Pfeiffer Vacuum E-PDQ Programming And Operations Manual
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Pfeiffer Vacuum E-PDQ Programming And Operations Manual

Pfeiffer Vacuum E-PDQ Programming And Operations Manual

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Programming and Operation Manual
Leak Test Instrument
Model E-PDQ
Firmware Revision 2.3.14 or 2.3.15
Hardware Revision A
July 6, 2021
Manual Revision 1.5
Proprietary Note:
The IGLS, Mass Extraction Technology, Adaptive Test and Leak-Tek ©, Leak-Rx© programs are
proprietary products belong to ATC, Inc. and are protected by existing patents (5,861,546;
6,3085,56B1; 6,584,828B; ,6,854,318B2; 7,231,811,EP1-356-260-B1) as well as other US and
International pending patents. The Leak-Tek program©, Leak-Rx© program, Adaptive Test Utility
Program© and ATC Model-EPDQ are protected by international copyright laws.
© 1995-2015 ATC, Inc. All rights reserved.
This manual should not be copied or transferred to any third party without ATC's written consent.
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  • Page 1 Programming and Operation Manual Leak Test Instrument Model E-PDQ Firmware Revision 2.3.14 or 2.3.15 Hardware Revision A July 6, 2021 Manual Revision 1.5 Proprietary Note: The IGLS, Mass Extraction Technology, Adaptive Test and Leak-Tek ©, Leak-Rx© programs are proprietary products belong to ATC, Inc. and are protected by existing patents (5,861,546;...

  • Page 2: Table Of Contents

    ROUP A.13 T G ............................33 ROUP A.14 U-G ............................33 ROUP A.15 V G ............................36 ROUP A.16 X G ............................36 ROUP A.17 Y-G ............................37 ROUP A.18 Z-G ............................37 ROUP APPENDIX B – MODEL E-PDQ ASSEMBLY DRAWING AND WIRING DIAGRAM ......................38...

  • Page 4: Table Of Figures

    NEUMATIC IAGRAM 3.2.1 ..............................8 ABLE 3.3.1 – R I/O C ............10 IGURE ANEL TANDARD EMOTE ONNECTIONS 3.3.2 – S E-PDQ R I/O P ............11 IGURE TANDARD EMOTE ONNECTOR 3.3.3 – L ............11 IGURE IST OF ASS AND AILURE ODE WITH IN OUTS 3.3.4 - S...
  • Page 5 WARNING: This product deals with gas that will expand under pressure. Pressurized volumes (components, hoses, etc.) should be handled with proper protection to avoid any harm to the user. WARNING: Use this product for the purpose of leak testing or flow measurement and testing in the pressure and temperature range specified, ONLY! WARNING: Only qualified personnel should install, or use this product.
  • Page 6 CAUTION: Incoming supply outside 24 VDC +/-10% and unable to source 2 Amps it NOT recommended and may result in inaccurate results, product malfunction and/or damaged electronics.

  • Page 8: Introduction

    PLC or PC control. There are multiple options to interface to the Model E-PDQ. It can be operated using digital I/O through the 15 pin interface or via Ethernet. The 15 pin interface provides some additional flexibility which is not currently available through the Ethernet interface.

  • Page 9: Principle Of Operation

    The E-PDQ instrument can be configured to run up to four (4) types. Each of the 4 test types can include different test parameters or set-ups. Test type can be selected and verified via the rear 15 pin interface.
  • Page 10 INTRODUCTION The IGLS technology offers fast and repeatable leak tests. For shorter cycle time the signature concept can be employed. The signature concept is described in © detail the LeakTek software manual.

  • Page 11: Function Configuration

    INTERFACE 2. Function Configuration The IGLS can be used for several distinct applications as follows: 1. Conventional Leak Test: Automated leak testing with or without automatic pressure control. (The Intelligent Gas Leak System or IGLS) 2. Adaptive Leak Test: Based on dynamic leak flow analysis, the sensor will detect the leak flow result at any time during the leak test period depending on the flow stability and leak detection criteria.

