part - Manual testing of Tests same Master part twice using calibrated leak standard
Ext LS same part using mounted externally from the instrument. With integral
Leak Std outside tooling control, tooling does not retract between tests. A
instrument start input is required to start second test.
Two Parts Manual testing of Tests two different Master parts using the calibrated leak
Int. LS two parts using standard mounted on the internal pneumatic block. With
Leak Std in integral tooling control, tooling retracts between tests. A
manifold Start test input signal is required either via the keypad or
remotely using programmed start test logic to initiate the
second test after changing the Master part.
Two Parts Manual testing of Tests two different Master parts using the calibrated leak
Ext LS two parts using standard mounted externally from the instrument. With
Leak Std outside integral tooling control, tooling retracts between tests. A
instrument Start test input signal is required either via the keypad or
remotely using programmed start test logic to initiate the
second test after changing Master part with leak standard.
*Leak std. value must be pre-set in Part Config, Test parameters, under Leak Std Value.
Figure 92 Calibration Method options
AUTO RUN
The Auto Run function performs repetitive tests to verify the instrument's functionality or conduct
repeatability tests on one part. The system uses the Relax timer (set within PART CONFIG,
TIMERS function for each part program) as the delay timer between tests. If the system is using
the tooling functions, the tooling will not release between tests.
After sequencing through each test while in the MONITOR mode, the instrument will briefly
display the measured pressure loss and then calculated leak rate. It will then briefly show the
remaining cycles in Autorun followed by the decrementing relax timer until the next test starts.
To determine how many tests remain within the AutoRun routine, either observe the test
remaining at the end of the next test or press the PART CONFIG key and tab to the MISC screen
to observe the number remaining next to "Autorun Cycle Count". If the display is left on the
MISC tab in PART CONFIGURATION while running AutoRun, the number of remaining tests
will be displayed after each test on the bottom line of the display. The Autorun Cycle Count
display will not decrement. You must press a left and then right arrow key to refresh the screen.
Also after completing the tests, the "Autorun Enable" will remain as Yes after the test is
completed. To reactivate AutoRun, you must edit the "Autorun Cycle Count" to indicate the
number of additional tests desired and edit "Autorun Enable" to Yes and the press START to
begin the cycling.
To stop the AUTO RUN routine, press the STOP button at any time. To reactivate AutoRun after
it is stopped (by STOP), you must edit "Autorun Enable", to Yes and press START. If "Autorun
Cycle Count" is set at zero, the instrument will run one test.
UNITS OF MEASUREMENT
Figure 93 Units of measurement for part program (time, pressure, and leak rate)
Time Units
Establishes the resolution and length of the timer settings for the part programs. Each program
can operate with different units of time.
Pressure Units
Select the units of measurement for pressure readings by the part program. (Each program can
operate with different units of pressure.) Changing the units of reading re-scales all the pressure
readings to the new units of measurement. The available units are:
Establishes the units of measurement for pressure decay leak rate (flow) calculations on the
display. The numeric values entered for high and low limits and leak standard values must be in
the units of measurement set here. Units available are:
Select the units of measurement for pressure loss or pressure loss per second readings during the
test cycle by the part program. (Each program can operate with different units of pressure.)
Changing the units of reading re-scales all the pressure loss readings to the new units of
measurement. The available units are:
The Sentinel C28 can communicate with external hardware using digital inputs and outputs.
There are 6 input and 3 output terminals prewired to a terminal connector on the top of the
enclosure. The 3 sourcing outputs are solid state relays. As a group they are fused for 2.5 amps.
The 6 inputs are sinking. They can be wired to pushbuttons, prox switches, lights, relays,
solenoid valves, etc. or to a PLC for the interface or control of the process that the instrument is
monitoring. See Chapter 10 Digital Inputs/Outputs for more explanation.
Because of the variety of functions that these inputs and outputs perform, they are divided into
two general types: Universal and Part Program Specific. Universal inputs or outputs are
functions shared by all part programs so when selected within a part program their function is
automatically assigned to that terminal for all other part programs. These inputs and outputs are
usually connected to a Start button or Part Result light that serves the same function for every part
programmed in the instrument. The remaining inputs and outputs are selected specifically for the
part program in which they are picked. There are groups of outputs that can share a terminal and
have different functions depending on the part program. This provides the flexibility to have
defined inputs and outputs only operate within certain part programs. For instance, there may be
a tooling valve that operates an air actuated connector for sealing parts. Within each part
program this valve-connector can be used or not to seal different test parts. See pages 11-10
through 11-10 for an example.
The standard Sentinel C28 has six digital inputs wired to the I/O Connector on top of the
instrument. Define each terminal for wiring purposes before completing this program. Select the
use of these inputs within each part program. If an input is not used within the program, select
Unassigned. If the input was assigned to a Universal input within another program, it will be
automatically assigned within all other part programs. If the input terminal is assigned to one of
the Part Program Specific functions within one of the other part programs, Constrained will
appear on the Input terminal and only inputs within its part program specific group can be
selectable for that terminal in other programs. The complete list of available inputs follows.
Universal Inputs (Automatically set within all part program when defined in any one program.)
Part Program Specific Inputs Individually set within each part program. Each part program
can select whether to use one of these Part Program Specific Inputs in the test or not.
Binary inputs are Universal inputs that remotely select the new part program. The number of
Binary Input terminals required depends on the highest part number that is to be accessed. Part
program number 1 (1 terminal), programs 2 and 3 (2 terminals), programs 4-7 (3 terminals),
programs 8-15 (4 terminals), and programs 16-31 (5 terminals). The inputs must be appropriately
set before the start signal is sent. If all binary part program select inputs are low, the instrument
tests using the last part program selected.
See the programming option under the Tooling tab where tooling motion inputs are defined for
each part program.
Part Present This input (only one will be monitored) must be high when the start test
input is received. It must go low between part tests. Indicates the presence
of the part or component before receiving a Start input signal. This can
verify that a part is in the test fixture or provide one poki-yoki input signal.
AutoCal Remotely initiates the Auto Cal routine. Also requires the Start input(s)
when the master part is positioned in the fixture and ready for testing.
Open Leak Std. Opens the Leak Std Calibration valve during complete test cycle to add the
Leak Std to the test circuit.
Binary Part Selection Inputs
Universal Inputs (Number of required inputs depends on highest
part number to be selected.)
Part Select B1 One binary input for part program 1
Part Select B2 Two binary inputs for programs 2-3
Part Select B3 Three binary inputs for programs 4-7
Part Select B4 Four binary inputs for programs 8-15
Part Select B5 Five binary inputs for programs 16-31
The Sentinel C28 can sequence through two or three tests by wiring the part specific input Start
Part to part specific outputs like Test Passed and Test Failed. This is a hard wire approach to
multiple test sequencing. The part-specific test result output like Test Passed or Test Failed
is wired from one part program to the part specific Start Part input of a follow-up test program.
Each part program is independently executed including programmed digital inputs and outputs.
This method makes it possible to select a unique sequence of more than two different Test types
like a pressure decay test followed by an Occlusion test followed by a rate of change test. The
tooling control and all the digital I/O functions, test parameters, and test results for each part
program are performed in sequence and independently stored by each individual part program.
To use this method for performing more than one test requires individually programming and
calibrating each desired part program. The part programs are joined or linked by wiring the Test
Passed or Test Failed digital output programmed within a test program to the programmed
Start Part digital input of the succeeding test program. The number of available digital
I/O.limits the number of test programs that can be linked. It does not provide total part tooling
control continuity through the sequencing of the multiple tests. The test results are individually
identified by their independent test program numbers. Auto Setup and Auto Cal would be
performed for each part program independently.
Unassigned - No input within any part program has been assigned to this terminal. There is
the full range of inputs available for selection.
Constrained - A Part Program Specific input has been assigned to this input within another
part program. When attempting to edit the assignment of this terminal, only other input types
within the same input group will be displayed for selection. In most cases no other option is
available except Unassigned.
Programmed Part Program Specific Inputs Within a part program, if a terminal is already
assigned to a Part Program Specific input, only other Part Program Specific inputs within its
group can be selected for that terminal. When trying to change an assigned input from a
programmed condition, press the EDIT key and use the arrow keys to sequence through the
possible alternatives. To deactivate the use of this input terminal within this part program, select
Unassign. To change the input to a different function outside the previously selected group,
first select Unassign all part and press ENTER. Then press EDIT key and use the arrow keys
to sequence through the input choices to find the desired input function. But be aware that by
selecting Unassign all part, the input function is unassigned for all the other part programs until
they are reassigned.
Within each part program select the desired digital outputs for the assigned terminals as needed
for the part program. If an output is not used within the program, leave Unassigned. If the
output was assigned to a Universal output within another program, it will be already assigned
within all the part programs. If the output terminal is assigned to one of the Part Program
Specific functions within one of the other part programs, Constrained appears on the Output
terminal and only similar outputs will be selectable on that terminal in other programs. This
provides the flexibility to have defined outputs only operate within certain part programs. As an
example there may be a tooling valve that operates a cylinder for sealing parts. Within each part
program this tooling valve may or may not be required so some programs may use the tooling
motion and others not.
The standard Sentinel C28 has three digital output terminals. Define each terminal before
completing the wiring and programming. See the Output Timing chart below for information
about when the outputs occur. The outputs are Universal or Part Program Specific. Within
the Part Program Specific outputs, there are Groups of outputs that can share the same digital
output terminal between part programs. When programming the same terminal for different
outputs the device receiving the output must be capable of interpreting the signal differently for
different part programs. The available outputs are:
Universal Outputs (Automatically set within all part programs when defined in any one
program.)
Part Program Specific Output Groups (Individually set within each part program. Different
outputs within a group can be assigned to the same output terminals within other part programs. )
These outputs are programmed to go on during certain events of a typical test cycle for external
use. The chart shows the outputs for single pressure test configuration. Review the chart and
decide which outputs perform the functions desired for your tests. These sourcing solid-state relay
outputs are fused as a group for 2.5 amps and can handle either 120 volts AC or 24 volts DC
depending on I/O power configuration supplied (three soldered red mobs across terminals below
and to the right of the output terminals in upper right portion of the circuit board are for 120 VAC
I/O). See circuit board diagrams on 5-24 and page 11-13 for location of these mobs. The
Input/Outputs are powered independent of the instrument power supply so that safety interlocks
with emergency stop and light curtains will not shutdown instrument power.
Output Selections
Part Results
Part Accept Signals the completion of an accepted part test after the last tooling
motion. For dual-test stations, this indicates that both tests passed. The
output stays on until the start of next part test.
Part Reject Signals the completion of a rejected part test after the last tooling motion.
For dual-test stations, this indicates that either of the dual tests failed. The
output stays on until the start of next part test.
Severe Leak Goes high after the last tooling motion for part tests that fail to reach
Minimum Pressure within the Pre-fill timer or remain above minimum
Pressure during Fill and Stabilization timers. It stays high until the start
of the next test. The reject output also goes high for a severe leak.
Malfunction Goes high after the last tooling motion for part tests that fault out due
tooling problems; start test, part presence, or ext press sw faults;
transducer faults; invalid calibration, leak standard, or flow sensor data; or
outside target window during test cycle. It stays high until the start of the
next test.
Test Results
Test Passed Signals the completion of a test that passed at the start of the exhaust
cycle. This output stays on until the start of a new part test.
Test Failed Signals the completion of a failed test at the start of the exhaust cycle.
This output stays on until the start of a new part test.
Below low limit Goes high at the start of exhaust cycle when test results are below the
Low Limit set point and stays high until the start of the next test.
Between limits Goes high at the start of exhaust cycle when test results are between the
Low Limit and High Limit set points and stays high until the start of the
next test.
Above high limit Goes high at the start of exhaust cycle when test results are above the
High Limit set point and stays high until the start of the next test.
Unassigned - No output within any part program has been assigned to this terminal. There
is the full range of outputs available for selection.
Constrained - A Part Program Specific output has been assigned to this output within
another part program. When attempting to edit the assignment of this terminal, only other
selected output types within the same output group will be displayed for selection.
TIMING CHARTS
AutoCal Mode
AutoCal Master
AutoCal LS
In Relax
First Test of Master Relax Second test of Master +LS
Pre-
Fill Fill Stabilize Test Exh.
