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Table of Contents
Related Manuals for Zaxis Isaac HD
Summary of Contents for Zaxis Isaac HD
- Page 1 User’s Guide Ver. 2.01...
- Page 2 This page has been left blank intentionally.
- Page 3 For Your Safety Install all equipment according to local safety codes. Here are some additional safety guidelines when working with the Isaac or iKit leak tester: ➢ Wear eye protection when working with compressed gas. ➢ Beware that hazardous voltages could be present inside the enclosure. ➢...
- Page 4 Each unit is identified by serial number in a permanent record of the company. If at any time with-in three years after any ZAXIS INC. product has been shipped to a customer (user), it fails to perform according to ZAXIS INC. literature, the product, with written explanation of the problem, may be returned, freight prepaid, to ZAXIS INC.
- Page 5 Introduction: The Isaac HD Multi-Function Leak Tester is the newest product from Zaxis, designed to meet today’s quality assurance demands. The compact size of the Isaac enables it to be used in close proximity to fixtures and operators utilizing a small footprint of bench top space. By reducing the internal and connection volume the test sensitivity increases and test times can be decreased.
- Page 6 Font Panel Touch Screen Interface (TSi) - The liquid crystal touch screen display is the primary control of the leak tester. Abort Button / Fail Indicator Light / Retest Button - Red LED indicator marked with an ‘X’. Start Button/Pass Indicator Light - Green LED indicator marked with a ‘√’. Test Ports - Each port is a 1/8”-27 F NPT (similar to R1/8 BSPT British Standard Pipe Taper) female threads.
- Page 7 Rear Panel 1. Foot Switch Connector: For starting a test. Any closed contact switch may be used to start a test by shorting pins 1 & 3 Mating Conn. & Pins – Tyco Electronics 1-480305-0 (Digi-Key A1400-ND), 60618-1 (Digi-Key A1422-ND) 2.
- Page 8 i-Kit rear panel Power Entry Connector, Supply is 24VDC 60watts (Mating connector S760K-Switchcraft) Power Switch Rear Test Port (optional) I/O Interface Connection (Wiring Chart) Test Pressure Supply, (Air or other test gas) Connection is 1/8”-27 F NPT (Similar to R1/8 BSPT British Standard Pipe Thread) Supply gas must be clean and dry.
- Page 9 Calibration (2) Clock (3) I/O Setup (4) Data Logging (5) Lock tester (6) Change PIN (7) Serial Port (8) Ethernet Settings. Each screen is described later in the setup section. (About) - The “About” screen lists the firmware revision level for the TSi and Isaac, serial number, as well as contact information for Zaxis.
- Page 10 Data input Two input screens are used throughout Isaac’s setup and operation; they are the Numeric and Alpha-Numeric Keypad screens. The Numeric Keypad screen is used to input values for timer and limit fields. The Alpha-Numeric Keypad screen is used in fields such as the program name field.
- Page 11 There are two run screens available to choose from: Large Numeric( single channel), Large Numeric (multi-channel), or Graph Mode Run Screen Graphics...
- Page 12 Return to the setup screens. Setup help Buttons. Cycle between the run screen selections. (Graph, Numeric, and Bar) Clear the previous test graph traces from the screen. (Graph only) Change to Program Number. (Decrement) Change to Program Number. (Increment) Type Test Selected Test Counters Touch to Reset...
- Page 13 Bar Graphics The ‘BAR’ run screen shows the relevant test values at a graphical glance. During the Fill and Settle steps the center of the graph equals the set test pressure value. The top of the graph is + tolerance and the bottom of the graph is the –...
- Page 14 Setup Screens Program The darkened button shows the active selection. Press the ‘i’ to get more information about the settings Setting Test Pressure To set the test pressure, press the data field and enter the test pressure value on the keypad. For machines with the electronic regulator option see below for test pressure setting instructions.
- Page 15 Setup Screens Program Setting Test pressure (Electronic Regulator) To set the test pressure, place a master part or plug onto the test port. Set the desired pressure in the ‘test pressure’ value box as well as the plus+ and minus– tolerance, then check the “Valve On”...