  • Page 12: Interface

    3. Interface 3.1 MECHANICAL INTERFACE AND CONNECTION of the Model E-PDQ: WARNING: The standard Model E-PDQ is not rated to operate in class 1 or 2 environment. WARNING: Test gasses should be compatible with IGLS wetted materials. Gasses currently supported are dry air, nitrogen, carbon dioxide, and helium. For other test gas usage, please consult ATC.
  • Page 13 INTERFACE Figure 3.1.1 - Pneumatic Diagram NOTE: Please see Appendix B for connection and assembly Material selection and pressure ratings: Ensure that pneumatic interface components are compatible with test gas. Ensure all components exceed test pressure requirements. Ensure tubing and fittings meet leak specification of 10 times less than leak test specification limit.

  • Page 14: Environmental Conditions

    3.2 ENVIRONMENTAL CONDITIONS: The Model E-PDQ is designed for internal use only. The Model E-PDQ has no altitude restrictions as long as the unit is configured and/or calibrated to work at the desired altitude. The Model E-PDQ operating relative humidity range is 20% to 80% non- condensing.

  • Page 15: Electrical Interface And Connection

    Model E-PDQ enclosure, the supplied power should be disconnected! WARNING: The outer cover of the Model E-PDQ is to be assembled prior to energizing the unit. Do NOT operate unit without cover mounted (exceptions are for ATC qualified personnel only during inspection/testing/troubleshooting of the instrument).
  • Page 16 The Model E-PDQ includes (2) 3.5A fuse for incoming 24VDC supply. (example: Littelfuse PN: 015703.5DRT) The remote I/O connectors located on the rear panel of the Model E-PDQ are arranged as shown in Figures 3.3.1 & 3.3.2. See Appendix B for wire...
  • Page 17 INTERFACE Function Specifications Pin 1 Remote Output Common 5-30 VDC, source or sink*, 100 mA max. Pin 2 Custom2 Output 5-30 VDC, source or sink*, 600 mA max. Pin 3 Pass Output 5-30 VDC, source or sink*, 100 mA max. Pin 4 Fail Output 5-30 VDC, source or sink*, 100 mA...
  • Page 18 INTERFACE Figure 3.3.2 – Standard E-PDQ Remote I/O Pin Connector Condition Description Pin out The test met all criteria set in the set up Pin 3 Pass screen Pressure is below the Pressure Min Gross leak Fail Pin 4 setting in pressure testing...

  • Page 19: Guideline For Pneumatic Interface

    INTERFACE Up to 9 Model E-PDQ instruments can be connected in a serial loop. A typical serial loop connection with two instruments is shown in Figure 3.2.4. MODEL “E-PDQ” #2 MODEL “E-PDQ” #1 1 2 3 4 5 6 7 8 9...

  • Page 20: Guideline For Setting Up Model E-Pdq Instrument

    VCO or VCR fittings are recommended for low leak specification and vacuum applications (Mass Extraction). The Model E-PDQ is equipped with options that can be configured to detect UUT blockage. An external pressure switch is required to detect that the UUT has been pressurized from one end and vented from a second port.

  • Page 21: Verification Procedure

    Periodic system verification is recommended during normal operation of the Model E-PDQ. Run a test with a known good part and the internal calibrated leak included in the circuit. This test should fail. Run a similar good part without the calibrated leak.

  • Page 22: Model E-Pdq Operation Sequence

    OPERATION SEQUENCE 4. Model E-PDQ Operation Sequence The Model E-PDQ leak test will run based on the sequence below after the “start” input is received via Ethernet or through the remote I/O connector. A typical Test Sequence is as follows: 1.
  • Page 23 OPERATION SEQUENCE NOTE: © If a PC is attached to the Model E-PDQ with LeakTek running the Pass/Fail will be © displayed in the LeakTek run screen; however the Pass/Fail decision is made by the Model E-PDQ. CAUTION: A “Flow saturation” or “Gross Leak” failure is a significant leak and can deplete the isolation tank.

