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Leakage Testing System - Dr. Wiesner Steuerungstechnik GmbH

1. aso KbSTARIB OOO O EE ig BS 3 5 fato KbSTOPB O 4 astia Tiggeg DE ang me O a FR 3 o pona ea III 35 our _ a XOQUT Kot a Kot I ERR EES E HE poma SSS 6 pons SSS a pome CO a jma i GGG a i 1 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix I O bit number assignment table NC NC NC HESE HESE Maga SS Maga obt LL EE EE CC HagBiG3 Lee X3INS0 X3INS01 X3INS0p X8IN308 X3INS04 IC X3INS05 IC D n X8INS07 ana IL X3IN201 CC C Ee IC X8INZ04 O SoS S RN IC X3IN200 C RN IL CC N ee ana IL an IC DK IC enig O O oSoSoSSSSSSSSSSSSSS SS Nis IL Ban IL N IL XsIND0O SSSS S SCSCCCCSCSCTCC C r Ran X3INQgg ana RN Lee Ran IC Dun C Du IC EE ES COU 0 e Rouen LL DOT CL XSOUTSQ4 Rou EE XSoUTSQ C XSOUT200 XSOUT201 DOT SSCS XSOUT208 LL 2 Dr Wiesner Westst
2. 5 5 2 Volume flow measurement For this method the test piece is also filled via a bypass pipe with a large cross section At the end of the filling process the bypass valve is closed The air escaping from the test piece is led to a laminar flow element The pressure difference generated in laminar flows is directly proportional to the volume flow and can therefore be used as a measured value The method is especially suitable for testing parts with a large volume and medium to larger permissible leakage rate and for checking a target flow The method is only a little temperature sensitive with compa rably short test cycles 5 6 Volume measurement option Besides leakage and flow testing the leakage testing system INTEGRA can also measure and evaluate volume optional Measuring the volume is a modification of the relative pressure testing method and can be divided principally into two different methods 5 6 1 Volume testing with Test Leak For this testing method the test piece as with the relative pressure test method is impinged with test pressure and the pressure decay resulting when a test leak is connected is measured From the drop in pressure and the known volume flow of the test leak the connected test piece volume can be calculated 5 6 2 Volume testing with reference volume For this method a reference volume is first impinged with test pressure and subsequently the test piece is connected The final pressure reached
3. 20 Inputs AnyBus 1 X3 Bytes 04 07 1 21 Outputs AnyBus 1 X3 Bytes 04 07 22 Inputs AnyBus 1 X3 Bytes 08 11 1 23 Outputs AnyBus 1 X3 Bytes 08 11 3 24 Inputs AnyBus 1 X3 Bytes 12 15 1 25 Outputs AnyBus 1 X3 Bytes 12 15 3 26 Inputs AnyBus 1 X3 Bytes 16 19 1 27 Outputs AnyBus 1 X3 Bytes 16 19 3 28 Inputs AnyBus 1 X3 Bytes 20 23 1 29 Outputs AnyBus 1 X3 Bytes 20 23 3 30 Inputs AnyBusf1 X3 Bytes 24 27 1 31 Outputs AnyBus 1 X3 Bytes 24 27 3 32 Inputs AnyBus 1 X3 Bytes 28 31 1 33 Outputs AnyBus 1 X3 Bytes 28 31 Explanations for the comments 1 These ports are usually unsuitable for test result output 2 These ports contain the I O signals that are usually used to control the test procedures and that can be assigned to each test circuit function in the system configuration 3 These ports are accessible via PCP array in the case of using a Interbus module 41 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 19 Maintenance and cleaning The test device is largely maintenance free If there is a risk that during venting of the test piece contamination can escape from the test piece into the test device a filter must be built into the test piece pipe The seals of the test valv
4. Note Initially the basic screen displays the program that was active so far the corresponding limit values and the last test result The newly selected program number is only displayed in the header separated by a slash from the old one In the example to the right program no 209 has been active so far the newly selected program is no 123 As soon as the new program is started by pressing the F1 key or by pressing the F2 key once or twice the display of the old program is cleared and the newly activated program with its corresponding parameters is displayed 11 3 2 Display Mode Choose this submenu to select the display of the basic Screen The standard display 0 has already been described in chapter 11 2 In display mode 2 only the limit values set for evaluation and the test result are displayed Two program windows are visible In full screen mode 1 not only the limit values set for evaluation and the test result but also the pressure values after each test step and the resulting pressure value profile are displayed Use the cursor keys to display all program parameters see chapter 11 3 5 and base data see chapter 11 3 6 and to browse up or down Use the F1 key to start a test and the F2 key to stop it By pressing Pause the process is interrupted at the end of the step currently carried out The time display continues but with a negative sign Furthermore a blinking white bar displays the text Stop
5. 0 Count Pass 0 Count Fail 0 Min 000 00 mbar Max 000 00 mbar Mean 000 00 mbar One TC All TC FUNC GRAPH BACK 0 500 0 500 mbar 299 0 300 ZoomX ZoomX FUNC BACK Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 34 info drwiesner de www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 16 Error messages The test device automatically runs a system test before every test procedure in which the state of the measuring signals is checked If one of the entered limit values is exceeded or not reached the test piece is evaluated as NOK and the error cause is displayed The most common errors and their causes are listed in the following Initial pRel LoLimit or Initial pRel HiLimit At start the measured value of the relative pressure sensor for test pressure monitoring was outside the range of limit values for start pressure monitoring Possible causes limit values set wrong recommended values 0 1 0 1 bar negative or excess pressure at the test piece connection calibration or scaling error relative pressure sensor defective measuring electronic defective Initial pDif LoLimit or Initial pDif HiLimit At start the measurement value of the differential pressure sensor was outside the range of limit values for start pressure monitoring for the
6. Format f72 ml min Format Offset 0000 000 mbar min mue ni E Nominator Enter the nominal leakage rate of Denominator 0030 000 mbar min the test leak in ml min Posi e d Eu cde D Denominator Enter the displayed pressure Br decay rise rate in mbar min Nominator PRINT BACK 12 4 Relative pressure test method classic pRel classic Setting parameters for the classic relative pressure test method is done in analogy to the differential pres sure method described in chapter 12 1 The parameters for the differential pressure method are not dis played 12 5 Relative pressure test method with differential evaluation pRel differential Setting parameters for the relative pressure test method with differential evaluation is done in analogy to the differential pressure method described in chapter 12 2 The parameters for the differential pressure method are not displayed 26 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 12 7 Volume measurement option Volume measurement is a modification of the relative pressure test method parameter setting differs only in a few points 12 7 1 Volume testing with Test Leak When doing volume measurements with test leaks you must enter the nominal value of the test leak for the parameter Lea
7. Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces Important With appropriate entries in the system configuration and use of the BIT command the set up test programs can be controlled in the same way via digital I O signals start stop pause acknowledge etc When giving a bit number please note the following 1 The bit number is usually a hexadecimal number Alternatively it can be given in decimal form by a preceding The BIT 512 and BIT 200 commands are therefore identical in the second case without the it is in hexadecimal form 2 The user I O bits 0 255 available for test programs see also appendix or Excel sheet start at bit number 512 i e 512 decimal must be added to all numerical values given in the table 3 Accessing smaller bit numbers is intended for service and diagnostic purposes the end user should generally avoid using them Uncontrolled writing of the bits under 512 can lead to unpredictable system behavior and disruptions Here are three examples for the intended use of the BIT command bit 513 1 setting Start button of test circuit1 bit If in the system configuration of test circuit 1 the entry Kb Start contains the value 001 the program of test circuit 1 is started as if the START1 button had been pushed on the
8. This constant display value can be easily recognized by the operator and indicates a sufficient length of all time controlled processes At the beginning of the test period the steady signal is adversely affected by disturbances When using the evaluation according to the delta p process a relatively long test period is necessary due to the resulting variance to achieve a sufficient distance between good and poor When evaluating with the differential method a valid and stable result with significantly less variance is achieved much earlier Because of the constant display value it is much simpler for a less experienced operator to determine a sufficient test period Extensive measuring series to determine the necessary process time are no longer necessary Setting the filling and damping period is also much less critical If these times are set too short more noise is generated at the beginning of the test period Because of the mathematical analysis of the measuring values in the differential method noise at the beginning of the test period is automatically suppressed Measurement series have shown that if filling or damping time is too short the necessary test time ex tends so that the overall duration of the test process is almost unchanged 7 autoTune method option The autoTune method is the extension of the differential method With the autoTune method the proce dures and evaluation made possible by the different
9. optional page 22 11 3 8 Data Administrationin Ee page 23 11 3 8 1 Create new DOSEN page 23 11 3 8 2 Duplicate delete existing Program page 23 11 3 8 4 Program dil ctOlyz oec nna winnie in Oa ea utes een serie page 23 11 3 8 5 Management of base data ees page 23 11 3 8 8 Special eler e page 24 11 3 8 8 1 Fic datablock sizes2 30 2c aa a AAN AN page 24 11 3 8 9 Password management page 24 11 3 9 Diagnestics amp le E page 24 11 3 10 System COMNQUIFATION EE page 24 12 Parameter setting 444444444440nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn page 25 12 1 Differential pressure test method classic pDiff classic page 25 12 2 Differential pressure test method with differential evaluation pDiff differential page 26 12 4 Relative pressure test method classic pRel classic u nenn page 26 12 5 Relative pressure test method with differential evaluation pRel differential page 26 12 7 Volume measurement option page 27 12 7 1 Volume testing with Test Leak uuusssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn ann page 27 12 7 2 Volume testing with reference volume page 27 12 8 Flow test method mass flow or volume Tow page 27 12 9 Automatic adding of test leak connection option page 27 13 Test procedu te porre ete ERR ERE REREEERERRREREERPRERERPP ERE PES page 28 14 Parameters iere deeg ERR RR RR deeg e e edege
10. If you enter 0 here these volumes are included for volume calculation see chapter 12 7 For volume measurements with a test leak the nominal value of the test leak must be entered Using this value and the measured pressure decay the volume is calculated see chapter 12 7 14 2 Extended Parameters Use the F4 key to access additional parameters If there is entered 0 in certain parameters the value will be evaluated dynamically or changed into pre configured standard values In the following these parameters are marked with The texts in are indicate the automatic generated values if enter 0 Chain if PASS Chain if FAIL Chain if ERROR Call at Beg End Call when Testing Call synchronized Startup delay Signaling delay Initial pRel LoLimit Initial pRel HiLimit Initial pDif LoLimit Dr Wiesner Steuerungstechnik GmbH Enter here the three digit number of one of the 256 possible programs to be run after an OK test e g flow test after a leakage test Enter here the program to be run after an NOK test Enter here the program to be run after an error Enter here the four digit number of a subroutine that is run before and after the actual test cycle This can be e g a program for controlling movements or a program for reading a bar code Enter here a subroutine for operations to be run at the beginning of a test sequence Enter here a subroutine to be run for synchronous operations Time p
11. In this mode press the F1 key to print the statistics Use the F2 key to print all data from the cyclic buffer To print select the appropriate interface COM1 COM3 from the selection dialog using the F1 F3 keys Weststrasse 4 D 73630 Remshalden Germany Dr Wiesner Steuerungstechnik GmbH PK1 Result Result Result PK1 Result Result Result PK1 Result Result Result Program 209 pDiff Classic LoLimit 99 99 ml min k HiLimit 099 99 ml min o of Test 000 00 ml min Program 209 pDiff Classic LoLimit 99 99 ml min k HiLimit 099 99 ml min o of Test 000 00 ml min Program 209 pDiff Classic LoLimit 99 99 ml min k HiLimit 099 99 ml min o of Test 000 00 ml min START1 START2 START3 MODE MENU Program Tests Tests Pass Tests Fail Test Circuit Attribute Count Total Count Pass Count Fail Min Max Mean 209 pDif Classic 0 0 0 T pDif Delta 0 0 0 000 00 mbar 000 00 mbar 000 00 mbar One TC A11 T c FUNC GRAPH BACK Program Tests Tests Pass Tests Fail Test Circuit Attribute Count Total Count Pass Count Fail Min Max Mean 209 pDif Classic 0 0 0 1 pDif Delta 0 0 0 000 00 mbar 000 00 mbar 000 00 mbar PrnStat PrnMem FUNC GRAPH BACK Phone 449 0 7151 9736 0 Fax 49 0 7151 973636 20 info drwie
12. Pipe pressure should be at least 1 bar higher than the desired test pressure If the pipe pressure varies strongly a pressure regulator should be built in If the pipe pressure is too low a pressure intensifier or an additional compressor must be used The nominal width of the pressure pipe should be adjusted to the supposed consumption This is especially important for large test pieces or high pressures Since the temperature of the compressed air has a decisive influence on the leakage test the air flowing into the test piece should have room temperature Avoid using too cold or too warm fresh air to generate the compressed air If using vacuum for leakage testing a vacuum pump suitable for the desired vacuum must be used Usu ally maintenance free membrane vacuum pumps are used to achieve a better vacuum oil sealed slide vane rotary vacuum pumps must be used Please note that the direction of pressure for vacuum is re verse to that of the excess pressure testing Thus the strain on the test piece during admission is also reverse When testing with a vacuum the nominal width of the supply pipe must be sufficient 11 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 8 4 Test device The test device like the test appliance should be set up in a suitabl