Tool Extend 1
Press Select
In Prefill
In Fill
In Stab
In Test
In Exhaust
Tool Retract 1
Test Passed
Test Failed
Below Lim
Between Lim
Above Lim
Part Accept
Part Reject
Severe Leak
Malfunction
TOOLING CONFIGURATION
The Sentinel C28 will support one tooling motion, part present, and start test options. There are 6
digital inputs and 3 digital outputs to program within the Input and Output screens to interface
these control functions with each part program. The option for a tooling motion is set for each
part program within the Tooling screens. Selection made on this screen defines some of the
outputs selections found on the Outputs screen.
Number of Motions (0 or 1)
There are 0 or 1 tooling motions or control outputs available for each part program. Each part
program can have a different tool output. The selection of a tooling motion here will define if a
tooling output will appear in the Outputs screens. After defining if a tooling motion output or
part presence is required, go to the Input and Output screens to program the sequence of inputs
and outputs to the wired to the I/O terminals.
The Extend and Retract motions have Extend and Retract timers without Extend and/or Retract
digital inputs to control the sequence to the test cycle. There is no feedback, but there is a timer
delay for the tooling motion before the start of a test or display of the test result.
All the Digital Inputs and Outputs must be wired to the 6 input and 3 output terminals I/O pins of
the connector on top of the enclosure. The source power for the I/O should be independent of
instrument power. Do not use the internal 24 volt power supply as the source for the 24 volt
I/O board because it is not sufficient.
Pre-wired I/O
To simplify the wiring of the digital inputs and outputs, the input and output terminals of the
instrument are wired to an external 14 pin connector mounted on the top on the enclosure. An
interface cable is offered as an option. The diagram below indicates the internal termination, wire
color code, and function of each pin for the internal 14 pin I/O cable and connector.
Turck Wire Color Function ST3 on board ST2 on board ST1 on board
Internal and External digital outputs digital inputs DC power
Pin # Cables
A Brown Output 3 OT3 output 3
C Red/Blue Input 1 IN1 Input 1
E Black Neutral ION Neutral
G Pink Input 3 IN3 Input 3
J Green Output 2 OT2 output 2
L Blue
M Orange Input 5 IN5 Input 5
N Gray/Brown
O Violet Input 2 IN2 Input 2
P White Input 6 IN6 Input 6
R Red Hot IOH Hot
S Gray
T Yellow Input 4 IN4 Input 4
U Tan Output 1 OT1 output 1
Figure 111 Internal Input/Output Connector Cable and Pinouts to Internal Connectors
The pneumatic module is mounted in the bottom of the enclosure. It interfaces to the circuit
board, operator keypad and display. The enclosure limits the number of total regulators to one.
The following details descriptions of the tests, pneumatic circuits, and timing diagrams.
The basic principle of operation of a pressure decay leak test instrument is to fill the test part to a
specified target test pressure, isolate the test part from the source air and allow the pressure to
stabilize, and then measure the pressure loss due to a leak over a defined time. The leak test
instrument translates the pressure loss value measured over the fixed test time to a leak or flow
rate. To achieve the greatest accuracy and repeatability in this test the Sentinel C28 corrects all
pressure loss values and leak standard flow rates for deviations in pressure from the Target
pressure of the test using the formula below.
With these corrected values the instrument calculates the leak or flow rate basically using the
following relationship. The instrument measures and corrects the parameters of dPM and dPM+LS
during the Auto Cal function and stores these parameters for the calculations.
dPPart - dPM
Leak Rate = ---------------- x LRLkStd + EDC
dPM+LS - dPM
*Pressure loss and leak rate values are adjusted for pressure variations from target pressure per
the formula shown above.
The settings for the Pre-fill, Fill, Stab, and Test timers influence the resolution and
repeatability of the instrument under test conditions. Calibrating the instrument to each part type
using the timer settings establishes the pressure loss to leak rate relationship for that part under
the conditions of the defined test cycle and that particular part volume.
Pressure Decay, Pressure Loss, Pressure Rate of Change, and Occlusion Testing with
Absolute Pressure Transducer
Part
Isolation Pressure
Fill/Exhaust Valve Transducer
Valve
Test
Part
Regulator Leak
Standard
Calibration Valve
Figure 113 Version PA, PB, and PN Pneumatic diagram for pressure decay, pressure loss,
pressure rate of loss, and occlusion tests
Fill/Exhaust Pilot Valve Part Isolation Pilot Valve Fill/Exhaust Pilot Valve
Part Isolation Pilot Valve Fill/Exhaust Pilot Valve Calibration Pilot Valve
Calibration Pilot Valve Calibration PilotValve Part Isolation Pilot Valve
A precision mechanical regulator controls the fill (evacuation) pressure for the test through a
normally vented fill/exhaust valve and a normally open part isolation valve. After the fill cycle,
the part isolation valve closes and then the fill/exhaust valve changes to vent the closed part
isolation valve to atmosphere during the test cycle. This prevents leakage from the air source into
the test pneumatics, which might hide a leak condition. At the end of the test cycle, the part
isolation valve opens to exhaust the part. The normally closed calibration valve opens
automatically only during the second test of the Auto Calibration routine and during Auto Setup
routine in order to connect the calibrated leak standard to the test volume. There is also a manual
control of the calibration valve within the SELF TEST, Open Orifice routine for calibration
verification. There is a programmable digital input option to activate this isolation valve to the
Leak Standard as an automated way of verify the system calibration. In AutoRun there is an
option to open the Calibration Valve to add the Leak Standard for every third test.
Some applications require a fast fill capability because of the large volume of the test part. The
purpose of the high flow pneumatics is to quickly get air into (or evacuate) the part for testing and
exhaust (or vent) the part at the conclusion of the test. The high flow valves minimize the pre-fill
and exhaust times, therefore minimizing the total cycle time. The high flow pneumatics valves
have a Cv factor or flow coefficient that is approximately 5 times greater than the standard valve
package.
Part Isolation
Valve
Calibration*
Valve
*only activated during second test of Auto Cal, third test of Auto Setup or manually via Self
Test or digital input.
Figure 117 Timing sequence for Version PA PB, and PN pressure decay, pressure loss, and
pressure rate of change tests
Test Exhaust
Fill/Exhaust
Valve
Figure 118 Timing for occlusion tests in all manifold types that offer Occlusion testing
Hi Lo
Lim Lim
p/f p/f p/f
The test evaluation criteria should be set to reject test results greater than the high limit value and
accept parts between the limits. The area below the low limit is also set to fail. It is usually
desirable to alert the process when parts test significantly better than when initially calibrated so
it is set to fail any value that is below the low limit.
For occlusion (blockage or back pressure) applications, it would be desirable to check that the
effective pressure when pressurizing a part is within limits of back pressure that is controlled by
the flow going through a part. High flow will cause low back pressure while low flow will cause
high back pressure. The Low Limit Pressure set point will be on the right side of the display and
High Limit Pressure will be on the left side of the display. This is consistent with Low Lim and
High Lim display for the all the other tests.
For flow applications, it is usual to accept values that are between a low and high limit. All
values greater than the high limit and less than the low limit should be set to reject. The Low
Limit flow set point is on the right while the high lim flow is on the left side.
The environmental drift correction routine helps to maintain the calibration of the system by
continuously monitoring and calculating a correction factor for changes in the test conditions.
This routine dynamically compensates for slow changes in the test environment like room
temperature changes, part temperature changes, test air temperature changes, part elasticity
changes, part absorption characteristics, etc. These factors influence the dynamics of how the test
part reacts to the testing process and the determination of the relationship of pressure changes to
leak rate. "Environmental Drift Correction defines how wide of a band around the Master Part
Loss value will be considered as normal variations in flow rate for a non-leaking part. The
"Environmental Drift Correction (+EDC %) is based on reject rate. The instrument continuously
calculates a running average of test results that fall within the band (+EDC %) about the original
Master or No-Leak part curve. It corrects each future result by the calculated drift determined
from previous test results. The drift value is calculated as shown.
n Flow
Environmental Drift Correction = ------------- - Master Part Flow
n
Typical settings for Environmental Drift Correction are 10, 25, 50, and 90%. The sample size
is set as EDC quantity (3 or greater). Flexible parts require a greater Environmental drift
correction than rigid parts.
The Environmental Drift Correction effectively defines how much shift can occur. This limits
the routine from continuing to compensate for possible growing leaks in the seal or test
pneumatics.
Minimum Pressure, Target Pressure, Maximum Pressure, and Target Press Window
The Target Pressure is the specified test pressure. Set the regulator to match the specified
Target Pressure by using the "Set regulator" routine within the SELF TEST display function.
Adjust the regulator to display the desired Target pressure.
The Minimum Pressure (automatically set at 90% of Target Pressure or Target pressure
minus 0.5 psig, whichever is the lowest pressure) must be met initially within the Pre-fill
timer to start the fill cycle. The test pressure must remain within Minimum and
Maximum Pressure limits about the Target Pressure to assure that the part is charged to
the proper pressure or vacuum during the fill (and stabilization) timers. Failure to
maintain pressure within these limits will stop the test as a Severe Leak. The Minimum
and Maximum Pressures are automatically set at +/-10% or +/-0.5 psi, whichever is the
greater band about the specified Target pressure.
During the Test timer the pressure in the part must remain within the Target Press
Window percentage about the Target Pressure (set at 50%). Failure to stay within this
window during the Test timer results in a Malfunction and a test result error message of
Test Pressure Low or Test Pressure High.
Minimum Pressure, Maximum Pressure, and Target Press Window value are not
displayed and are not editable.
Target Pressure
Master Part Loss = -------------------- x Measured Master Loss
Master Press
The purposes of the pre-fill, fill, and stabilization times are to increase the internal air pressure
from atmospheric to test pressure and allow adequate time for the pressure inside the part and test
pneumatics to stabilize. The effect of the fill time upon the stabilization time is discussed below.
When filling the part, the incoming air compresses the atmospheric air inside the part. This
causes heat generation due to the initial air in the part being compressed suddenly (adiabatic
compression). The pressure in the part will match the regulator pressure during the fill cycle
using the relieving characteristics of the regulator to bleed excess pressure or supplying additional
air. When the stabilization cycle begins (for pressure decay tests), the test part is isolated from
the regulator and the part pressure continues to seek equilibrium in an exponential fashion. The
part pressure quickly decreases at first but then slowly decays through the remaining stabilization
time and into the test cycle. The amount of decay in the stabilization cycle is moderated by the
amount of time spent in the fill cycle.
The pressure loss during stabilization and test is governed by the following:
- The air volume inside the part
- The test pressure
- The thermal conductivity of the part
- The temperature of the part
- The temperature of the incoming fill air
- The ambient temperature conditions
- The elasticity of the part and fixturing
- The absorption characteristics of part construction
Room temperature variation can affect the repeatability of the system but are usually minimal.
This variable can be corrected by more frequent calibration or use of the Environmental Drift
Correction feature in the Sentinel C28 instruments.
The fill cycle helps to stabilize the initial rise and fall of pressure in the part by leaving the
regulator connected to the part until the end of the fill timer. Adequate time should be put on the
fill timer so that the pressure does not drop below the minimum test pressure parameter. Because
all pressure loss or flow readings are corrected for deviations from the Target Pressure, it is
usually beneficial to get into stabilization quickly as long as the pressure remains above the
Minimum Pressure.
The stabilization timer is the time allowed for the temperature and volume of the part to stabilize
before the test starts. Enough stabilization time is required by the system so that when calibrating
a good part there is not more than 0.1% loss of test pressure during the test timer cycle.
Minimizing the pressure loss for a good part during calibration will improve the test repeatability.
The Sentinel C28 instrument has a pressure-streaming feature via the RS232 ports. This feature
outputs the test pressure every 0.01 seconds from the start signal through the exhaust cycle.
These pressure values can be recorded and plotted via HyperTerminal on most computers using a
data program like MS Excel. The plotted curve may assist in setting the timers if you are
manually trying to set the timers. More information about the pressure streaming values can be
found on page 9-2.