- Page 16 Setting Test pressure (Manual Regulator) To set the test pressure, place a master part or plug onto the test port. (1) Set the desired pressure in the test pressure value box as well as the plus+ and minus– tolerance(1a), then check the “Valve On”...
- Page 17 Clamps, Coupling outputs Fixturing Timers , and are all similar terms used to describe pneumatic outputs that can be used for various functions. These outputs can be used to actuate tooling, manipulate a part, or activate a pneumatic seal around a part. All outputs are supplied as four-way valves with one normally open and one normally closed port.
- Page 18 Cycle Cycle Initiated Pre-Test Leak Pre-Test Test Clamp Valve 1 Pre-Test Pre-Test Clamp Valve 2 Status During Test: Selecting the fixture valves to be off during test will turn off the output during the ‘TEST’ step. The default action is ‘ON’ The typical use is on an occlusion (blockage) test type where the clamp valve will be used to release the part to allow pressure drop to occur to meet test limits.
- Page 19 The timers shown in the settings menu will vary according to the test type. Refer to the test type setup section for details on each specific test type. This example is for Pressure Decay or Vacuum Decay. Fast Fill: (Option) Fast fill allows the device under test to be filled via a second regulated source, typically at a higher pressure for increase air volume.
- Page 20 This calculation should only be used as a reference. For a true decay based on a volumetric leak rate, Zaxis manufactures transfer standards to your leak rate specifications. This ‘leak standard’ is NIST traceable and can be used for a daily verification of you test...
- Page 21 Units There are six selectable engineering units on the setup screen. These units are: o psig – pounds per square inch gauge. o mbar – millibars. o mmHg – millimeters of mercury. o inH2O – inches of water column. o kPa - kilopascals. o cmH20 –...
- Page 22 National Institute of Standards and Technology (NIST) that is tasked to maintain standards for values of SI units and industrial standards, calibration has become a helpful tool in providing the traceability of their subjects of study by adhering to the basic standards of calibration. All Zaxis calibrations are traceable to standards set by the NIST.
- Page 23 Calibration Sensor Selection Screen Selecting the calibrate button will open the sensor selection screen. A warning box will appear. To continue into the calibration screens press ‘Calibrate’. Three sensor types are shown Pressure, Vacuum, and Flow. Even though all three sensor types are shown each unit will have model specific sensors installed.
- Page 24 Live Pressure Reading Pressure Sensor Calibration The following procedure is done with a manual regulator. For machines with the optional Electronic Regulator see the adjustment control section for fine-tuning details. Enter calibration screen and connect the test port of the Isaac to a pressure standard. Select the sensor number to be calibrated in the upper right corner.(Concurrent models have multiple sensors to calibrate) To apply regulated air to the sensor, press the Valves: “ON”...
- Page 25 To change or fine tune a set point, do the following. Adjust the regulator to the desired calibration point on the pressure standard. Press the value field of the calibration point to be modified. A numeric keypad will appear, enter the value to be set, or press enter if the value is correct.
- Page 26 Flow Calibration – There are two typical flow standard systems to use in calibration of Isaac flow sensors. The first is an orifice that with differing applied pressures produces multiple flow rates. The second is a high accuracy flow element with an analog output or display. Because both are calibrated and traceable either can be used to calibrate and Isaac.
- Page 27 Electronic Regulator (Optional Item) With the optional electronic regulator installed adjusting pressure values is done through the software via buttons on the touch screen. The calibration procedure will follow as listed in this manual; the only difference is how the regulator is adjusted to achieve the set points. In the calibration screen and additional button is available: This button will open the regulator control screen.
- Page 28 NOTE: To decrease the effects of hysteresis, perform the adjustments of the electronic regulator in the upward direction, that is, approach the target from a lower value without going over. After the calibration has been performed, press the BACK button to exit to the run screen.
- Page 29 Options Menus The option screen has eight menu buttons: 1) Touchscreen Calibration 2) Clock 3) I/O Setup 4) Data Logging 5) Lock tester 6) Change PIN 7) Serial Port 8) Ethernet Settings...
- Page 30 The touch screen has been factory set. Typical use of the Isaac will not require this function to be used. Entering the calibration screen the user will be asked to touch specific targets to adjust the touch pad to the display.