13. Volume 40 000 1 again Leak Volume min 40 000 1 Parameters are saved automatically when exiting the PRINT Bas Dat Ext Par BACK menu using the F5 or Esc key Use the F3 key to select the corresponding base data set see chapter 1 1 3 6 Start entering input after pressing the Enter key If the specified base data set does not exist input is not accepted Use the F4 key to set or change extended parameters see chapter 14 1 Use the F1 key to print the program parameters To print select the appropriate interface COM1 COMO from the selection dialog using the F1 F3 keys 11 3 6 Base Data Here you can enter or change various program independent basic settings formatting and scaling The meaning of base data is explained in chapter 14 3 Each test program accesses a base data set A base data set can be used for an unlimited number of test programs The assignment is defined when a program is created see also chapters 13 4 8 1 and 12 Use the F1 key to print the base data To print select the appropriate interface COM1 COM3 from the selection dialog using the F1 F3 keys Weststrasse 4 D 73630 Remshalden Germany Dr Wiesner Steuerungstechnik GmbH Base Data Set Fail Ack required Volume Data Format Reference Volume Dead Volume Leak Volume min Prg Active Output Physical Dim 1 Format Offset Nominator Denominator Analog Output Format Off
14. Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces 3 6 Commands for control of keyboard screen and system UO Use the following commands to remote control with some exceptions INTEGRA via serial interface KBC send keyboard character Format KBC key code lt key_code gt Effect This command enables you to write any character to the keyboard buffer of INTEGRA These characters have the same effect as pressing the corresponding device button A command can contain up to 4 keys please note that the characters are stored in the keyboard buffer in reverse order The keyboard codes must be given in decimal and correspond to the ANSI codes see down Response KBC followed by a list of keyboard codes in the order written into the keyboard buffer The following codes are used for additional characters special keys lt BACKSPACE 8 ENTER START 13 ESCAPE STOP 27 Arrow up 69 E Arrow left 83 S Arrow right 68 D Arrow down 88 X 177 F1 102 P F2 103 g F3 104 h D hr F4 105 i F5 106 j KBS send keyboard string Format KBS string There must be a separator string between the KBS command and string This can consist of
15. after connecting the reference volume is proportional to the test volume This method is especially suited for obtaining more accurate measuring results for small test volumes because of the need for a reference volume and an additional separating valve this method is somewhat more expensive 9 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 6 Differential method For tests using the relative or differential pressure method the Leakage Testing System INTEGRA allows evaluation according to the differential method as an alternative to the usual delta p evaluation Evaluation according to the differential method has the following advantages less variance of measuring values shorter test periods since no increased safety factors are necessary simplified set up procedure of a leakage test job display of measured value as change in pressure per time unit e g mbar s or volume flow e g ml min as desired The differential method is based on the continuous mathematical analysis of the pressure or vacuum flow during the test Due to the sliding differential representation of the first order an almost constant display value is reached after a short time during the test period that is free of random influences from different behavior of the test subjects
16. be terminated at a certain point e g to create a certain state after an emergency shutdown For this STOP and ACKNOWLEDGE must both be cleared previously and then set simultaneously for more than 1 second During this delay time the running test program can abort the test procedure in analogy to STOP If after this time the test program does not terminate by itself the supervisor enforces an immediate program abortion In this case please note that the test circuit may remain in an undefined state making a reset of the test circuit see further down recommendable After killing the process ERROR is set and OK is cleared If or as soon as INTEGRA is ready to take a new start request READY is set 17 5 4 Acknowledge and clear message When no test program is active setting ACKNOWLEDGE or STOP clears all set status signals OK NOK ERROR TEST RUNNING PAUSING and sets the DONE signal 17 5 5 Reset test circuit After all messages have been acknowledged see previous section setting ACKNOWLEDGE or STOP again causes a reset of the test circuit At first all signals pertaining to the test circuit are cleared and all display data of the assigned test program are re initialized If or as soon as INTEGRA is ready to take a new start request READY is set 39 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage
17. data 3 5 Commands for managing logical data blocks parameter data application programs Within the EEprom memory the data is organized in logical binary data blocks comparable to files on the hard disk of a PC This form of organization makes it possible to read out or write individual parameter sets without changing other data sets e g calibrating data For transferring and managing the data blocks the following commands are available For the effective transport of pure binary data the same commands and mechanisms are used that were described in the previous section see also RB WD and RC commands Please note that creating changing and erasing data blocks is at first only done in the RAM Only by using the COMMIT command is the EEprom memory updated NOTE COMMIT can also be initiated by the user interface see also COMMIT command further down EEDIR read directory of EEprom Effect Output of a list of occupied data blocks block registry Response List of entries as described followed by EEDIR Each entry is listed like this ENTRY BlockType BlockNumber Size in Bytes address lt BlockType gt BlockNumber Size in Bytes first word The first line contains details about the INTEGRA RAM The entry address gives the storage address in RAM for diagnostic purposes The second line is for control and diagnosis and contains the data read out from the memory address specified Bl
18. digits any value Expressions in angle brackets define the type of data to be entered in this spot If the data format doesn t ensue from the date type the format is arbitrary i e numerical values can usually be entered including or excluding leading blanks or zeros 3 3 Commands for general device and communication control and status query WA G WFZB DF Establishing connection This cryptic string activates processing of further commands INTEGRA responds with HELLO Tip As mentioned above for various reasons characters can be received prior to your application program giving this command so that the command is not accepted In this case repeat the command empty string line end character only Synchronization Response empty string INTEGRA answers with terminator This command can be used for synchronization purposes if the connection is disturbed or disrupted It is also possible to check whether INTEGRA is online and ready to receive data RZ read Bootld No function only for compatibility with predecessor series Response RZ B WG reboot Effect System restart hardware reset WH soft reboot Bootrom Effect System restart software reset If supported by the installed boot ROM a diagnostic menu is started instead of the firmware RV read version id Effect Output of firmware version ID Response RV hhhh the individual digits in hhhh are to be interpreted as follows 1 Digit major version num