  • Page 24: Communication Protocol

    COMMUNICATION PROTOCOL 5. Communication Protocol NOTE: All commands and responses should be terminated by <lf><cr> 5.1 Conventional Commands for Sensor Parameters Read Command Format: “!0” + ADDRESS + ”R” + COMMAND Response Format: “$0”+ ADDRESS +”R” + COMMAND; DATA Save Command Format: “!0”...
  • Page 25 COMMUNICATION PROTOCOL DAQ string response is in the form of !01SQ5; Data1;Data2;Data3;Data4;Data5;StepNo Where: Data1: temperature reading Data2: pressure reading Data3: flow reading Data4: external pressure reading Data5: adaptive test flow reading StepNo: The step no will be interpreted as Hex value, especially if the sensor is configured to run more than 9 steps.
  • Page 26 COMMUNICATION PROTOCOL Response: $01SQ5;Data1;Data2;Data3;Data4;Data5;StepNo Data1 refers to temperature in Degree C Data2 refers to pressure in kPa Data3 refers to flow in cc/min or g/min Data4 refers to external pressure (4 analog input) in kPa Data5 refers to Adaptive flow or steady state flow in cc/min or g/min SQ1;6 Command: !01SQ1;6...
  • Page 27 COMMUNICATION PROTOCOL Data1 refers to temperature in Degree C Data2 refers to pressure in kPa Data3 refers to flow in cc/min or g/min Data4 refers to external pressure (4 analog input) in kPa Data5 refers to Adaptive flow in cc/min or g/min SQ1;B Command: !01SQ1;B Response:...
  • Page 28 COMMUNICATION PROTOCOL NOTE: For all SQ1 commands, the sensor will respond with two strings with the first string similar to $00SQ1;1, DAQ string as the second one if U6<>0. Otherwise, it will respond with the DAQ string only. If the sensor is configured as mass extraction mode, Data1 carries the accumulated mass or volume instead of temperature during the test step.

  • Page 29: Step Number

    COMMUNICATION PROTOCOL 5.3 Step Number Typical Step Number Table (Hex System) Step Built-in Customized Sequence/Description Sequence 0, 100 Standby Standby Open Clamping Customized Valve Open Pressure Customized and Fill Valve Filling Customized Stability Customized Test Customized Close all valves Customized Stop Customized Customized...
  • Page 30 COMMUNICATION PROTOCOL LoFlow_RM Relative Measurement Baseline Flow Too Low LargeLeak Large Leak Check Failure (Flow larger than V7 at Large Leak check Step) UnderPres Under Pressure Failure (Pressure Lower than K3 ) in vacuum testing GrossLeakV Gross Leak Vacuum Failure (Pressure larger than K2 ) in vacuum testing PresRng-Hi External Pressure higher than set limit (KA)

  • Page 31: Maintenance And Troubleshooting

    WARNING: Calibrated leak should under no circumstances should it be opened or tampered with. WARNING: The Model E-PDQ may contain pressure. Make sure to deplete internal pressure before performing any maintenance work that requires opening any internal components. WARNING: The Model E-PDQ should only be serviced by trained and authorized personnel.
  • Page 32 MAINTENANCE AND TROUBLESHOOTING First test: Run with an instrument test port capped and install the QD male plug at the QD port. Run 1 to 3 times and record the readings. Second Test: Remove the QD male plug and install the calibrated leak orifice.

  • Page 33: Troubleshooting

    Loose connection over-pressurized. No power supply IGLS flow Leakage downstream Isolate E-PDQ by plugging the reading High all to the IGLS UUT outlet, check downstream the time, and in Fill valve not opening fittings and tubing to the IGLS.
  • Page 34 MAINTENANCE AND TROUBLESHOOTING has moved Check / replace fill valve If high readings persist, plug the IGLS outlet, check A/D counts and compare to original calibration. Auto zero the sensor if A/D counts are below 200. IGLS flow Leakage through the Check/replace inlet filter reading too low fill line...
  • Page 35 IGLS connected to a remote PLC or PC control system IGLS Pressure Upstream pressure Check Model E-PDQ connections. or Flow fluctuation cannot be Disconnect I/O connector, to readings damped enough by isolate for test machine possible unstable the expansion tank common-ground problems.