- Page 31 To modify either the time or date, touch the field to be changed. A keypad will pop-up to make the desired changes. Cycle power after changing each field.
- Page 32 Binary Programmable Selection Bits Each stored program can be selected by a digital bit pattern. Select the number of programs to be used by the I/O. This action will disable the program number select on the front display and will always return to the program selected by the active inputs.
- Page 33 This screen allows the user to test the input bit pattern to help debug wiring from the remote control (PLC etc.). The value from the input register will display when the input is held active. (See I/O pin out chart for Input Test Values) In this screen when an input is active its corresponding output will also be active.
- Page 34 CONN PIN 24-28AWG GOLD CRIMP –Tyco Electronics – Part #66507-4 (Digi-Key #A23004CT-ND) The plug, back shell, and pins will be supplied if a cable is not purchased at time of manufacture. Pre-wired cables from Zaxis: Part number# ISC-ESA031-26-A, (16ft length standard)
- Page 35 Input / Output Connector Pin-out Item Description Input Test Value IN 1 START IN 2 START (ANTI-TIE ENABLED) IN 3 BCD 1 (LSB) IN 4 BCD 2 IN 5 BCD 3 IN 6 BCD 4 IN 7 BCD 5 IN 8 BCD 6 IN 9 BCD 7 (MSB)
- Page 36 I/O Circuit Input Circuit Diagram Output Circuit Diagram...
- Page 37 I/O Hardware The I/O on the Isaac have the ability to be active high or active low (sourcing or sinking) The supply voltage also can be selected between Internal and External. Selection is made on the I/O with jumpers. By selecting External supply, +24VDC and GND must be supplied to the I/O, this will be the voltage supplied when outputs are active.
- Page 38 I/O Timing Chart Test 1 Test 2 BINARY START BUSY PASS FAIL 1 – Binary should be active 100ms (min) before the Start signal 2 – Binary and Start signals should be released after Busy is verified...
- Page 39 Test result fields are TAB delimited. Log Result Only (Header for descriptive purpose, not printed in data string) Date Time Program # Program Name Test Type Result Value 01/26/09 11:10:34 PROG 0 Flow2 Low Flow 0.01 01/26/09 11:10:42 PROG 0 Flow2 Pass 100.21...
- Page 40 Three sections of the tester can be locked (not able to be edited). Select the section to lock by touching its radio button. Locking the calibration will not allow access into the screens entirely. To lock the tester a PIN number (4 digits) must be established. The Current PIN: from the factory is blank.
- Page 41 This feature allows data logging via the serial port. The data bits, parity, stop bits, and flow control are hard coded in the Isaac. • Data bits - 8 • Parity - None • Stop bits - 1 • Flow Control – None The baud rate is selectable and has four selections, 9600, 19200, 57600, and 115200 To receive data from the serial port, the RS232 selection must be enabled for each test you wish to collect.
- Page 42 Serial Port (RS232) Wiring The RS232 serial port on the rear of the test is a valuable tool to collect test results. The serial connection is a simple ‘three wire cable’. The RS232 serial port on the rear of the test is a valuable tool to collect test results. The serial connection is a simple ‘three wire cable’.
- Page 44 ASCII data over the Ethernet The test data from an Isaac can be collected by a computer via the Ethernet connection on the back of the Isaac. To collect data on a laptop you will need a crossover Ethernet cable (see diagram) and a terminal emulation program such as HyperTerminal.
- Page 45 Starting HyperTerminal, the opening screen asks for a connection description, this description can be saved for future use to avoid going through all the configurations. We have chosen to call our example ‘Isaac’. With a connection description made the next screen to appear is Connect To. Hyper terminal has multiple ways of communicating.
- Page 46 With the TCP/IP selection made the Host address and port numbering must be entered. The IP of the Isaac is the Host. The port number is always 23. Pressing OK will initiate the socket connection from HyperTerminal to the Isaac. A successful connection will be show by the connected counter in the lower right corner of the HyperTerminal screen.
- Page 47 To gather multiple tests automatically, HyperTerminal has a feature to collect the text and save it to a file. Select ‘Transfer’ then ‘Capture Text…’ HyperTerminal will now ask for a filename for the data. Remember to make sure the extension is .TXT With a file name chosen, press start to begin the collection.