19. key to enter the main menu Use the F1 key to start a test directly Use the F2 key to stop a test and by pressing it again to abort the test Use the F3 key to switch between different test circuits for multiple circuit systems Use the F4 key to switch between different display modes During the test run the current relative pressure the remaining time for the test step and the current differential pressure respectively the calculated leakage rate are displayed The current test step and the current measurement value are clearly displayed in two yellow text boxes At the end of the test the test result is displayed instead of the current value In addition the test result is displayed as OK NOK on a green respectively red field and numerically as measurement value in a yellow field If in the base data set the option Acknowledge NOK see also chapter 12 is activated an NOK test result must be acknowledged by pressing F2 before a new test can be started 11 3 Main Menu The main menu displays all submenus By pressing the cursor keys D and confirming with the Enter key or by using the alphanumerical keypad C program selection 1 display mode 2 statistics 3 program parameter 5 base data 6 self optimization autoTune optional 7 data administration 8 diagnostics and setup 9 or the system configuration 0 can be selected Press the F5 key to return to the basic screen If the
20. keyboard bit 544 1 set the first digital output OUT1 Bit no 32 according to I O table By setting the bit further actions can be initiated depending on the setting of the system configuration or a running test program bit 528 query of the state of the first digital input IN1 Bit no 16 according to I O table Notes It is usually meaningless to write I O bits that are intended as input signals according to the table This can cause conflicts between the actual input and the serial control command and can therefore cause unexpected or random reactions of the device I O bits that are assigned to optional bus modules can be used just like normal digital signals or flag bits 3 7 Other commands INTEGRA has a number of further commands that are necessary or helpful for the development and test of application programs To understand this group of commands extensive programming and system knowledge is necessary Because of the extent and the limited number of users this knowledge and the corresponding commands are taught in special training courses 13 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Digital I O Interface Digital I O interface The device is equipped with a digital I O interface featuring a 37 pin male D Sub
21. or deactivated Pre filiing with a usually higher pressure than the test pressure is used to let sealings in the test piece settle Time period between beginning and end of the pre filling procedure Enter here the target value of the pre filling pressure Lower limit value for pre filling pressure monitoring 3 of target value but min 0 33 of measuring range Upper limit value for pre filling pressure monitoring 5396 of target value but min 0 33 of measuring range Time period between end of pre filling procedure and beginning of filling procedure Selection or deactivation of filling function Here you can select whether filling of the test piece with test pressure or evacuating it for the vacuum model is time controlled controlled by a pressure limit value or deactivated Lower limit value for filling pressure monitoring 3 of target value but min 0 33 of measuring range Upper limit value for filling pressure monitoring 3 of target value but min 0 33 of measuring range Time period between end of filling procedure and beginning of stabilization period Lower limit value for test pressure monitoring 56 795 of target pressure value but min 0 33 of measuring range Upper limit value for test pressure monitoring If during the stabilization period the test pressure goes below the lower limit value or if the test vacuum exceeds the upper limit value the test is aborted with the r
22. outputs are that are used for controlling the test valves 18 4 List of available ports Port Direction Description normal function Comments no 0 Inputs internal flags and digital inputs IN1 IN16 1 2 Outputs internal flags valves and digital outputs OUT1 OUT16 1 2 2 Inputs AnyBus 1 X3 Bytes 00 03 1 2 3 Outputs AnyBus 1 X3 Bytes 00 03 4 Inputs AnyBus 2 X2 Bytes 00 03 1 2 5 Outputs AnyBus 2 X2 Bytes 00 03 2 6 Inputs AnyBus 2 X2 Bytes 04 07 1 2 7 Outputs AnyBus 2 X2 Bytes 04 07 2 8 Inputs AnyBus 2 X2 Bytes 08 11 1 9 Outputs AnyBus 2 X2 Bytes 08 11 3 10 Inputs AnyBus 2 X2 Bytes 12 15 1 11 Outputs AnyBus 2 X2 Bytes 12 15 3 12 Inputs AnyBus 2 X2 Bytes 16 19 1 13 Outputs AnyBus 2 X2 Bytes 16 19 3 14 Inputs AnyBus 2 X2 Bytes 20 23 1 15 Outputs AnyBus 2 X2 Bytes 20 23 3 16 Inputs AnyBus 2 X2 Bytes 24 27 1 17 Outputs AnyBus 2 X2 Bytes 24 27 3 40 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual Port Direction Description normal function Comments no 18 Inputs AnyBus 2 X2 Bytes 28 31 1 19 Outputs AnyBus 2 X2 Bytes 28 31
23. parameters except degree of optimization equal the entries in the program parameter set If these are changed the changes are transferred to the program parameters after running autoTune After connecting the test piece and a test leak autoTune can be started by pressing the F1 key Since the test process is optimized to the inserted test leak the test leak should be such that its leakage rate equals the minimum leakage to be detected The system then calculates the optimal process time periods automatically After completing the optimization cycle the display switches automatically to the program parameter set to show the newly generated parameters or if necessary to correct them manually To confirm the parameters leave the menu window by pressing the F5 or Esc key The individual time periods and the overall process time created plus emptying are shown in display mode 2 on the display Weststrasse 4 D 73630 Remshalden Germany Dr Wiesner Steuerungstechnik GmbH PK1 Program 209 pDif Classic Result LoLimit 0099 0 Result HiLimit 0099 0 Result of Test 0032 347 mbar min Sum 16 7 s Fill Time L525 e Stabiliz Time 2 8 s Testing Time ae Filter Interval 0 3 s Differential Pace 0 8 s dp dt 0001 750 mbar min E Rate 0 4 s START1 STOP1 NextPro MODE MENU Phone 49 0 7151 9736 0 Fax 49 0 7151 973636 22 info drwiesner de www drwiesner de Leakage Testing System INTEGRA steu
24. protection of protected parameters e g program parameters cf chapter 11 3 5 is switched off by entering a password the protection can be turned on again by pressing the F4 key PK1 Program 034 pDif Differential Result LoLimit 99 99 ml min Result HiLimit 099 99 ml min INTEGRA Leak Test System Version 01 06 0 Main Menu 1 Select Program 2 Change Display Mode 3 Statistics START1 STOP1 NextPro MODE MENU PK1 Program 034 pDif Differential Result LoLimit 99 99 ml min o k Result HiLimit 099 99 ml min Result of Test 000 00 ml min 000 00 0 Main Menu 1 Select Program 2 Change Display Mode 3 Statistics START1 STOP1 NextPro MODE MENU 1 Select Program 2 Change Display 3 Statistics Mode 5 Edit Program Parameters 6 Edit Base Data 7 Self Optimization autoTune 8 Data Administration 9 Diagnostics amp Setup 0 System Configuration 01 01 06 13 09 15 Trace LogOut BACK Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 17 info drwiesner de www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual Press the F2 key to return to the Trace function Use this Seep eee function to output selected data gathered by a running test automatically via one of the serial interfac
25. test results are cleared by Stop 190 191 192 193 194 195 196 197 198 X2 OUT 0 06 Test circuit 1 Error CF The test device recognized an error caused by a violation of limit values at 192 193 194 195 196 197 198 the start or end of the filling process or an internal electronic error has been detected X2 OUT 0 07 Test circuit 1 Mark good part This output can be programmed using the Marking time of the measuring electronic It is only set when the test result is OK and a marking period 0 S is programmed It can be used for controlling a marking device X2 IN 7 00 Test circuit 3 program bit 1 5 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix I O bit number assignment table TO bit no Poribi X2 IN 7 07 Test circuit 3 program bit 8 S Setting this input starts the test procedure Setting this input stops the test procedure RZ Setting this input aborts the test procedure 203 X2 IN 6 03 Test circuit 3 Acknowledge bad part pen PINSON Tas impu mustbe sotforNOktestresuts 000 204 X2 IN 6 04 Reserve free input This input can be used freely e g for controlling devices 205 X2 IN 6 05 Reserve free input This input can be used freely e g for controlling devices 206 X2 IN 6 06 Re