The Auto Setup routine in the Sentinel C28 instrument automatically performs a series of tests to
determine the optimal timer settings for Pre-fill, Fill, Stabilization, Test, Exhaust, and Relax to
achieve the optimal test within Desired Cycle Time. The Auto Setup routine is addressed on the
Function panel of the display keypad.
.
Pre-fill Timer
The pre-fill timer serves as an initial check on the tooling and part. It establishes the maximum
time allowed for the measured pressure in the part to reach the Minimum Pressure value. Once
the pressure reaches the Minimum Pressure, the instrument automatically moves onto the Fill
timer. This timer is usually set at twice the normal time it takes to reach Minimum Pressure. A
Severe leak error message will occur if the pressure does not reach Minimum Pressure within
the Pre-fill time. There are test failed, severe leak, and part reject outputs at the end of the test
cycle and the reject lights go on. Any tooling will retract at the end of the test cycle without
using STOP/RESET unless the Retract on Reject is set for NO.
There is a selectable digital output that goes high during this timer.
Fill Timer
To begin establishing the amount of time required for fill, set the fill timer initially at 2 seconds
for small parts (less than 15 cu. in. or 250 cc. internal volume), or 5 seconds for larger parts. Set
the stabilization and test timers initially to 10 seconds each.
When any change is made to the Fill, Stab, or Test timers, the instrument display will
indicate Calibration required after pushing the START key. An Auto Cal routine must be
successfully performed before another test can be run.
Enter all the test parameters and push MONITOR. Push START to initiate a test on the master
part. Observe the pressure during the fill cycle. If the fill pressure remains above the minimum
test pressure for the duration of the test, reduce the fill timer by 10 to 25%. If the fill pressure
dropped below the minimum test pressure, increase the fill timer. Repeat the test on the master
part and observe the fill pressure to be sure it remains above the minimum test pressure. Repeat
the above to determine an optimal fill time. Once the optimal fill time is set, increase the pressure
regulator setting by 1/2%.
When the pressures drops below Minimum Pressure during the stabilization timer, a Severe
Leak error message will occur. The severe leak and reject outputs will go high until the
start of the next test. If the pressure goes above the Maximum Pressure during stabilization,
Test Pressure High error messages will occur at the end of test and the Malfunction output will
go high but no test lights go on. Any tooling will retract at the end of the test cycle without using
STOP/RESET unless Retract on Reject is set No.
There is a selectable digital output that goes high during this timer.
Stab Timer
Before setting the stabilization timer, the fill timer should be set. The optimal settings will
minimize the pressure drop for a good part during test. For small parts, initially set the
stabilization timer to 5 seconds and the test timer to 3 seconds. For larger parts, set the
stabilization and test timers to 10 seconds. Start the test cycle on the master part and watch the
pressure during stabilization and pressure loss during test. If the pressure during stabilization
drops below the minimum test pressure, increase the fill timer. If the pressure loss during the test
cycle is excessive (greater than 0.1% of test pressure), increase the stabilization timer. If the
losses during stabilization and test are within acceptable limits, go to the next section, Test timer.
When the pressure drops below Minimum Pressure during the stabilization timer, a Severe
Leak error message will occur. The severe leak and reject outputs will go high until the
start of the next test. If the pressure goes above the Maximum Pressure during stabilization,
Test Pressure High error messages will occur at the end of test and the Malfunction output will
go high but no test lights go on. Any tooling will retract at the end of the test cycle without using
STOP/RESET unless Retract on Reject is set No. There is a selectable digital output that goes
high during this timer.
Test Timer
With the leak standard value and pressure set in the Test Parameter routine and all parameters
set for a test, activate the Auto Cal routine using the AUTO CAL button. At the completion of
the Auto Cal test routine, review the Master Part Loss and "Master+Leak Loss" values stored
in the PART CONFIG, Calib Parameter screen. The objective for setting the stabilization and
test timers is to achieve at least a minimum difference between the Master Loss and the
Master+Leak Loss values of 0.050 psi for small parts (<250 cc), 0.020 psi for medium parts,
and 0.005 psi for large parts (>15,000 cc) and have the Master+Leak Loss value be at least
twice the Master Loss value. The fill and stabilization timers affect the Master Loss value.
The test timer affects the difference between the Master Loss and Master+Leak Loss values.
Adjust the timers to provide the optimal overall time cycle. There is a selectable digital output
that goes high during this timer.
Exhaust timer
The purpose of the exhaust timer is to allow air to vent the part before retracting tooling. The
time required depends on the test pressure and part volume. The part starts exhausting
immediately after the test timer expires. Typical times are 1 to 3 seconds. The Exhaust output,
which is activated during the exhaust timer, can be used to open an extra exhaust valve to speed
up the exhaust process or divert possible dirty part air through an external valve.
Relax timer
The relax timer is primarily used as a delay time between the first and second test within the
automatic calibration routine and AutoRun routine. Sufficient delay is required so that the part
can return to a virgin state before the second test. It does not affect the normal testing cycle time.
It needs to be long enough to assure repeatable calibrations. Typical times range from 15 seconds
to 8 minutes depending the test pressure and size/material of the part. This timer is also used as
the delay time between tests when operating the instrument using Auto Run.
Quik Test
During calibration the Sentinel C28 stores the master part calibration test data and calculated
High limit and Low Limit parameters. At the Quik Test Percent of the Test Timer the instrument
measures the pressure loss and compares the projected leak rate from this reading against the
specified Quik Test Low Limit and High Limit bands. If the Projected Leak Rate is within either
of these two bands, the test continues to the end of the test timer. If the instruments projected
leak rate is outside of these bands, it will stop the test, output the results according to the Test
Evaluation criteria, and display the projected leak rate. Quik Test is only available for test types
that have an Auto Cal procedure that requires two tests (PLR Pressure decay).
The chart above shows the Master Part curve, the Low Limit with its LL Quik Test band limit,
and the High Limit with its HL Quik Test band limit. If the pressure loss is within either the LL
Quik Test band or HL Quik test band at the QT% of Test Timer, the test will continue and
complete the entire test cycle. If the results are outside the limit bands at the QT% of Test Timer,
the test will stop and the test result will reflect the Test Evaluation criteria (i.e. F/P/F for Fail
>HL>Pass>LL>Fail). Setting narrow bands about the Low Limit and High Limit is a very
aggressive approach that will greatly limit the number of tests that run to the end of the test timer.
Set wider bands as a more conservative approach to Quik Test.
An initial analysis of Quik Test should be performed before actually implementing this feature by
establishing the QT% of Test Timer at 10, 25, 50, 75, or 90% and setting Quik Test to OFF.
An Auto Cal must be performed after setting the "Quik Test Timer %" to measure the typical leak
response curve for the test and determine the response at the Quik Test Timer%. Test production
parts over a reasonable time (up to 1000 parts in various production conditions). The instrument
projects a leak rate at the Quik Test Timer% and then completes the full test cycle and calculates
the leak rate for the complete test. The Sentinel C28 stores up to 5000 test results that include
both the actual complete test result and a projected test result based on the Quik Test
measurement. By comparing the two leak rate results, a percent of error for the Quik Test feature
can be calculated. If the results are satisfactory, the Quik Test feature can be implemented by
setting appropriate High Limit and Low Limit Bands based on the test comparison and Enabling
Quik Test. This feature will save the time difference between a full test time and the Quik Test
Time for almost all of the accepted parts and most of the rejected parts. If the results are not
consistent to each other, test further by increasing the Quik Test Timer %, re-calibrate the
instrument, and compare the results again.
The Self Test key accesses several functions that check or verify the proper test operation of the
Sentinel C28 instrument. The functions include:
Verify or calibrate the pressure transducer
Verify or adjust the pressure regulator setting
Self Test the instrument pneumatic manifold for leaks
Verify leak rate calibration by opening the leak standard calibration valve
Make sure to supply air to the Sentinel C28 system. After editing to Yes, follow the display
instructions. Connect a Master Pressure Gauge to the test port and press ENTER.
The instrument takes a minute or so to monitor the signal level of the transducer to measure the
base atmospheric pressure reading and the transducers signal stability. The instrument displays
the pressure readings as gage pressure relative to the current atmospheric pressure. Every test
pressure reading is displayed as gage pressure relative to an atmospheric pressure reading made
immediately before the start of the test cycle.
CANCEL OK
Follow the instructions on the screen. If the Master Pressure Gauge reading is different then the
Instrument reading, press EDIT and enter the Master Pressure Gauge reading.
The purpose of checking the span of the pressure transducer is to allow the instrument to recheck
the noise level of the transducer signal and correlate the pressure readings to a traceable pressure
gage. This assures that the test pressure readings are accurate.
Mechanical Regulator
Tests conducted with a mechanical regulator depend on the setting of the regulator prior to testing
to provide consist part-to-part pressures for a leak or pressure loss tests. The Sentinel C28
corrects each pressure loss readings for variations of the actual test pressure during the test cycle
verses the tests Target Pressure to achieve greater part-to-part accuracy and repeatability.
To initially set the regulator for testing, perform the Set Regulator routine below.
Follow the instructions on the screen by connecting the Self Test plug into the test port in place of
the quick connect test line. Select OK by pressing ENTER, as instructed on screen to proceed.
(To exit the Set Regulator routine, push the left arrow key to select CANCEL and press ENTER.)
The current air pressure setting for the regulator displays on the line next to Instrument
pressure.
Regulator Knob
Self Test Plug
Test Port
Figure 124 Regulator Knob and Self Test Plug in Test Port
Adjust the regulator knob, shown in Figure 124. The regulator knob is the black wheel (or gray
knob). Adjust the regulator knob until the required air pressure value is indicated on the display
screen.
The SELF TEST function provides a way to check the integrity of the Sentinel C28 pneumatic
circuit. By isolating the instrument from the test part and the external tooling and plumbing, this
special test will verify that the instrument is performing a valid test free of possible internal leaks
in the instruments pneumatics. If there is a question about where a leak might exist in a
complete test setup or why an unacceptable test result is occurring in a general test, performing a
Self Test on the instrument will clarify if the instrument is contributing to the problem.
The pressure units are defined by the pressure units selected in Auto Setup. Press the Auto Setup
key twice and edit the desired pressure units. Then return to Self Test.
CANCEL OK
If the Self Test plug is not already connected to the test port, remove the test line quick connect
fitting and connect the Self Test plug for the Self Test function. See Figure 128 below to identify
the Self Test plug and Test port fitting.
The instrument conducts a pre-programmed extended leak test on the instrument. If there is no
internal leak, the following message will appear, "Self Test Passed". Reconnect the test line to
the quick-connect test port and return the self-test cap (plug) to the self-test holder.
If there is an internal leak, the following message appears: Self Test Failed"
Verify that there is an inlet air supply to the instrument and confirm that the regulator is
set to the correct pressure.
Check the oring on the Self Test plug for cuts or knicks.
Check all the plumbing connections on the pneumatic manifold for possible leaks using a
soaping agent. If it is difficult to see all the fittings, you can remove the pneumatic
manifold block and reconnect the supply air to another air source. This should make it
easier to check for leaks with a soaping agent.
If no leak is found, there may be an internal leak across the part isolation valve or leak
standard isolation valve.
After fixing the leak, perform another Self Test to verify the pneumatics integrity.
Reconnect the test line to the quick connect at the test port.
Do not tighten the male quick connect fitting of the Sentinel C28 into the pneumatic block.
Tightening the fitting may crack the pneumatic block and void the warranty.
It is important to periodically verify the leak rate calibration of the instrument. It is desirable to
do this without re-calibrating the instrument because of the time involved and the benefits of
having Environmental Drift Correction adjust the calibration to the process. Testing a Master
(No Leak) part with the internal leak standard added to the test circuit is a quick and effective
way to verify the instrument's calibration without changing anything. By simply testing the
master part with the calibration valve energized, the instrument should measure a leak rate very
close (+10%) to the Leak Standard value (displayed in PART CONFIG, Calibration Parameters
screen for the part program).
To execute this simple calibration verification routine, mount a Master part into the test fixture.
Edit the "Open Leak Std" item to Yes. Push the MONITOR key to monitor the test. Start the test
on the Master part. When the pre-fill cycle begins the Leak Standard Calibration valve opens and
stays open until the end of exhaust. During the time when the Leak Standard Isolation valve is
open a symbol appears on the bottom line of the display next to the password lock symbol.