- Page 48 Test Type Setup The Isaac series of leak testers are multi-parameter instruments. Each unit can have multiple testing techniques installed. Some of the available testing techniques are: • Mass Flow – Flow (ΔT) • Mass Flow – Flow (Laminar Element) •...
- Page 49 PD (Pressure Decay) There are four timers in a typical pressure decay test. Optional timers would include Clamping and Fast Fill. Fast Fill – This timer requires optional pneumatic components to operate and works in conjunction with the F Fill Pressure field. Fast fill is a primary fill step used to quickly fill large volumes by using a secondary regulator set at a higher pressure to increase the volume of air being introduced into the part.
- Page 50 Vent - This is the amount of time to exhaust the pressure from the unit under test. Primarily this is used as a safety to remove pressure away from the operator. The pressure is vented internally to the Isaac. If the auto button is checked, the unit will automatically vent until test cavity pressure is less than 20 mbar.
- Page 51 Mass Flow The mass flow test is used to quantify air flow values through a part, inspect for occlusions blocking the flow path, and can also be used as a leak test. The main program screen is identical to the setup of a pressure decay test. The coupling menu will behave as described earlier in the manual.
- Page 52 Burst The burst test can be used in both destructive and non-destructive applications. A single sensor will be used for all parts of the burst test. The device will be tested by a ramping pressure, at the point of rupture or opening a small pressure drop is sensed by the internal transducer. This drop is the burst event;...
- Page 53 Occlusion The occlusion test will check for blockages in the air flow path of a part. This test is similar in setup to a pressure decay test with two exceptions, first no settle step is used, and an occlusion test needs to see a large drop in pressure in the test step. The clamping output can be used to drive devices or pinch tooling to clamp off the part prior to test.
- Page 54 Crack The crack test is similar to the burst test in that it finds the opening point of a device. But the crack is more sensitive to smaller opening pressures, or parts that weep open. A second pressure sensor is set on the downstream side of the part and monitors for the crack event. The downstream transducer can also be a mass flow sensor.
- Page 55 Should the tool be dedicated to a single task or fit multiple models? • Size o How much production space do you have? • Component Selection Custom designed pieces or off-the-shelf technology? Zaxis can deliver a complete turn-key system designed to your specifications.
- Page 56 Pressure Decay and Occlusion pinch test fixture for a cassette with a tube set. (Two station) Pressure Decay, Mass Flow, and Burst test pinch fixture with shield and interlock for operator safety. Zaxis can deliver a complete turn-key system designed to your specifications.
- Page 57 Engineering Data: Converting Pressure to Flow Rate You can determine the leak rate in flow units (cubic centimeters per minute) based on the pressures measured by Isaac. In a pressure decay test, Isaac holds the pressure drop on the main screen. The pressure drop is the delta pressure (ΔP) in the formula. Delta time (Δt) is the test timer value set in Isaac’s pressure decay program (provided the test passes).
- Page 58 Physical Laws We present here an abbreviated history and overview of fundamental laws dealing with pressure and flow measurement. Pressure In physics, pressure is a force measured in terms of its distribution over a given area. This is expressed as force (F) divided by a unit area (A) of the surface area to which the force is applied. Air pressure most commonly refers to a force exerted uniformly in all directions.
- Page 59 Fluids vs. Solids The distinguishing feature of a fluid (gas or liquid), in contrast to a solid, is how easily the fluid can be deformed. If a shearing force, even a very small force, is applied to a fluid, the fluid will move and continue to move as long as the shear acts on it.
- Page 60 Re = (ρ) Lv/μ. Reynolds Number (Re) The Reynolds number has no unit of measure it is a pure number. As long as Reynolds number is small, the flow remains laminar. When the Reynolds number becomes greater than a critical value, the flow becomes turbulent. With rho {ρ}, L, and mu {μ} constant, Re varies simply as velocity changes.
- Page 61 Ideal Gas Law The Generalized Gas Law can be written in a slightly different manner from the Generalized Gas Law: PV = nRT When written this way it is called the Ideal-Gas Law. R is the gas constant, and n is the number of moles of gas. The gas constant can be examined experimentally as R = 0.082 liter atm/Kelvin moles.