26. 05 Test circuit 2 Test done This signal is set at the end of the test run and stays active until the next start or until the test results are cleared by Stop 182 X2 OUT 1 06 Test circuit 2 Error The test device recognized an error caused by a violation of limit values at the start or end of the filling process or an internal electronic error has been detected 183 X2 OUT 1 07 Test circuit 2 Mark good part This output can be programmed using the Marking time of the measuring electronic It is only set when the test result is OK and a marking period 0 S is programmed It can be used for controlling a marking device 184 X2 OUT 0 00 Test circuit 1 Ready The test device is switched on and the test circuit is ready for testing 185 X2 OUT 0 01 Test circuit 1 Test is running This output is set from receiving the start signal until the very end of the test run including periods of interruption after Stop during the waiting period for Acknowledge bad part and during the marking and signaling period The test procedure was paused 187 X2 OUT 0 03 Test circuit 1 OK The measured values of all steps of the test were within the set ranges the test piece is OK 188 X2 OUT 0 04 Test circuit 1 NOK The measured values of at least one step of the test were outside the set ranges the test piece is NOK 189 X2 OUT 0 05 Test circuit 1 Test done m This signal is set at the end of the test run and stays active until the next start or until the
27. 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 3 General notes The Leakage Testing System INTEGRA is a multi functional testing system Its main applications are tests with fluidic media especially leakage and flow tests using compressed air or other gases or vacuum Because of the free programmability of the control software electrical or mechanical tests can be carried out as well Furthermore not only the inspection process can be controlled but also entire testing devices or test stands 4 Device types The Leakage Testing System INTEGRA can be equipped with almost any common test process This depends basically on the built in sensor and valve equipment Apart from custom made models the following standard devices are available INTEGRA RDV Relative pressure method test pressure and measuring range 1 0 bar INTEGRA RD1 Relative pressure method test pressure and measuring range 0 1 bar INTEGRA RD4 Relative pressure method test pressure and measuring range 0 4 bar INTEGRA RD6 Relative pressure method test pressure and measuring range 0 6 bar INTEGRA RD10 Relative pressure method test pressure and measuring range 0 10 bar INTEGRA DDV Differential pressure method test pressure range 1 0 bar measuring range 20 mbar INTEGRA DD1 Differential pressure method test pressure range 0 1 bar measuring range 20 mbar INTEGRA DD6 bDifferential pressure method
28. ANSI character set is used as it is in Windows External devices that only support the ASCII character set can be used however special characters may not be represented correctly To send binary data firmware parameter files all available 8 bit characters are used The soft and hardware used must support this operation mode and must not for example suppress null characters For text oriented command and data lines CR carriage return ANSI code 13 marks the end of a line For text output lines are terminated with CR LF LF line feed ANSI code 10 Data sets that are output automatically as plain text or upon request from the user interface are structured according to the following description The data format for command controlled data exchange is described in chapter 3 2 1 Automatically output test results in plain text Example Id 02 Prg 023 05 04 21 19 45 30 RO77 Test pressure 1 525 bar ok R098 Test result 8 25 ml min ok General structure a header with device ID program number date and time of the test Id device number according to system configuration for the time being this is only a comment The date and time format can be selected in system configuration one or more lines containing test data Within the line there are the following elements RO77 register number of the value This register number facilitates automatic data filtering and processing Test pressure T
29. HiLimit 99999 0 Pa SeparValve Time 0 0 s Filter Interval 0 3 s Differential Pace 1 2 s Result as dpRel dt Deflate SetPoint 0 0 Pa End of Data Block General structure Each record starts with two header lines The middle one contains information about the data block date and time Then the data itself follows corresponding to the representation in the user interface The end of the record is marked by End Data block 3 Command controlled data exchange 3 4 Basic procedure The controlling computer sends a command as plain text The end of the command character string is marked by CR or an asterisk The type is available only for compatibility reasons with the former model it is strongly recommended to use CR as the terminator as far as possible INTEGRA starts interpreting and processing the commands only after receiving the terminator Depending on the type of command a block containing binary data can follow The preceding command specifies the number and if applicable the type of characters that are then stored transparently i e without further interpretation of control characters etc in the data buffer If the command received is valid it will be executed Execution is usually acknowledged by repeating the command or by sending the requested data for details see each command If INTEGRA is unable to recognize or execute a command acknowledgement consists of the received line with a
30. M1 COM2 and COM3 are set to the following data format 115200 bps 1 start bit 8 data bits ASCII characters 1 stop bit no parity check The settings of COM1 and COM2 cannot be changed COM3 can be configured For a detailed description of the interface refer to the appendix Serial Interface 10 2 Digital UO interface The leakage testing system INTEGRA is equipped with a digital I O interface featuring a 37 pin D Sub connector According to DIN EN 61000 6 2 table 3 cable length is limited to 10 m The single total capacity of the outputs is 500 mA When using multiple circuit systems the interface is used to control the additional test circuits Therefore as a standard the base device for multiple circuit systems contains a PROFIBUS slave interface For the allocation of input and outputs refer to the Digital I O Interface appendix 10 3 PROFIBUS interface option The leakage testing system INTEGRA can optionally be equipped with a PROFIBUS coupling module thus allowing for the operation in an automated manufacturing facility The installation of the slave module in slot X2 and the master module in slot X3 is standard Caution Special applications could necessitate a differing assignment of the slots Addressing switches can be found underneath the panel left units right tens Inputs and outputs are freely configurable The assignment is described in the O bit number assignment table appendix The status LEDs 11 indicates a