Upon completion of a test cycle, the leak rate test result will be displayed. Compare the leak rate
test result to the stored Leak Standard value Corr. Leak Std Flow for the selected part program,
found in PART CONFIG, CAL:PLR. If the two values are reasonably close (+10%), the
instrument's calibration is satisfactory.
Be sure to close the Leak Standard Calibration valve before proceeding with your normal
leak testing operation. Push the SELF TEST key twice and edit the Open Leak Std line to read
No. The Leak Standard symbol will stop appearing during each test.
There is one RS232 termination, (9 pin connector) on the operator panel on the front of the
instrument. The USB port is located inside the instrument at the bottom center of the door. The
TCP/IP jack is located near to the USB port on the inside of the instrument. See Figure 129
below for the location of the internal terminals.
TCP/IP USB
The standard RS232 interface cable for a portable printer is a nine-pin female to nine pin male
serial null (leads for transmit and receive are crossed between pin connections) cable. The RS232
interface cable for a computer is a nine-pin female to nine-pin female serial null cable.
For TCP/IP communication, the instrument must have an IP address. Enter the information
regarding the Gateway/Router, Subnet Mask, and instrument IP address or obtain an IP address
by setting the Obtain network address to DHCP within INSTR CONFIG, TCP/IP
communications. The instrument power must be cycled if an IP address is changed.
There are several communication and terminal parameters that must be setup within your
computer to enable communication with the Sentinel C28 instrument. Computers with Microsoft
Windows 98, XP, etc. usually have standard communication software called Hyper-Terminal
found under START/ Accessories/ Communications.
The Sentinel C28 communicates in two ways. It can output a number of standard reports via the
RS232 or TCP/IP. See Figure 132 below for a list of available reports. Review Chapter 4 on how
to select these reports.
The test report output format for Last 20, 100, 1000, All Part Results, and All Results are set for
either Space delimited or Fixed Width output.
Transferring data from the Sentinel C28 instrument to a computer with Windows 98 or higher
1. Connect null-modem cable to the com port of the computer from external RS232 connection
or connect an ethernet cable via a hub
2. Start Windows 98 or higher.
3. Choose START, PROGRAMS, Accessories, Communications, and HyperTerminal.
4. Choose HyperTerminal icon
5. Enter a connection name such as "
RS232" or Ethernet and choose
desired icon, OK.
6. Within Connect to window, set
"Connect using" to the com port for
your computer, like "com 3" or
select TCP/IP for Ethernet
connection. For TCP/IP
connections enter instruments IP
address and Port Number 23.
Configuration settings for serial communication (example of Windows XP). These settings
should match the Configuration setting within INST CONFIG for the serial device (RS232).
When using HyperTerminal as an ASCII terminal, the following settings need to be set in
HyperTerminal or the communication software as properties to receive and display data
When the instrument is setup to communicate with RS232 or TCP/IP, the operator can
command the instrument to send out any desired information via the INSTR CONFIG
key. The operator chooses the desired report from the communication options defined by
the combined settings of Interface, Function, and Output within the RS232 or
TCP/IP. After entering the desired choice, the information is sent to the computer that
is connected for the transfer. Full details about requesting the reports through the keypad
for these communication options are described in pages 4-4 through 4-15.
A remote computer can request information from the Sentinel C28 via the two-way
communication capabilities. Sending the desired alpha-numeric character string outlined
below will either:
Enter HyperTerminal and connect with the Sentinel C28 instrument via TCP/IP. The
display will indicate that a connection is made.
Type help (return) and the following will display on the computer screen when the proper
connection is made with the Sentinel C28 instrument.
help
*************************************************************************
* TREE ROOT CONTROLLER *
*************************************************************************
* <I>: Instrument config *
* <P#>: Part config menu (please select a part number) *
* <T#>: Test data (please select a part number) *
* <S#>: Self test (please select a part number) *
* <A#>: Autosetup *
* <M>: Module menu *
* <U>: Update Firmware *
* VER: Display Version Number *
* Dir: Display Current Branch *
* Help: Help *
To address a particular menu, type the letter within < >, and Return or Enter. The
submenu for that letter will be sent.For instance, to find out about the Part Configuration
for part 01, type p01, Enter.
p01
* Part Configuration
**************************************************************************
* <X>: Tst type, Test description for this part. *
* <R>: Timers, Test timer settings for this part. *
* <P>: Pressure, Pressure settings for this part *
* <S1>: tst *
* <C1>: cal *
* <M>: misc *
* <U>: units *
* <I>: inputs *
* <O>: outputs *
* <T>: tooling *
* VER: Display Version Number *
* Dir: Display Current Branch *
* Help: Help *
*************************************************************************
R
*************************************************************************
* Timers, Test timer settings for this part. *
*************************************************************************
* <1B0>: Prefill 0.15 sec *
* <230>: Fill 0.60 sec *
* <320>: Stabilize 6.55 sec *
* <420>: Test 1.45 sec *
* <5F0>: Exhaust 0.15 sec *
* <8D0>: Relax 11.85 sec *
* VER: Display Version Number *
* Dir: Display Current Branch *
* Help: Help *
*************************************************************************
Figure 140 Part configuration, Timers menu output
If you have entered into the Part Configure menu via the commands just discussed, you can
change a timer by using the following command. The command involves entering the variable
character found within < > and the new value for the variable. For instance:
The direct way to change that one variable while in the original screen after entering the
connection would be:
P01R1B0=0.5
This directs the change to Part Program 01 (P01), Timer value (R), Pre-fill timer (1B0).
To determine the correct variable code, you should enter into HyperTerminal and determine the
correct codes for the variables desired. The main TREE ROOT codes are:
TREE ROOT
TREE ROOT Description
Code
I Instrument Configuration
P# Part Configuration menu (specify with part number)
T# Test data (specify with part number)
S# Self Test (specify with part number)
A# Auto Setup (specify with part number)
Module menu
Update Firmware
VER Display Version Number
Dir Display Current Branch
Help Help
See the list of configuration and menu codes for Instrument Configuration below.
Instrument Configuration
TREE Config Menu Description
ROOT Code Code
I Instrument Configuration
H Hardware, Instrument Hardware Settings
530 Manifold Type
7B0 Number of Parts
541 Transducer Type 1
671 Regulator type 1
S RS232 Port 1 Front door
I RS232 Port 1 Interface
C RS232 Port 1 Configuration
F RS232 Port 1 Function
S RS232 Port 1 Output
T Instrument Networking Settings
4 Obtain network settings
IP Instrument IP address
M Mail Server IP address
G Gateway IP address
S Subnet Mask
C MAC address
1 TCP/IP 1
I TCP/IP 1 Interface
F TCP/IP 1 Function
P TCP/IP 1 Output
U USB Universal Serial Bus Settings
P Update firmware
M Drive control
E Email, Instrument email settings
I User id
P Email Password
R From Address
F Email Function
AF Email Function address
M Misc, General instrument settings
IN Instrument name
S Serial number
C Edit/View security
T Time
D Date
To request a download of test data independent of what is requested through the keypad of the
instrument, enter codes as though you were going through the keypad to request the output. For
instance to output the last 1000 test results via TCP/IP 1, you would enter a string of characters
going from the TREE ROOT through the menu code.
The menu codes vary by test type within Part Configuration. If you want to change or define the
part configuration values via an RS232 or TCP/IP, input P# and enter and the Configuration code
and enter. The menu codes within the Configuration code will output with their identification.
Use these menu codes to enter new values using the format described above.
To back out from a menu, Type exit to escape back to the TREE ROOT menu.
To determine the available choices within a Menu, type the menu code and >. For instance to
determine the available choices for Manifold type within Hardware:
Exit, return
I, return
H, return
530>, return
To request reports from the Sentinel C28 via RS232 or a TCP/IP connection using Hyper-
Terminal, the path to the reports is similar to using the keypad to find the menu where the desired
output is selected. So to output the Last 20 test results (Function selection) in Fixed Width format
(Interface selection) with All the Test Results (Output selection), you need to find the INSTR
CONFIG functions on TCP/IP or RS232 communication.
*************************************************************************
* Instrument Configuration *
*************************************************************************
* <H>: Hardware, Instrument hardware settings. *
* <S>: Rs232 1, Front door comm port interface. *
* <T>: TCP/IP, Instrument networking settings *
* <1>: TCP/IP 1, User defined TCP/IP interface. *
* <U>: USB, Universal Serial Bus settings. *
* <E>: Email, Instrument email settings. *
* <M>: Misc, General instrument settings. *
* <V>: Version, Detailed instrument version settings. *
* VER: Display Version Number *
* Dir: Display Current Branch *
* Help: Help *
*************************************************************************
*************************************************************************
* TCP/IP 1, User defined TCP/IP interface. *
*************************************************************************
* <I>: TCP/IP 1 Interface Fixed width out *
* <F>: TCP/IP 1 Function Sta Last 20 *
* <P>: Fixed width out Part result only *
* VER: Display Version Number *
* Dir: Display Current Branch *
* Help: Help *
*************************************************************************
Figure 145 TCP/IP 1 menu displayed on Hyper-Terminal
To get the right format output make sure that INTERFACE is set for Fixed width out,
Function is set for Sta Last 20, and Fixed Width out is set for All result information. The
above display showing the current settings for our desired output is not quite right. We need to
change the Fixed width out. If we do not know the code for the desired output, we can enter an
inquiry command to list the available code and outputs.
Type the letter code in the < > follow by an >. Therefore to find the options for the Fixed
Width out output options,
To change the Output option to All result information which is selection A for the options
above.
Type P=A
Now test results will be sent after each test by the instrument in the All result Information
format. To download the last 20 results, find the code for sta Last 20.
Figure 149 Portion of the Sta Last 20 Test Result All Result Information output on
Hyper-terminal.
INSTRUMENT CONFIGURATION
The Instrument Configuration report displays the setup parameters from the INSTR CONFIG
setup screens: This includes the current settings for the communication options (RS232 and
TCP/IP), firmware versions, and other miscellaneous instrument settings.
RS232 1
===============================================================
RS232 Port 1 Interface Fixed width out
RS232 Port 1 Config 115200/8N1/none
RS232 Port 1 Function Station Cntrs
Fixed width out First 2 test results
TCP/IP
===============================================================
Obtain network settings DHCP
Instrument IP address 172.16.0.97
Mail Server IP address 170.16.0.4
Gateway IP address 172.16.0.1
Subnet Mask 255.255.0.0
MAC address 001127041214
TCP/IP 1
===============================================================
TCP/IP 1 Interface Fixed width out
TCP/IP 1 Function Instr Config
Fixed width out First 2 test results
USB
===============================================================
Update firmware No
Drive control Unmount
EMAIL
===============================================================
User id I24
Email password password
From Addr: I24@cincinnati-test.com
Email Function Station Cntrs
Fnc Addr: ggrebe@cincinnati.com
MISC
===============================================================
Instrument name I24 STATION 1
Serial Number 1029384756 I24 CONTROLLER
Edit / View Security ON
Time 11:17:16
Date 11/14/08
VERSION
===============================================================
System Version 104
Build number 081113164839
Sram 0.37
SECURITY
===============================================================
Secure Calibration No
Secure Change Part No
Secure Part Config No
Secure Instrument Setup No
Secure Clear Data No
Secure Reset Cntrs No
Change Password (11534336) 0.01
STATION CONFIGURATION
This report indicates the setup of the instrument hardware for the test station. Parameters include
the manifold type that will define the type of tests available for selection within the part
configuration section. The remaining parameters define the established pressure transducer and
regulator type and range. Also displayed is the number of part programs that are accessible.
HARDWARE
===============================================================
Manifold Type PA - Std Cv 1P
Number of Parts 32
Transducer Type 1 Druck 20PSIA
Regulator Type 1 Mechanical
PRESSURE STREAMING
The pressure streaming output is a string of information identifying the significant information
about a test every 0.01 seconds. This data output is only available via the RS232 port when the
RS232 Interface is set for Terminal. The RS232 Ouput must be set for Streaming or Streaming
and Test. To make the information output as short and concise as possible for each data point, the
data identifiers are output in hex code. The data provided changes depending on the test type and
phase or segment of the test. The data string consists of a station number, part number, segment
or phase of the test process, elapsed time, time within each segment, pressure measurement,
pressure loss or flow measurement, and potentially EDC correction. Each set of variable data
consists of a variable identifier, variable unit of measurement, and the measured variable.