  • Page 36: Appendix A - Command List

    APPENDIX A COMMAND LIST APPENDIX A - Command List Notes: 1. All calibration coefficients are in the unit of °C, flow base unit or kPa if applicable. 2. Density is in the unit of mg/cc. 3. Time is in the unit of 10 ms. 4.

  • Page 37: D Group

    APPENDIX A COMMAND LIST Lo First-order Flow Coef(cc/min/count or g/min/count) float float Lo Second-order Flow Coef(cc/min/count g/min/count or g/min/count float Lo Third-order Flow Coef(cc/min/count float Percent Divider % (such as 10) float Smooth % (such as 1) float Calibrated Gas Constant float Calibrated Gas Viscosity A.4 D Group...

  • Page 38: L Group

    APPENDIX A COMMAND LIST float Pressure Upper Limit(kPa) float Pressure Lower Limit(kPa) float Pressure Setting for Leak Test mode (kPa) for large leak check with dual pressure settings float Pressure Upper Limit(kPa) for large leak check with dual pressure settings float Pressure Lower Limit(kPa) for large leak check with dual pressure settings...

  • Page 39: S Group

    APPENDIX A COMMAND LIST A.12 S Group Command Type Note String Serial Number: Up to 14 characters are allowed to enter. For example: XX XX XXX XXX X XXX 1 = Release of month, i.e. 06 = June 2 = Release of year, i.e. 98 = 1998 3 = Serial No.

  • Page 40: T Group

    APPENDIX A COMMAND LIST A.13 T Group Command Type Built-in Timers Customized Timers Integer Filling delay time Step timer in 10ms in 10 ms Integer Stability delay Ditto time in 10 ms Integer Test time in 10 Ditto Integer Clamping delay Ditto time in 10 ms Integer N/A...
  • Page 41 APPENDIX A COMMAND LIST 3: Relative Measurement 4: Digital Input Pulse/Level Set to 1 if Level detection is desirable 5: Vacuum Testing Message 1—Vacuum 1st Byte Bit 0: Measurement Unit Mass Flow Base 1 g/min as Base Unit Volume Flow Base 0 cc/min as Base Unit Bit 1: Gas Compensation Gas Compensation 1 No Coef Compensation 0...
  • Page 42 APPENDIX A COMMAND LIST 2 -hour 3-SCCM etc. 16*HighNibble+LowNibble Besides: 7*16+3-SCCM 8*16+3-SLM 9*16+3-SCFM 7*16+4 SCCSe-6 Integer 0: One string of response to SQ1 command 1: two string of response to SQ1 command Integer Baud Rate: 0, and else: 9600 2:19200 4:38400 12:115200 The Parameter will take effect after the power reset of...

  • Page 43: Group

    APPENDIX A COMMAND LIST A.15 V Group Command Type Note Min. Flow Alarm for leak test mode in cc/min, g/min or float selected unit based on X6. float Max. Flow Alarm for leak test mode in cc/min. or selected unit based on X6. For mass extraction method, Max.

  • Page 44: Y-Group

    APPENDIX A COMMAND LIST The Basic Check verifies the sensor is not saturated ). “XC” and pressure is not out of settings (P and P Note: 1. If XC was set such as 0xFF, the gross leak check will be disabled. 2.

  • Page 45: Appendix B - Model E-Pdq Assembly Drawing And Wiring Diagram

    APPENDIX B MODEL E-PDQ CONNECTIONS and WIRING DIAGRAM APPENDIX B – MODEL E-PDQ ASSEMBLY DRAWING and WIRING DIAGRAM...
  • Page 46 APPENDIX B MODEL E-PDQ CONNECTIONS and WIRING DIAGRAM...

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