31. Test leak connection Power supply connector Mains switch Main fuse Digital UO interface e g for connecting to a superior control system 37 pin Sub D assignment cf appendix Allocated for multiple circuit systems serial interface RS232 e g for PC settings cf appendix serial interface RS232 e g for printer settings cf appendix serial interface RS232 e g for bar code scanner settings cf appendix Bus interface with built in coupling module e g for Profibus Interbus optional Bus interface with built in coupling module e g for Profibus Interbus Status LED Connection for pressure supply vacuum connection on vacuum devices 4 6 hose Filter Connector to test piece 4 6 hose Connector to reference volume usually blocked 4 6 hose Test pressure connectors for up to 3 external test circuits 4 6 hose optionally Spare connectors for custom built devices e g control pressure for external test circuits 4 6 hose Digital I O interface for connection to X1 when using external test circuits 37 pin Sub D optional Digital UO interface for up to 3 external test circuits 15 pin Sub D optional Analog interface for up to 3 external test circuits 9 pin Sub D optional cover for addressing switch 14 Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 10 1 Serial interfaces The three built in serial interfaces CO
32. Testing System INTEGRA steuerungstechnik Instruction Manual 18 Test result output in digital I O area 18 1 General description The test results of each test circuit can be made available for other bus participants in the digital I O area e g in the PROFIBUS output data area Upon reset and when confirming the START request the results and the OK NOK signals are set to 0 At the end of the test before setting OK or NOK the test result is updated in the data area Please note that in case of NOK the numeric test result may be undetermined e g sensor overflow big leak premature test abortion etc making the test result unsuitable for controlling the data exchange between the bus participants 18 2 Data format The test result is stored as a signed 32 bit binary value starting with the most significant byte The numeric value is equal to the test result shown on the screen without the decimal point 18 3 Configuration In System configuration Main menu option O you can specify for each test circuit separately for which virtual 32 bit port the output is intended set Result output port for every test circuit You can see from the port table below which available port is assigned to which physical I O areas Basically any port can be used for data output However it is usually not advisable to use input ports for output or to assign ports that are already used for other applications such as Port 1 where the internal digital
33. Volume measurement nennen nnne nnne nnn nnne nnns page 9 5 6 1 Volume testing with Test Leak nnns page 9 5 6 2 Volume testing with reference volume page 9 6 Differential method ettet diti detected page 10 7 autoTune method option page 10 8 Conditions for optimal leak testing sssssssssseenn page 11 8 1 TeSEplOGO cedet ti AAAA page 11 8 2 dest appliance EE page 11 8 3 Uude page 11 8 4 Dude ie aenn TEAT T TAn ATE EE EATE TEA EATER T TEA ELT EA ETETE EEE RATAT page 12 8 5 EAT EET E E page 12 9 SOUP xx roS A Len LED Ne ke page 12 10 June page 13 10 1 Serial interface A page 15 10 2 Digital VO interface ssssssssssssssssesseeeeenenenmennn nennen nnne nnn nnns page 15 10 3 Profibus interface opiton nnns page 15 10 4 Interbus interface option page 15 11 ovi E M page 16 11 1 Control and display elemente nennen page 16 11 2 Basie Sch aan Er al page 17 11 3 METRI MEME ERE c page 17 11 3 1 Program selection eeeesssssssssssssssssseesee eene page 18 11 3 2 BI Ee page 19 2 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 11 3 3 iecore page 20 11 3 5 Program Parameters A page 21 11 3 6 Base RE EM M ttn at att ae ed aa el page 21 11 3 7 Self Optimization autoTune
34. Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces Notes Erasing the EEprom memory prior to burning is not necessary unlike the flash memory If necessary EEprom pages are erased automatically prior to burning After burning the data a reset is recommended since some settings take only effect after a restart The content of the memory should always be transferred completely Otherwise there is a danger of various areas containing inconsistent data NOTE Special caution must be exercised when using this command The EEprom memory contains calibrating data all user programs and settings If memory content is incomplete or faulty this can lead to error messages and usually malfunctions In this case the memory content must be transferred and burned again WR write RAM Format WR hhhhhhhh Effect Data in the transfer buffer are transferred into the battery buffered RAM starting at the specified address Response WR hhhhhhhh 0 If an error occurs during writing a number gt 0 is returned instead of the last zero Notes After writing to the memory a reset is necessary since some files take only effect after a restart The content of the memory should always be transferred completely Otherwise there is a danger of various areas containing inconsistent
35. a blank but can also consist of an arbitrary sequence of blanks and commas It follows of course that the character string must not begin with a blank or comma Effect The given string that begins after the separator string and runs to the end of the command line is stored in the keyboard buffer character for character It must be noted that this is a string a number of actual characters letters numbers etc and NOT their numerical ANSI code as with the KBC command The desired string can contain the substitute characters for additional characters given above however not the functional characters CR 13 LF 10 or NUL 0 Response KBS followed by the string in the keyboard buffer DSY get display buffer Effect Query and transfer of screen buffer Text characters on the screen are sent line by line Attributes colors flashing etc are not sent neither are graphics BIT read write i o bit Format BIT lt BitNumber gt lt NewValue gt Effect This command enables reading or writing a bit in the memory for physical inputs and outputs If the optional parameter NewValue is missing the queried input output bit is only read out If NewValue is given the bit is set to the new value before readout One value 0 represents Bit erased one value lt gt 0 Bit set Output bit BitNo decimal Do hex Value O0 or 1 12 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de
36. a program the program number source to be copied must be entered first then the new program number target If the desired program is already allocated input is refused You either have to select a different program number or delete the existing program Pressing the F1 key executes each action 11 3 8 4 Program directory Press the 4 key to call the program directory If the cursor is moved to the appropriate program line the program name can be created or changed by pressing Enter A text box appears in which a name can be entered using the alphanumerical keyboard Press Esc to exit the text box If you press F1 while in the program directory the name of the program selected is deleted Use the F3 key to call the program parameters and the F4 key for the corresponding base data set 11 3 8 5 Management of base data sets Managing base data sets is done in analogy to program management 23 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 11 3 8 8 Special functions 11 3 8 8 1 Fix datablock sizes This function enables you to change the size of existing sets of program data generated with firmware versions lt 1 3 to the new size After execution the number of blocks updated and the possible occurrence of problems is shown on the display Sa