Stream of typical test data associated with a reading every 0.01 seconds
Data Value
Data value
Data value
Data value
Segment of the test
Part Program number
Station Number
Data Value
01 Variable code - Elapsed Time (See Variable table, Figure 153)
5D Unit code - Seconds (See Unit table, Figure 154)
5.13 Variable 5.13 seconds of elapsed time into the overall test cycle
Data Value
02 Variable code Segment timer (See Variable table, Figure 153)
5D Unit code Seconds (See Unit table, Figure 154)
3.00 Variable 3.00 seconds of time remaining in segment
Hex code
Variable Measurement Type
01 Elapsed time with Segment (incrementing time in test)
02 Segment timer (decrementing time remaining in segment)
03 Isolation decay timer
07 Total test time
0D Test Pressure
12 Measured Pressure
1C Pressure loss (Corrected)
44 Measured flow
4B EDC offset
This Test output is a result of setting the Interface to Terminal and Output to include
Test. The result information has more complete descriptions of each test result parameter.
Test result Station No. Part No. Date Time Unique ID Part Result
Test type
Figure 155 Test output report for RS232 Port: Terminal (Pressure Decay Test)
With Interface set to Fixed Width Out, the Sentinel C28 can output the results in one of three
ways at the completion of each test via RS232 or TCP/IP.
With the Output set to Part results only the following test result data appears. Test results
are in order of most recent data at bottom.
Part no. Link info Date Time Unique ID. Part result
First 2 test results are for each part for Station 01. The results are in order of most recent data at
the bottom. The First 2 test results output is established by setting the Interface to Fixed
Width Out and Output to First 2 test results.
Part No. Link Info Date Time Unique ID. Part Result Test Type Leak Rate
SPC Flag Test Result
Figure 157 First 2 test results output (for single pressure decay test)
The All result information output is established by setting the Interface to Fixed Width Out
and Output to All Result Information. All result information is for each part for Station 01.
The results are in order of most recent data at the bottom.
STATION COUNTERS
The Counters report provides the counter data for the current active part number. To
obtain reports for the other part numbers, Change Part to the desired part number and
request the Counter report again.
COUNTER INFORMATION
Cycle Since New This count is an instrument count. It reflects the total number of tests initiated
for the instrument since the instrument was manufactured or the memory chip was changed.
Accept Cycles This is the total Part Accept results for the active part program shown in the
lower right corner of the display since the counters were reset.
Reject Cycles This is the total Part Reject results for the active part program shown in the
lower right corner of the display since the counters were reset. This includes Severe Leaks in the
pre-fill, fill, and stabilization cycles and rejects in the test cycle.
Malfunction Cycles This is the total number of tests that did not complete cycle because of
faults in the test process excluding test integrity errors. Any disruption in the test cycle except a
severe leak (which is classified as a reject) results in a malfunction.
Cycles Since Cal This is the total number of part tests initiated for the active part program
shown in the lower right corner of the display since the last completed calibration.
Clear Part Counters (No or Yes) This function resets the counters for Accept Cycles, Reject
Cycles, Malfunction Cycles, and Cycles since Calibrated for the active part program shown in the
lower right corner of the display.
Clear Stn Counters (No or Yes) This function resets the counters for all the part programs of
the instrument except the Cycles Since New.
Clear Stn Results (No or Yes) This function clears all the Test Result data shown in the next
display for all the part programs in the instrument.
TEST RESULTS
The second display is test results stored in the system for the instrument since the test data was
cleared. The most recent results are on top. Use the Up or Down arrow keys to scroll through the
test results. The scroll bar on the right side indicates the relative location of the test data within all
results stored.
Press the TEST DATA key twice to see the data on recent parts tests.
Part program number (P#) Part program number used to perform the test.
Date (MM/DD) Month and day when the test was performed.
Time (HH:MM:SS) Hour, minute, and second when the test was performed.
Part Test Result (Accept, Reject, or message) Brief result information about part test. See
Figure 64 on page 4-11 for the possible Part Test Result codes.
Test Type Code (PLR, Plo, DPT, OCC) Test type performed
Test Pressure (psig, psiv, kPa, etc) Measured pressure during test (for all pressure tests)
Pressure Loss (psig, psiv, kPa, etc.) Measured pressure loss during test cycle (for
pressure decay or loss tests only)
Pressure Loss Rate (psi/s, kPa/s, etc) Pressure rate of change during test cycle (for rate of
change test only)
Leak Rate (sccm, scfm, etc.) Calculated leak rate value for the test (for pressure decay leak rate
tests)
STATISTICAL INFORMATION
For Leak Rate Results only. This function does not work for pressure loss, rate of loss, or
occlusion tests.
Press the TEST DATA key three times to see the statistical report on recent parts tests.
The statistical calculations are performed on test results for a selected part program shown in the
lower right corner of the display. To view statistics for different part programs push the
CHANGE PART key until the desired part number appears or press and hold the CHANGE
PART key and then enter part number.
Stat History Length Defines the number of most recent test results within the selected part
program over which to perform the statistical analysis.
The instrument performs the following calculations on the specified history of test results within
the selected part program. It calculates the results on the accept parts only and the reject parts
only. It ignores severe leaks and malfunctions that occur.
Accept Average Average value of leak rate (pressure loss for pressure loss tests) of accept parts
for the selected part program.
x1 x2 ... xn
xmean
n
Reject Average Average value of leak rate (pressure loss for pressure loss tests) of reject parts
for the selected part program
x1 x2 ... xn
xmean
n
Accept Std Dev + of accept parts for the selected part program
Accept SPC Std Dev. Standard deviation of the accept parts that were identified by the
Universal digital input SPC Test Part before these parts were tested.
Accept Percentage Percentage of accepts out of total accept and reject test results. Does not
account for malfunction tests.
Reject Percentage Percentage of rejects out of total accept and reject test results. Does not
account for malfunction tests.
These input and output functions are selected in the PART CONFIG function (Tooling, Inputs
and Outputs).
The inputs and outputs are divided into two basic groups Universal and Part Program
Specific. When a Universal input or output is assigned in a part program, it is automatically
assigned within all part programs to the same terminal. When deleting one of these inputs or
outputs using Unassigned all parts within any part program, it automatically removes it from all
the other part programs. When a Part Program Specific input or output is assigned in a part
program, that terminal is Constrained in other part programs to functions that are in a common
group.
An additional condition to start a test can include a Part Presence input that must be high
before receiving the one start input. This input is Part Presence. It will be discussed below
within the Part Program Specific input options.
There are two basic methods to stop the Sentinel C28 during test operation. The first is a
Stop/Reset request (whether via keypad, communications, digital input, or test malfunction).
The second is a Vent/Halt request (via digital input or test malfunction). Regardless of the stop
type, the Sentinel C28 will always produce a result and I/O indicating result (Part Accept, Part
Reject, Severe Leak, or Malfunction). With no tooling control functions performed by the
instrument, these two functions are the same. When the Sentinel C28 is controlling the one
tooling function, the Vent/Halt function deactivates the test process to the quickest and safest
point of no tooling motion and part de-pressurization. Stop/reset conducts the vent/halt function
of the testing process and continues with the reset of the tooling process back to a known
retracted state for the next test.
The Vent/Halt would typically be used by the Emergency Stop function to quickly get any
tooling functions to a safe state, de-pressurize the instrument, and control the instrument until
released for a stop/reset request to reset any tooling back to the start position.
Vent/Halt
The Vent/Halt input safely ceases the operation of any tooling motion (described below
under Vent/Halt request), removes all energy from the part by advancing through the
exhaust cycle, and stops operation. Any programmed tooling motion required to return to
the fully retracted positions must be initiated by the Stop/Reset input. While the
Vent/Halt input is high, no additional test activity or tooling resets can occur.
Besides a user generated Vent/Halt input, a number of test errors will generate a
Vent/Halt request. Possible scenarios include:
Transducer Malfunction (zero or over-range),
External Switch Fault (not low or high at appropriate time)
Severe Leak
Pressure Low/High
Calculation Faults
Calibration Errors
General Part Fault (setup errors)
Stop/Reset
Stop test/Reset input is available to stop tests and retract tooling. When a stop/reset input
is received the test cycle goes immediately through a Vent/Halt routine and then
advances to retract the tooling. The Malfunction output (if programmed) will go high at
the end of the last tooling motion for errors defined as malfunctions.
In addition Stop/Reset input is required:
After any tooling motion or test malfunction where the instrument completed
Vent/Halt to safe state and stopped.
Tooling must be reset to fully retracted position to start next test
Stop Request
The design of a Stop request is to safely remove all energy from the part, place the tooling into a
fully retracted state, and stop operation. Depending upon whether the instrument is actively
testing or idle, the stop request has two modes of operations.
Besides a user generated Stop, a number of test errors will generate a Stop/Reset request that
causes a Vent/Halt routine and continues with the tooling reset. The possible scenarios include:
Transducer Malfunction (zero or over-range), External Switch Fault (not low or high at
appropriate time), Severe Leak, Pressure Low/High, Calculation Faults, Calibration Errors, and
General Part Fault (setup errors).
Vent/Halt Request
The design of a Vent/Halt request (including initial phase of the Stop/Reset request) is to cease
operation of tooling motions, safely remove all energy from the part, and stop operation.
A Vent/Halt request operation has multiple operations depending upon the state of the instrument
while testing. For better understanding the test sequence can be broken into three basic groups:
Tooling Extend, Part Testing, and Tooling Retract. The Part Evaluation (Accept Part/Reject
Part/Malfunction/Severe Leak) is always after the Tooling Retract.
Besides a user generated Vent/Halt input, a number of test errors will generate a Vent/Halt
request. Possible scenarios include:
Hold
The Hold input halts or suspends the testing sequence as long as this input is high. This can be
used to stop the testing while awaiting some other action to occur.
Start Part
This part program specific input starts a test using the one part program in which it is selected.
The instrument continuously scans for this input between tests. This input can link the test result
output of another part program by wiring from that test result output programmed specifically to
that part to the Start Part input specifically programmed to the second test part. When the first
part finishes its test with the desired outcome, its test result output will trigger the start of the next
part test by activating the Start Part input for the next part program. Care must be taken when
tooling control is involved between tests. See page 5-17 for more information.
Auto Cal
The Auto Cal input prepares the instrument to perform an Auto Cal routine as defined within Part
Config/MISC/Cal Method (one or two parts and Leak std internal or external). A Start input
initiates the tooling motion and Auto Cal routine. If the Auto Cal routine is setup for two parts, a
second Start input will be required for the second test after the parts are exchanged. For One
Part Auto Cal routines, the instrument does not retract the tooling between tests.
Part Presence
A digital input (PART PRESENCE) can be used as an additional input required to start a test.
The PART PRESENCE input must be high before a start test input is received. It also must go
low between part tests (after any tooling motion and before the start of the tooling motion for the
next test). If the input does not go low between tests, a Malfunction output and display Error:
Part Not Changed are initiated. If a tooling motion were initiated when receiving a Part Presence
Error, a Stop/Reset input will be required to reset the tooling.
The Part Presence function must be setup.
Part Config/INPUTS assign a terminal to Part Presence
Open Lk Std
The Open Leak Standard input will open the Leak Standard Calibration valve during the pre-fill,
fill, stabilization, test, and exhaust cycles. The valve will only open during the testing cycle when
the Open Lk Std input is high. If the Open Lk Std input goes low during the testing cycle, the
Leak Std Calibration valve will close. This input is generally used to automatically verify the
calibration of a system by indexing or placing a good part in the test fixture and adding the
internal leak standard to measure a part with the leak rate equal to the internal Leak Standard.
Ex Pres Sw
The External Pressure Switch input must go high before the end of the fill cycle. This input
indicates that a detected response occurred by the end of the fill cycle. This input is generally
used to validate that the test part is properly charged by detecting pressure downstream of a
potential blockage point. Failure to receive this input before the end of the fill cycle causes a
malfunction result and a Ext Switch did not go high error message.