- Page 62 Reference: List of Terms and Where to find additional information Abort a test, how to Press the start button during the test. ABORT pops up in the status box telling you the process has stopped. An aborted test does not register on the tested or reject counters. atmosphere Atmosphere (1) in this guide, means room air pressure.
- Page 63 Counters, (Reset) By selecting the “Cycles” or “Failures” numeric fields, the “Reset Counters” dialogue box will appear, press the clear button then press “OK”. Coupling Port The coupling port supplies air pressure to product sealing fixtures or other external pneumatic components.
- Page 64 Flow Control Isaac has a built-in flow control to provide a slow pressure increase (ramp up) needed for burst and crack testing. Users can precisely set the flow control for the exact pressure build-up required for the product to be tested.
- Page 65 Pilot Air Certain applications require the use of pneumatics that is pilot actuated. A steady air supply is required to assist in the operation of these valves. Zaxis’ proprietary air valve requires 85-100psi to function correctly. Program Screen This screen is used to enter all setpoints and limits concerning pressure decay, flow, and burst test.
- Page 66 “HI Pressure “error will report. If the test pressure falls below the mark during the Settle step, a “Gross Leak” error will report. Pressure Regulator Isaac uses a precision pressure regulator that controls line pressure. The pressure regulator is adjusted during setup to set test pressure. Pressure Standard A precision measuring instrument that can be connected to Isaac as part of a pressure or flow calibration.
- Page 67 NPT (Similar to R1/8 BSPT British Standard Pipe Taper) female thread bulkhead. Air must be clean, dry, and free of oil Target A preprogrammed number that Zaxis stores in firmware used to calibrate Isaac’s pressure and flow sensors. The target value is matched to a pressure or flows standard to create a lookup table for sensor linearity adjustment.
- Page 68 Timers Isaac uses microprocessor timers to establish time intervals for a variety of test functions. Time values are Program set in Isaac’s screen by the user to control coupling time, fill time, settle time, and test time. Timers are Program Screen calibrated in seconds with a maximum setting of 999.9 seconds.
- Page 69 Maintenance/Troubleshooting Warning! Disconnect power before servicing the unit. Special Precautions If at any time the cover is removed from the tester for service, verify that the flex-ribbons connecting the display to the main PCB (printed circuit board) and the main PCB to the I/O are seated and are square to the connectors.
- Page 70 Internal Leaks At the factory a baseline leak test is performed to verify leak-tightness and functionality. This test is a good indicator of an internal leak. The parameters are listed below. Running a capped port test with these parameters should yield a decay value less than 0.005psig (0.344mbar).
- Page 71 Pressure Transducer Valve 2 Valve 1 Pneumatic Diagram When the test pressure is vented, the airflow path is through Valve 1 (on) and out to atmosphere through Valve 2 (off). Debris from test parts or dirty air can be trapped between the spider seal and valve seat of the 2- Way valve, holding the valve in an open position.
- Page 72 Valve manifold (removed from machine for clarity, removal of manifold is not necessary for cleaning or inspection) Type 2 Valve Manifold Cylinder Head Screws Pressure Transducer 3-Way Valve 2-Way Valve Test Port Fitting The most common place for leaks to occur is at the junction of the test port fitting to the valve manifold.
- Page 73 Valve Seat Piston Seal Face To clean debris from the valves, remove both cylinder head screws. The cylinder head and manifold body will separate. Check and clean for debris on both the valve seat and piston seal face. To re-assemble, verify the manifold body o-rings are in place, replace the cylinder head on the manifold, (pins will aid in alignment).
- Page 74 Filtration If a mist separator filter was purchased, the filter media can be inspected and cleaned. Some units will have a regulator/filter combination. Disassembly of the filter portion is identical. The filter size is 5 micron. Filter element Capture bowl Protective cover Element lock-nut...
- Page 75 Fuse Warning! Disconnect power before removing fuse holder. The installed fuses are: 5 X 20mm, 250V F 2.0A. Both line and neutral are fused. The fuse should be seated towards the insertion end of the cradle (as shown, typ. 2plcs).