37. and comparison volume are sealed from each other Before the subsequent test period the measurement display must be tared If the test piece is leaking there will be a difference in pressure between it and the comparison volume that can be measured and evaluated Thus the measuring accuracy is independent of the absolute test pressure since only the difference between reference volume and test piece is meas ured By connecting to a test leak an equivalent volume flow can be assigned to the resulting pressure difference 5 3 Pressure rise method The pressure rise method is a variation of the relative pressure or differential pressure method Not the change of the test pressure is used as the relevant value but the change of the pressure in an enclosure bell jar or chamber surrounding the test piece The advantage of this method lies in the fact that the changes in pressure of the test medium have only very little influence on the measuring result Often however very high expenditure is required for the test appliance In addition the surrounding volume must constantly be tested for leaks since a leak could be the cause of false OK parts 5 4 Test of hermetically sealed components When testing hermetically sealed components for leaks the difficulty lies in the fact that the interior of the test piece cannot be impinged with pressure In this case too a volume surrounding the test piece is used which is subjected to pressure or vacuum If the te
38. and number of the data block are contained within the data block If such a block does already exist it will be overwritten by the new version otherwise the block is created Then the internal block list is generated again Response BLPUT lt BlockType gt lt BlockNumber gt lt Size_in_Bytes gt If the command cannot be executed e g syntax error no data memory full etc the original command is returned with an added question mark BLGET block get Format BLGET lt BlockType gt lt BlockNumber gt Effect The specified data block is prepared for a subsequent transfer via RB command Response BLGET lt BlockType gt lt BlockNumber gt If the command cannot be executed e g block missing the original command is returned with an added question mark IBLINIT init blocks erase EEprom and load default blocks Effect Except for calibration data all data blocks are erased subsequently a system configuration data block and a block for basic data set 1 is generated according to the default given by the firmware Response BLINIT NOTE By this command and subsequent COMMIT all user programs and settings are erased for good also all special programs and extension options ICOMMIT Effect this command commits i e burns to the EEprom all changes made to the EEprom data Response COMMIT NOTE COMMIT can also be initiated by the user interface e g when an editing mask is called or exited 11 Dr Wiesner
39. ase flash memory Effect Erase flash memory and prepare for firmware update Response WN O If the flash memory cannot be erased a number gt 0 is returned instead of the last zero NOTE Extreme caution must be exercised when using this command After erasing a new firmware must be installed immediately For example if the firmware is incomplete or damaged because of a reset power loss etc the device does not function anymore INTEGRA can then only be revived with a special original software Prior to erasing the flash memory INTEGRA is switched into a state where all non vital functions execution of programs updating of user interface etc are deactivated or treated with low priority This state can only be left with a reset WP write flash memory Format WP hhhhhhhh Effect Data in the transfer buffer are burned into the specified address of the flash memory Response WP hhhhhhhh 0 If an error occurs during burning a number 0 is returned instead of the last zero NOTE Extreme caution must be exercised when using this command See also explanation for the WN command After successfully burning the entire firmware INTEGRA must be reset WE write EEprom memory Format WE hhhhhhhh Effect Data in the transfer buffer are burned into the EEprom memory starting at the specified address Response WE hhhhhhhh 0 If an error occurs during burning a number 0 is returned instead of the last zero 9 Dr Wiesner
40. asuring electronic defective To acknowledge an error press the F2 key 35 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 17 Signal exchange for sequence control 17 1 Introduction The execution of test programs in the INTEGRA can be controlled using the built in keyboard or digital I O signals Appropriate setting of the system configuration determines which signals are assigned to which control function The following description is valid for all standard programs in the INTEGRA Application specific programs may deviate from this Two independent instances are involved in sequence control in the INTEGRA a A superior monitoring entity the Supervisor This entity is responsible for starting loading and executing the test programs and for unscheduled abortions b The running test program As long as a test program started by the Supervisor is active it controls further signal exchange autonomously For the sake of simplicity the following description will use a PLC as the partner in the signal exchange throughout Even if in the actual application a different control device or just manually controlled I O interfaces instead of a PLC are used the basic procedure for the signal exchange is always the same 17 2 Signals and UO channels Th
41. ber 2 Digit minor version number 3 Digit release number 4 Digit release status For example 121F is version 1 2 1 final and should be interpreted as follows If is firmware with version number 1 2 first release It is a final version release status F 6 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces Note The INTEGRA series is continuously developed further and new or improved features are added When new functions are added or the user interface is visibly changed the firmware version number is changed to be identical to the one of the user manual For minor internal optimizations the release number is increased Usually every new release is distributed with the status F i e the release is in the final approved state In exceptional cases it may be necessary or desirable to make a release available before final approval In this case the last digit contains a number giving the intermediate version number of this release Early updating to the final version is recommended RU read RTC date time Effect gives date and time read from the internal real time clock The actual readout takes place in cycles in the background approximately every 2 seconds Response RU ddmmyyHHMMSS the letters represent day month year ho
42. ces 3 4 Commands for transferring binary data Application programs firmware memory contents etc are usually transferred in binary form Data transfer takes place via a data transfer buffer The size of this buffer is limited to 16 kByte thus larger amounts of data must be sliced into smaller units and transferred in sequence Data transfer takes place as follows Transferring data from INTEGRA to control computer The computer sends a command requesting transfer of binary data and specifying the memory range and amount of data needed INTEGRA then prepares the transfer and acknowledges the command Now the computer requests the actual data transfer INTEGRA acknowledges the request and transfers the prepared data to the computer Finally the computer requests the checksum of the transferred data compares it with the calculated data and if necessary initiates the repetition of the transfer Transferring data from the computer to INTEGRA The computer sends a command to announce the transfer of binary data INTEGRA then prepares the reception and acknowledges the command Now the computer transfers the binary data INTEGRA stores the data in the transfer buffer without interpreting them Then the computer requests the checksum of the transferred data compares it with the calculated data and if necessary initiates the repetition of the transfer Finally the computer sends a command specifying the storage place for the data and requ