The Sentinel C28 instrument has high impedance, solid-state inputs. Therefore, prox sensors,
solid-state palm buttons, and other devices that have leakage current may require a pull down
resistor (sized as required) across the input for proper operation.
A 22k 0.5 Watt resistor is a typical value used as a pull down resistor. The input and output
terminals are 24 VDC or 120 VAC depending on the I/O circuit board supplied. Additional drain
resistors across the inputs may be required.
Tooling Extend 1
Press Select
Pre-fill
Fill
Stabilization
Test
Exhaust
Tooling Retract 1
Test Passed
Test Failed
Test Below Limits
Test Between Limits
Test Above Limits
Part Accept
Part Reject
Severe Leak
Malfunction
AutoCal Mode
The Auto Cal Mode output goes high whenever the instrument is performing an Auto Cal cycle.
It goes high at the beginning of the pre-fill for the Master Part test. It stays high until the end of
the exhaust for the Master plus Leak test. This output signals to a PLC that the station is in the
calibration mode so that part movement or another test cycle cannot be initiated until the Auto
Cal cycle is completed.
Severe Leak
If a test fails to reach Minimum Test Pressure within the Pre-fill timer or fails to maintain at least
the Minimum Test Pressure during the Fill and Stabilization timers, the instrument will exhaust
the pressure in the part and output Severe leak high. The tooling will retract. A reject output also
goes high.
Malfunction
If a test has an error or disruption to the normal process and faults out of cycle before the normal
completion, a malfunction will occur. With tooling control if the error or disruption occurs
during initial tooling action, the tooling will retract. If the error or disruption occurs during the
testing cycle, the test will advance immediately to exhaust and the tooling will retract
automatically. The Malfunction output goes high at the end of the completion of the last tooling
motion.
Part Accept
The Part Accept output goes high at the completion of the tooling motion if the test passes.
Part Reject
The Part Reject output goes high at the completion of the tooling motion if the test fails. Part
Rejects also include Severe Leaks when Minimum Pressure is not reached within Pre-fill timer or
maintained during the fill or stabilization timers.
Calibration Group
The Auto Cal process is a two-step process. During the first test the instrument is testing a
Master (non-leaking) part to determine the baseline pressure change for the testing cycle. The
second test measures the Master part with a Leak Standard added to determine the scaling factor
for the test method to the Leak Standard. Either the AutoCal Master or AutoCal LS outputs
defined below can be assigned to a terminal within different part programs.
AutoCal Master
The AutoCal Master output goes high during the first complete test on the Master part starting at
the beginning of pre-fill timer to the end of the exhaust timer. This output is used to alert an
external process that the instrument is in the first test of calibration.
AutoCal LS
The AutoCal LS output goes high during the second complete test cycle on the Master part when
the Leak Standard is added beginning with the pre-fill timer to the end of the exhaust timer. This
output is used to alert an external process that the instrument is in the second test of calibration.
Test Passed
This output goes high at the beginning of the exhaust cycle for tests that pass and stays high until
the start of the next part test.
Test Failed
This output goes high at the beginning of the exhaust cycle for tests that fail and stays high until
the start of the next part test.
Below Lo Limit
This output goes high at the beginning of the exhaust cycle for tests where the result is less than
the Low Limit set point and stays high until the start of the next part test.
Between Limits
This output goes high at the beginning of the exhaust cycle for tests where the result is between
the Low and High Limit set points and stays high until the start of the next part test.
Above Limit
This output goes high at the beginning of the exhaust cycle for tests where the result is greater
than the High Limit set point and stays high until the start of the next part test.
program before the Extend and Retract outputs can be assigned. There is also corresponding
Extend and Retract timers that must be set for the tooling motions.
The Sentinel C28 instrument has one circuit board. The main circuit board contains the Test
Module, test firmware, input A/D, terminals for the transducer, battery backup, USB port, TCP/IP
connection, power supply terminals, three output terminals, six input terminals, and a supply
fuses. This circuit board is mounted to the door of the wall mount enclosures.
A
B
Seal A
Input 4 and 6
Part Presence Input 3and 5
Switch B Part Presence
Switch A
Input 1 Input2
IOH IOH
Figure 169 Tooling example for two similar parts in a common tooling fixture
Setup for tooling control
Programming of Sentinel C28 to perform the required tooling control for a part
The programming for the tooling control for the part is performed within the Part Config menu.
Because each part requires different tooling action, the part programs will be different. The
following table shows the set up required for operating the tooling to these parts where part
presence sensors detect which part is in the fixture and automatically selects the correct part
program setup as Part 1 and 3. Common start station and stop/reset buttons initiate and stop the
tests. The individual part presence sensors are wired to the part present input specific to a part
and also to the appropriate binary coded Part Select input to select either Part Program 1 or
Program 3. Depending on the part detected, the corresponding seal, manually placed in the part
opening, will activate for the test when the Start station button is pushed.
Use this as an example for setting up the appropriate tooling control for other parts.
Figure 170 Configuration of the Part Configuration, Tooling menu, for the two parts
Figure 171 Configuration of the Part Configuration, Input menus, for the one part
Figure 172 Part Configuration, Output menus, for the two parts
Check instrument catalog number on label located on the right side of the instrument. It will
indicate the Supply Voltage and I/O Voltage. The instrument Supply Voltage can be different
than the I/O voltage. The instruments incoming power can be wired to the instrument using the
power cord supplied. For 120 VAC models the power cord will have a three-prong plug on the
end. For 24VDC and 220 VAC models the power cord will be a pigtail cord.
Use supplied power cord or replace with new wiring for incoming main power. The Neutral (or
white) wire is connected directly to terminal 2 on the power supply. The Line (or black) wire is
interconnected to the blue wire from the On/Off switch. The switched power then goes to the
Power Supply (120VAC or 220VAC on terminal 1. Supply for the digital inputs and outputs
should be supplied separately to the main circuit boards power terminals.
Yellow Blue
+24V Clear
Rtn Common White
Black
Egn Ground Shield Gnd Common
Line
ION
IOH Green
Black
Black
Ground
24V
Line AC
Com
Neutral AC
Lid Base
enclosure
Figure 173 AC Source Power (120 VAC with plug or 220 VAC without plug) diagram
The 24 VDC wires are use a reverse color code. The white wire in the supply power cord is +24
volts. It is connected directly to the blue wire of the power switch. The black wire of the supply
power cord is -24V or common. It is connected to a black wire from the Common (RTN)
terminal of the main circuit boards power terminals. The green ground wire is connected to the
enclosure ground located at the top left side inside the enclosure.
Yellow Blue
Clear
+24V Black
RTN Common White
Shield Gnd Black Common
EGN Ground +24 V
ION
IOH Green
Lid Base
enclosure
Figure 174 DC Source Power wiring diagram
Drivers
Inputs
Valve
IION
+V1
+V5
+V4
+V3
+V2
ST2
ST4
IN6
IN5
IN4
IN3
IN2
IN1
-V5
-V4
-V3
-V2
-V1
Outputs
terminals
Power
+24V
I/O Fuse
EGN
OT3
OT2
OT1
RTN
IOH
IOH
ST3
Power 120VAC I/O (3)Resistors
ION
ST1
Supply 2.5 amp 24 VDC I/O (no resistors)
Fuse
2.5 amp
Transducer
Pin 5 = Shield
(Black wire)
Pin 4 = PEX-
(Negative Supply, white wire)
Pin 3 = PVO-
(Negative Output, blue wire)
Pin 2 = PVO+
(Positive Output, yellow wire)
Pin 1 = PEX+
(Positive Supply, red wire)
Memory
Backup 3V
Jumper System USB Jumper
TCP/IP
Position Reset port Position
Port
Button
Figure 175 Main circuit board with input power, I/O, and transducer terminals
Different manifold types have dedicated outputs for the test valves. No connection should be
made to these outputs except for the individual test valves on each module. The connection
pinouts below are only provided as a reference for service and installation. To utilize equivalent
signals for external use (external valves, etc.) select the appropriate programmable outputs in
software and use the provided output terminals. Any connection to these valve drivers other than
that listed below will void the warranty. Since each manifold has potentially different
connections, each is listed below.
Ethernet
Provides Ethernet communications for remote process monitoring and system updates. This is an
industry standard RJ-45 connector following IEEE 802.3 (10Base-T).
Input Terminals
Check instrument cataiog number and electrical specifications contained on the label located on
the right side of the instrument. It will indicate the Supply Voltage and I/O Voltage. The
instrument Supply Voltage can be different than the I/O voltage. Wire the supply voltage via the
optional external interface cable to the I/O connector on the top of the enclosure. These
terminals are also the common terminals for the input and output signals.
The 6 inputs are selected uniquely for each part program via PART CONFIG, TOOLING and
INPUT screens. There are 15 available input functions that can be assigned to these terminals
within the constraints of their Universal and Part Program Specific group functions The inputs
are identified in Figure 175 above and corresponding numbers in the PART CONFIG, INPUT
screen. Use the source voltage and common to the external interface cable for the sinking the
inputs.
Output Terminals
Check instrument cataiog number and electrical specifications contained on the label located on
the right of the instrument. It will indicate the Supply Voltage and I/O Voltage. The instrument
Supply Voltage can be different than the I/O voltage. Wire the supply voltage via the external
interface cable to the I/O connector on the top of the enclosure. These terminals are also the
common terminals for the input and output signals.
The 3 outputs are selected uniquely for each part program via PART CONFIG, TOOLING and
OUTPUT screens. There 19 available output functions that can be assigned to these terminals
within the constraints of their Universal and Part Program Specific group functions The outputs
are identified in Figure 175 above and corresponding numbers in the PART CONFIG, OUTPUT
screen. Use the source voltage and common to the external interface cable for the sourcing
outputs.
Backup Battery
Button battery located on the main circuit board provides uninterrupted memory for storage of
test parameters, counters, and test results. (Panasonic 3V, BR2032)
Periodically conduct visual check of the clear air line going into the inlet port of the
instrument for dirt or water.
Conduct Self Test on pneumatics periodically to verify integrity of internal pneumatics.
Replace inlet air filters (5.0 and 0.3 micron) quarterly
Re-certify leak standard (every 6 months or annually) - return leak standard to CTS for re-
certification.
Clean the front panel with a damp cloth and dry thoroughly - Do not use solvents.
All the unique parts supplied by Cincinnati Test Systems including operator panel, electronics,
and pneumatics are specific to the Sentinel C28 and should be supplied solely by CTS or our
authorized service agents.
If changes are required in the operating firmware of the instrument, it is easy to perform an
upload of new firmware. Insert the USB flash memory stick with the new firmware into the USB
connection port located on the bottom of the circuit board mounted to the door of the enclosure.
The aluminum protection plate must be opened to access the USB
connector.
Press INSTR CONFIG key repeatedly until the USB tab is
highlighted on the top line of the display.
Move the > next to Update firmware. Press the EDIT key.
Use the up or down arrow keys to select Yes and press
ENTER key.
The instrument display will show the versions of firmware Figure 178 USB Port
stored on the USB flash stick. Use the arrow keys to select the
latest version of firmware and press ENTER.
The instrument will upload the new firmware automatically
and indicate when it is complete. This takes several minutes.
If new firmware is obtained via a file attachment, it will be sent as a zip file.
SPARE PARTS
Pressure Transducer Assembly
(Includes transducer, connector cable, and O-ring.)
Pneumatic Manifold Block (Pneumatic block, valves and all hardware fittings). Does not
include pressure transducer, leak standard, regulator, or mounting bracket.
COUPLING-
SENTINEL--USB MEMORY
SERVICES
Instrument Refurbishment
Includes new valves if needed, manifold cleaning, O-rings, and leak standard re-certification. All
components are inspected for damage and wear. Instrument is functionally tested to original
specifications. Includes 1 year warranty.
The instrument has messages and test codes to define the outcome of each test initiation.
The following tables provide the Messages, Codes and Explanations for the messages.
Master Part C2 The pressure loss during the first test of Check the seals and
Loss> Max Auto Cal on the Master part exceeded the master part for
Mstr+Leak Max Mstr+Leak Loss set point. This leaks, or extend
Loss results in a Malfunction, stabilization timer.
Check that Max
Mstr+Leak Loss
was correctly set.
Master C3 The pressure loss during the second test of Check the seals and
+Leak Loss > Auto Cal for a differential mass flow test master part for
Max on the Master part exceeded the Max leaks, or extend
Mstr+Leak Mstr+Leak Loss set point. This results in stabilization timer.
Loss a Malfunction, Check to leaks
about leak standard.
Check that Max
Mstr+Leak Loss
was correctly set.
Master C9 The pressure loss reading during the first Check for blockage
Loss<Min test of Auto Cal cycle for a pressure decay in the test line of
Master Loss test was less than the Min Master Loss set part.
point. This results in a Malfunction.
Calculation CE This result occurs from illegal part
Error configurations, calculation errors when
trying to convert vacuum pressures to
positive pressure readings, and other
occurrences.
Calibration ID The calibration data for the part is not Check the data in
Data Invalid consistent with the test. There will be no PART CONFIG,
output resultant Cal to make sure it
is appropriate.
TRANSDUCER ERRORS
At the beginning of each test the instrument quickly performs initial transducer checks to verify
the atmospheric zero pressure reading and zero flow (for mass flow version). Excess pressure or
flow will stop the testing process.
PART PRESENCE
If activated within a part program in the INPUT screen, the Part Presence input checks for a high
input when the Start input is received .
TOOLING ERRORS
Each part program can have a unique combination of input and output functions to perform a leak
test. If these function inputs and tooling motions do not properly sequence, there are error
messages to identify the faults.
Stop Input SH The Stop input was high when the Start Check the Stop
High input is received. This results in a input wire for a
Malfunction fault.
Test Errors
Message Code Description Corrective Actions
Part Accept A Part tested successfully, for multiple tests
all tests passed
Part Reject R Part test was not successful, for multiple
tests if any test fails, the part is rejected
Sequence QC Sequence Complete
Complete
Severe Leak SL Severe Leak indicates the test process did Check pressure
not achieve Minimum Pressure within Pre- regulator setting,
fill timer or failed to maintain Minimum cut seals, bad parts,
Pressure during fill or Stabilization timers. or tooling control
This results in a Reject Part. pressure by testing
with Master part
Test Pressure PL Test pressure was below Minimum
Low Pressure during Pre-fill or fill cycles.
This results in a severe leak.
Test Pressure PH Test pressure was above the Maximum Check pressure
High Pressure during fill or stabilization cycles regulator setting
resulting in a Malfunction and tooling control
pressures
Below Target PB The test pressure during test was below the Check the test
Pressure Target Pressure by more that 50%. This is pressure regulator
outside the range for acceptable pressure setting
correction. This results in a Malfunction.
Above Target PA The test pressure during test was above the Check the test
Pressure Target Pressure by more that 50%. This is pressure regulator
outside the range for acceptable pressure setting
correction. This results in a Malfunction.
Part Program A Start Input is received and there are no
Not program parameters stored for that part
Configured program.
Part Error EP This results in a Reject.
CHAPTER 14 SPECIFICATIONS
Pressure Regulators
Precision mechanical pressure regulator (bleeding)
Ranges: 0.5 to 2, 0.5 to 10, 2 to 30, 2 to 100, 2 to 200 and
0.5 to 14.7 psiv
Holds pressure to +0.25 in. water column (0.01 psi)
Transducers
Absolute pressure transducer
Ranges: 20, 45, 115, and 215 psia
Valves
Test valves on pneumatic test manifold
Pilot operated cartridge valves with standard flow or high cv capability and long cycle
life (PA, PB)
Solenoid valves: Ultra low heat gain activated by pulse-modulated outputs (Pneumatic
Manifold versions PN only)
Calibration system: NIST traceable calibrated leak standard (1% accuracy) sized to within 0 and
+5% of specified reject leak limit
Digital Outputs: Dry contact relays (120 VAC (50-60 Hz) or 24 VDC) depending on the
separately supplied power to I/O. The sourcing outputs are fused for a total of 2.5 amps. The
three terminals located on internal circuit board are wired to an external connector on top of the
enclosure.
Digital Inputs: Optically isolated 120 VAC (50-60 Hz) or 24 VDC depending on the separately
supplied power to I/O. All inputs are sinking. Six input terminals located on internal circuit
board are wired to an external connector on top of the enclosure.
Optional 14 pin industrial I/O cable is available to simply wiring to external devices.
Communication input/output:
Serial output to printer or portable computer
9600, 19200, 33600, 57600 or 115200 baud
No parity 8 bits 1 stop bit none
Dimensions:
Nema 12 Die Case Aluminum Industrial Enclosure, painted
8.8 W x 6.75 H x 7.5 D
Weight: 12.3 lbs
Environmental Conditions:
Indoor use only
Barometric pressure variation: 12.2 to 17.2 psia
Operating temperature: 5C (41F) to 40 C (109 F)
Maximum relative humidity: 80% up to 31C decreasing linearly to 50% at 40C
Installation category II
Pollution category II
Test connector: Standard pressure connector - 200 psig (or vacuum at 14.7 psiv)
Volume
The laws of physics require that test volume and test accuracy be inversely related. It is always in
your best interest, therefore, to reduce the volume of the test part, test lines, and tooling that are in
the test circuit. Some possibilities include:
- Use filler blocks when possible to reduce the internal (test) volume of the part.
- Mount the instrument as close to the test part as possible
- Use the smallest diameter test line possible (as long as the pre-fill or fill timers does not
have to increase).
The test line should be made of 2000 psi Parker tubing or similar with the shortest length and
smallest diameter (1/4" or 1/8") as possible. The instrument should be mounted above the part to
keep contamination away from the test pneumatics.
Isolate the test system from sources of warm or cold air (radiant heaters, air conditioning ducts,
loading docks, fans, etc.). They change the temperature of the part, causing the test pressure to
fluctuate. Test Parts should soak at room temperature before testing to assure consistent test
performance.
Cycle time
The easiest way to improve repeatability performance is to increase the total cycle time. Total
cycle time includes Pre-fill + Fill + Stab + Test + Exhaust timers. Unfortunately, there usually is
a limit on allowed cycle time due to production thru-put requirements. In general, since longer
test cycle times almost always improve performance, you should extend the total test cycle time
to the maximum allowed to meet production.
Pre-fill Timer
The value of this timer does not affect the overall time cycle for the test. The actual time it takes
to get to the Min Press does add to the overall time. Therefore, there is little to optimize here.
For large parts, adding an external fill valve through a larger test line can reduce the time it takes
to reach Min Test Press because it will get air into the part faster. The high Cv manifold offering
provide 5 times higher flow rates than the standard valves. This configuration will fill and
exhaust parts faster. Make sure there are no restriction in the test line less than for the
standard and high flow manifold circuits
Exhaust Timer
This timer does add to the overall time cycle. Observe the time it takes for the part to exhaust
down to 3 psi. Set the exhaust timer as close to this time as possible. One shortcut to exhaust
large parts faster is to add a normally closed, larger orifice valve (0.25 inch or greater) externally
to the test line. Wire this valve to the Exhaust output. The part will now exhaust through both
the external valve and the internal fill/exhaust valve. This valve must be leak tight because it is
now a part of the test circuit and therefore will be leak tested during each test. To avoid
exhausting dirty part air back through the instrument, use a 3-way valve that direct all the exhaust
air out the valve and avoid the instrument.
Test Time
Performance can often be improved by removing time from the Fill and Stabilization timers and
putting this time into the Test timer, (this is especially true when the test time is less than 5
seconds). To determine if this strategy will help, look at the Master Part Loss value in the
PART CONFIG, Cal tab. If the Master Part Loss value is very small (<0.0010 psi) or the
PERFORMACE FACTOR is greater than 50, we would expect better performance by increasing
the test time at the expense of fill/stab times. Similarly, if the Master Part Loss is more than
75% of the Master+Leak Loss (and especially if these numbers are greater than 0.050), then
you should increase the Fill and Stab time (at the expense of the test time if necessary).
SHIPMENT
CTS reserves the right to designate the method and means of shipment. All Products will be
shipped F.O.B. the CTS plant, Cleves, Ohio. Title, right of possession (unless liens are imposed),
and all risk of loss or damage shall pass to Buyer and delivery shall deem to be completed, upon
delivery of Products to the carrier, its agent or designee.
ACCEPTANCE OF PRODUCTS
Unless notice of defect, nonconformity or disparity in quantity (as compared to shipping
manifest) is received by CTS within thirty (30) days from receipt of the Products by Buyer, the
Products shall be deemed to be accepted by Buyer.
All quotations or proposals are for a gauged system for measuring production parts in a
production environment. Performance of the custom engineered test systems will be tested and
documented with a standard Gage R&R study performed at CTS as part of run-off procedures
prior to shipment. Such testing and qualification is independent of any Buyer part variation or
production environment variables. Unless expressly stated to the contrary, quotations do not
include time for Process Capability Studies using production parts. CTS will ensure that
fixturing will not introduce unacceptable variations in the testing process.
For custom-engineered test systems, Buyer will be given two weeks advance notification of the
intended run-off date. At such time, Buyer may inspect the Products. After inspection and
acceptance by Buyers representative, the Products will be shipped and payment will be due as
quoted. If Buyer elects to waive the inspection, the Products will be deemed to have met the
Buyers requirements and the Products will be shipped and payment will be due as quoted.
CANCELLATION
Buyers purchase order, when accepted by CTS, shall not, for any reason, be canceled in whole or
in part by Buyer without CTS prior written consent. If CTS consents to cancellation, Buyer shall
pay CTS reimbursement for all the applicable costs incurred and the reasonable allowance for
profit as stated by CTS in its written consent to cancellation by Buyer.
ENGINEERING CHANGES
If Buyer requires changes to be made to the Products, once a design of the Product is proposed
and accepted, the additional engineering time, material and shop time required for fabrication as a
result of the change will be subject to negotiation and additional charges will be invoiced
accordingly for the negotiated amount.
OSHA
The Products will be designed and manufactured to meet CTS interpretation of the Occupational
Safety and Health Act (OSHA). Specific Buyer requirements are not included as part of any
quotation or proposal unless the specified requirements were included in the request for quotation
or proposal. After a quotation or proposal is submitted, any other requirements shall be a
supplement to the quotation or proposal or be the subject of a new contract, and the price for such
requirements shall be subject to negotiation. While the Products have been designed to conform
to CTS interpretation of applicable OSHA standards, such compliance is neither warranted nor
guaranteed. Compliance with OSHA requirements is the sole responsibility of Buyer, and CTS
assumes no responsibility for damages suffered by Buyer relative to compliance with OSHA
regulations.
SOUND LEVELS
Sound levels produced by the Products quoted or proposed will not exceed 80 dba when
measured at the operators position and three feet around the perimeter of the Products. When
sound levels exceed 80 dba due to the characteristics of the part being assembled or tested,
special provisions which are not part of the initial quotation or proposal will be made wherever
possible to reduce the sound level. Such alterations to reduce sound level will be charged to
Buyer separately. In the event of a conflict between noise specifications and preferred
equipment, design specification waivers must be granted. When the Instrument is of a design or
manufacture which may be subject to state or municipal ordinances or insurance company
regulations, such Products will be designed and manufactured in accordance with generally
accepted practices and will be adequately tested. Unless expressly stated in the quotation or
proposal, the Products will not be designed or manufactured to conform to any particular
ordinance or regulation.
CTS assumes no liability for the failure of the products to comply with any particular
ordinance or regulation unless the quotation or proposal expressly warrants that the
products will conform to said ordinance or regulation. It is the responsibility of the buyer
upon inspection at the CTS facility to inform CTS of nonconformance with a particular
safety or design standard. Upon inspection by buyer or waiver of inspection by buyer, CTS
is released from any and all liability for failure of the equipment to conform to safety or
design standards.
WARRANTY
CTS warrants that the Products, under normal and proper use, shall be free from defects in
material and workmanship that impair its usefulness, for a period of twelve (12) months from the
date of shipment. Other manufacturers component parts installed in or on the Products are
products of reputable manufacturers sold to CTS under their respective brand or trade names and
shall carry the standard guarantee of the manufacturer thereof, if any, and CTS shall not be
responsible for any defective part thereof.
All tests performed on Buyers manufactured products are performed pursuant to the Buyers
specifications for its manufactured products, and by performing such tests CTS shall not assume
any liability for defects in such manufactured products, test data or test specifications. Buyer has
ultimate responsibility for the safety of Buyers manufactured product, including establishment of
leak standards. It is Buyers obligation to report any suspected defect as soon as possible after
discovery. Support service will be provided as soon as practicable to work with Buyers
personnel to remedy a suspected defect. If a service person is required to visit Buyers site, a
purchase order from Buyer to CTS will be required to cover the cost of such service call in the
event that the item serviced is not covered by the applicable warranty. No on-site service is
available for standard test machines unless the cost is prepaid by Buyer. If support service is not
successful in correcting the problem, the Products shall be returned to CTS at Buyers cost.
Products may not be returned without obtaining prior authorization from CTS. All Products
returned for warranty inspection must be securely packaged and shipped prepaid. The Products
will be inspected upon receipt for shipping damage and Buyer shall be notified by CTS if such
damage has occurred. In the event of damage, it is Buyers responsibility to notify and file
damage claims with the delivery company. After receipt of Products at the CTS facility in
Cleves, Ohio, and inspection by CTS, CTS will determine the extent or existence of defect.
CTS obligation under this warranty is limited to repairing or replacing, at CTS option, any
defective non-consumable parts. Consumable parts are specifically excluded from this warranty,
including but not limited to lamps, elastomers, seals, valve seats, and other wear surfaces. This
warranty is conditioned upon Buyer furnishing satisfactory evidence that the Products alleged to
be defective has been properly maintained and correctly operated under normal conditions with
competent supervision and within the operating limits for which such Products are offered and
sold. This warranty shall not apply to any Product that has been subjected to misuse, abuse,
neglect or improper storage, handling or maintenance, or modifications or repairs by any party
other than CTS. The installation of the Products must include proper filter and moisture
separation on the incoming air supply. Repairs required to remove foreign material from the
valves or test circuit will not be covered under the terms of this warranty.
Except as expressly stated in this warranty section, CTS makes no warranty, express or
implied, whether of merchantability or fitness for a particular purpose or use or otherwise,
with respect to any products.
LIMITATION OF LIABILITY
In no event shall CTS be liable for special, indirect, incidental or consequential damages, whether
in contract, tort, negligence, strict liability or otherwise, including without limitation damages for
injury to person or property, lost profits or revenue, lost sales or loss arising from or pertaining to
the use of any Products. Buyers sole and exclusive remedy against CTS and its distributors or
sales representatives shall be the repair or replacement of defective parts as provided herein.
CTS liability on any claim, whether in contracts, tort, negligence, strict liability or otherwise, for
any loss or damage arising out of or in connection with Buyers order, shall in no case exceed the
purchase price of the Products actually paid to CTS by Buyer.
SAFETY
Buyer hereby covenants that the Products sold hereunder shall be operated by Buyers employees
and agents utilizing all guards, warning signs and other safety devices that are provided with or
are a part of the Products. In addition to any other rights CTS may have against Buyer for breach
of this covenant, no warranty on the Products whatever, expressed or implied, shall be applicable
in the event such covenant is breached. Buyer further agrees: (i) that disconnections,
disassembly or nonuse of any of the guards, warning signs or other safety devices provided with
or which are part of the Products constitute a substantial change in the Products; and (ii) that it
shall indemnify and hold harmless CTS from all claims for damages and injuries made by any
and all parties through the use of such substantially changed Products.
PAYMENT
Buyer shall pay the purchase price as stipulated in the attached proposal, and shall in no event
exceed thirty (30) days after acceptance of the Products to make full payments. International
orders outside of the US and Canada require payment in full prior to shipment of the Products.
CHOICE OF LAW
All proposals, quotations and sales of Products shall be governed by and interpreted in
accordance with the laws of the State of Ohio, USA The applicability of the UN Convention on
the International Sale of Goods is hereby expressly excluded. Any legal action or proceeding
arising from or in connection with a proposal, quotation or sale of an Instrument shall be
brought exclusively in the courts of Hamilton County, Ohio, USA or in the U.S. District Court for
the Southern District of Ohio and shall not be transferred or removed to any other court,
provided, however, that CTS may commence an action in any jurisdiction where Buyer or its
assets may be located, for an injunction, collection or similar relief to enforce the provisions
hereof.
CHAPTER 17 GLOSSARY
Word Meaning
A-to-D Analog to Digital
Adiabatic The gas compression causes temperature of the gas to rise. The heat will
temperature effects cause metal parts to expand. The cooling gas will reduce the pressure.
atm atmospheres, Units of pressure
Bar million dynes per square centimeter, Units of pressure
Cv factor Flow coefficient
FNPT Female National Pipe Thread
iHG inches of mercury
iWC inches of water column
kPa kilo Pascals
ksc Kilogram per square centimeter
linking Joining several test programs into one sequential test
lpm liters per minute, measurement of Leak Rate
lps liters per second, measurement of Leak Rate
lph liters per hour, measurement of Leak Rate
Manifold Pneumatic circuit paths including valves and transducers
mHg millimeters of Mercury, Units of pressure
mbr millibar, Units of pressure
MPa Mega Pascals, Units of pressure
NPT National Pipe Thread
ozi ounces per square inch, Units of pressure
PLC Programmable Logic Controller
Psi pounds per square inch, Units of pressure
psia Pounds Per Square Inch Absolute
Psig Pounds per square inch gage, pressure difference from atmospheric
Regulator Device to control the pressure from the supply source to the desired
pressure for the test
scch standard cubic centimeters per hour, measurement of Leak Rate
Sccm Standard cubic centimeters per minute, measurement of Leak Rate
sccs standard cubic centimeters per second, measurement of Leak Rate
Stab Timer Timer to delay test after pressurization so that the temperature can equalize
or stabilize within the part under test and the test instrument.
Transducer An electrical device to convert energy from one form to another, such as a
sensor to convert pressure to an electrical signal
CHAPTER 18 INDEX
Above Limit.......11-6,11-9 INSTRUMENT CONFIGURATIONS. ... ..2-7,2-11,
Absolute pressure transducer4-4, Ch 6, 13-7 3-2,Ch 4,6-1
ACCESSORIES.1-17 Instrument Startup ................................................... 1-1
Air supply....1-1, 1-10 Leak Rate ..................................... 2-6,3-6,4-9,5-4,Ch.6
AlphaNumeric..2-4 Leak Rate Units ............................................... 3-3,5-13
Arrow keys......2-4 Leak Standards.1-2,1-16,2-10,Ch.3,Ch.5,Ch .6,
AutoCal1-3,2-6,2-15, Ch 3, 4-20, Ch 5, Ch 6, 7-6,12-4,13-1.14-1
12-5, 13-1, 14-1 Linking...5-17
Auto Run.5-5, 5-11 Low Limit ............................ 2-9,3-4,5-8,5-20,6-4,11-9
Auto Setup1-2, 2-6, Ch 3, 5-5 MAC Address4-12,8-9,9-1
Backup Battery...11-17, 12-3 main power ................................................ 11-18,11-14
Below limits....1-15,5-7,5-19,11-9 Malfunctions ..... 1-14,5-1,5-19,5-22,6-6,9-7,10-1,
Between limits...1-15,5-19,5-21,11-9 Ch 11,Ch 13,14-1
Binary inputs..4-3, 5-15,11-4 Manifold types4-2,5-3,Ch.6,8-9,9-2.11-16,12-3
Calibration. 1-3,Ch .2,Ch 3,Ch 4,Ch 5,Ch 6, Master part .... 1-3,2-6,3-5,4-10,5-7,7-5,Ch.6,13-1,15-1
Ch 11,Ch 13 Master+Leak Loss.4-10,5-6,6-7,Ch.13,15-2
Calibration methods...3-7,5-10 Master pressure guage....1-17,7-1,8-3
Calibration Verification........................2-6,2-12,7-6 Max Master+Leak Loss ................. 4-11,5-2, 6-7,Ch 13
Catalog Number1-6 Maximum test pressure .................... 5-6,6-8,6-19,11-5
CHANGE PART...2-11,2-14,4-3,4-20,5-1 Measurement units.....2-11,5-12
CHANGE PART key...2-11,4-3 Minimum Performance Factor.3-9,4-11,15-3
Constrained Inputs/Outputs...5-17,5-21,11-1,11-4 Minimum test pressure ..............................5-6,6-9,11-7
Controller board.....1-12,5-24 Monitor ................................................................. Ch 2
Counters2-6,4-7,4-17,8 -3,9-7,10-1,11-13 MOUNTING CONSIDERATIONS ........................ 1-8
Custom output formating....4-9 Occlusion testing...2-9,4-3,5-3,5-8,6-8
Cycle time.....1-2,2-14,3-2,6-10,15-1 Operator panel....1-4,2-1
Desired Cycle time1-2,2-14,3-4,6-27 Orifice (Leak Standard) value2-14,5-5,7-6,Ch.6, 12-
Digital Inputs....1-14,,2-6,5-3, 5-15,5-23, 2,13-5,14-1
Ch 11, 14-1 output functions ................................. 1-14,5-18, Ch 11
Digital Outputs..1-17, 2-7,5-6,5-18,5-25, Output Terminals ......................... 1-16,5-19,5-24,12-6
Ch 11,14-1 Output Timing Charts....5-19,5-22,11-6
Dimensions..1-9,,14-2 Part Accept.1-15,4-11,5-19,,10-1,Ch.11,
DISPLAY Panel.......1-4,2-2,2-6 13-5,14-1
Electrical Connections .......................................... 1-12 Part Configuration .................................. 1-14,Ch 5.8-9
ENTER key ............................................................. 2-5 Part Linking...5-17
Environmental Conditions .................................... 14-2 Part Name ..................................................2-4,2-7,5-10
Environmental Drift Correction.......5-8,6-5,9-7,12-1 Part Present ........ 5-20,5-30,11-1,11-5,11-11,13-3,14-2
Error messages .............................................. 2-6,Ch 13 Part program ................... 1-14,2-5,3-3,4-2,Ch.5,,Ch.11
Ethernet .................................... 1-1,2-7,4-14,8-1,11-16 Part Program Specific Inputs/Outputs..5-16,5-19,
Exhaust valve ......................................Ch 6,11-16,15-1 11-1,11-4,11-7
EXIT ....................................................................... 2-5 Part Reject.1-15,4-11,5-19,10-1,11-7,13-5,14-1
Fill time.............................. 3-6,5-4,5-20,6-9,11-6,11-9 Part select ............................. 1-14,5-1,11-1,11-12,14-2
Filters .............................................. 1-1,1-10,1-17.12-1 Part test........................................................... 5-1, 5-20
Firmware Update...............................2-12,4-15,12-1 Part Test Result codes.4-11
Fixed Width output..4-4,4-8,4-14,9-5 Password .................................................2-2,4-17,4-20
FUNCTION PANEL ...................................... 2-2,2-14 Performance Factor1-3,2-7,3-8,4-105-7,13-1,15-2
Fuses ................................................................... 11-15 Periodic Maintenance ............................................ 12-1
High limit ............................. 2-9,3-4,5-7,5-21,6-4,11-9 Pilot air..1-1,1-7,1-10,14-3
High Limit Loss ........................................ 5-7,6-7,12-2 Plumbing Recommendations ................................. 1-10
HOLD .................. 1-14,2-10,2-14,5-15,11-1,11-4,14-2 Pneumatic block ........................ 1-10,3-75-10,7-5,12-3
Hyper-Terminal. Ch 8 Pneumatic connections .......................................... 1-11
Incoming power connections ............ 1-12,11-13,11-14 Power Connection ....................................... 1-12,11-13
Inlet air .................................................................. 1-10 Power supply ...................... 1-13,5-24,11-13,12-3,14-2
Input Terminals ............ 1-13,5-3,5-24,11-4,11-16,14-2 Pre-fill output ............. 1-14,5-19,5-22,11-6,11-18,14-1
Installation1-7 Pre-fill timer ......................... 3-6,5-1,5-6,6-9,11-7,14-1
Press Select...1-14,5-19,5-20,5-22,11-6,11-9