43. connector According to DIN EN 61000 6 2 table 3 cable length is limited to 10 m The single total capacity of the outputs is 500 mA The following inputs and outputs are allocated by default allocations for custom built models can vary according to the Appendix technical data Inputs X1 11 Reference potential for the test device in and outputs The esed program number must be entered betore staring The desired program number must be entered before starting Program bit 1 system input X1 14 X1 33 Program bit 7 system input X1 15 Program bit 8 system input X1 34 IN 9 Start system input The input must be set until the device responds with Test running X1 20 X1 16 IN 10 Stop system input Setting this input stops the test process The test process continues when the input is reset Abort system input Setting this input aborts the test process Acknowledge bad part pre set input This input must be set for NOK test results X1 36 IN 13 Reserve free input EMEN This input can be used e g for controlling the device appliance X1 18 IN 14 Reserve free input This input can be used e g for controlling the device appliance X1 37 IN 15 Reserve free input Uu eee This input can be used e g for controlling the device appliance X1 19 IN 16 Reserve free input This input can be used e g for controlling the device appliance 1 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 i
44. d of the stabilization period The stabilization period serves to equalize the temperature between test medium and test piece Time period between beginning and end of the test To evaluate the test the change of pressure in case of pressure tests or the measured flow in case of flow tests is used Lower limit value for the evaluation of the test Upper limit value for the evaluation of the test If the test result is outside the range of limit values the test is evaluated as NOK Selection or deactivation of deflating of test piece Here you can select whether deflating of the test piece is time controlled controlled by a pressure limit value or deactivated Time period between beginning and end of the deflating procedure Selection or deactivation of marking device control Here you can select whether marking should take place before during or after deflating or not at all Time period between beginning and end of the marking command control signal The following parameters are for scaling the testing results for each program local ignoring the settings in the base data set It depends to the program type what data will be changed leak test programs conversion from pressure drop to leakage rate flow test programs evaluation of the flow volume test programs parameter for volume evaluation Only the enter of numbers is possible The format decimal places units is determined by the base data set If all va
45. dE e ege erEr HRG page 29 14 1 Program Parameters A page 29 14 2 Extended Parameterg AAA page 30 14 3 Base Data nee page 32 15 Graphical display een page 33 15 1 Display of the march of pressure ssssssssssseeneeeeenen nnns page 33 15 2 Statistics denlay ennt nnne nnns page 34 16 Error messages 2 mot tet i tust dmt MI tM IU E UE LE page 35 17 Signal exchange for sequence Control page 36 17 1 INTODUCON M see nee E page 36 17 2 Signals and I O channels nennen nennen page 36 17 3 Configuration of control sigonals nen page 37 17 4 Exchange of signals in normal test operation ccccecceeeeeeeeeeeeneeeeeeeeeeeeenaaees page 37 17 4 1 SWITCH ON Mode nennen page 37 17 4 2 Program pre selection and Start request by PDC page 37 17 4 3 INTEGRA starts the test program usrssnnesnnsnnnnennennnnnnnnnnnnnnnnnnnnnnn page 38 17 4 4 The PLC monitors the starting Drocedure page 38 17 4 5 Exec utingthlie tes ne notun tEn nE NOn D page 38 17 4 6 Report of the test result hiconoronor Re ensneenensneeipensnee page 38 17 4 7 enee E page 38 17 4 8 ENG Of progralm idee HERD EHERTHEH EHE eer eee page 39 17 5 Special CASS 15 2 nennen page 39 17 5 1 Eelere LEE page 39 17 5 2 Abort test procedure Gremaiurely page 39 3 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing S
46. differential pressure differential pressure test only Possible causes limit values set wrong recommended values 0 5 0 5 mbar negative or excess pressure at the test piece connection calibration or scaling error relative pressure sensor defective measuring electronic defective Del at Prefill lt LoLimit or pRel at Prefill gt HiLimit At the end of the pre filling period the measurement value of the relative pressure sensor for test pressure monitoring was outside the range of limit values of pre filling pressure monitoring Possible causes pre filling pressure set wrong limit values set wrong recommended values 90 1 1096 of the desired pre filling pressure a very large leakage or no test piece connected negative or excess pressure at the test piece connection calibration or scaling error relative pressure sensor defective measuring electronic defective pRel at Filling LoLimit or pRel at Filling gt HiLimit At the end of the filling period the measurement value of the relative pressure sensor for test pressure monitoring was outside the range of limit values of the filling pressure monitoring Possible causes filling pressure set wrong limit values set wrong recommended values 90 110 of the desired filling pressure a very large leakage or no test piece attached negative or excess pressure at the test piece connection calibration or scaling error relative pressure sensor defective me
47. e The pressures I O signals etc depend on the running test Mode no output The output is done in table fashion facilitating further TM processing of the data e g using Excel Circuits all Note When restarting the device all Trace options are reset to the default values This is a safety measure to Port Com prevent a generating a high volume of data traffic without explicit operator action The Trace options could be adjusted as follows Mode no output No output of trace data default each cycle Data is output after every measuring cycle for standard devices approx 10 times sec No output of time information only when changed Data output only when data has changed The output contains a time stamp displaying the elapsed time since the program was started in ms Format tabulated The data columns are separated by a TAB ASCII 8 CSV The data columns are separated by a comma default Circuits You can select any combination of test circuits Default all Port You can select one of the interfaces Com to Com3 Default Com It is possible and often necessary to name an interface that is already also used by other communication tasks such as a protocol of the test results It is up to the communication partner to direct the data stream properly 11 3 1 Program selection Window 1 PK1 Program 209 pDif Classic Program 209 Use this submenu to select the desired test program for each tes
48. e ERROR signal is set and READY is cleared The signals START STOP ACKNOWLEDGE and PAUSE must be cleared by the PLC 17 4 2 Program pre selection and Start request by PLC If READY is set and TEST RUNNING is cleared the PLC can prepare the program start The PLC sets the inputs PROGRAM BIT 1 to 8 as needed Note If these signals come from a different source than the START signal the PLC has to wait for a sufficiently long time to avoid problems due to different signal delays For directly connected digital UC circuits a delay time of 1 ms is sufficient If however signals are connected to different busses the minimum delay time is equal to the sum of the bus cycle time and a latency of 10 ms 37 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual Then the PLC sets the START signal 17 4 3 INTEGRA starts the test program As soon as INTEGRA has recognized the rising edge on START the following actions are taken The outputs READY TEST RUNNING PAUSING OK NOK and ERROR are cleared The output DONE is set The inputs PROGRAM BIT 1 to 8 are read and the number of the program to be started is determined according to the configuration settings The selected test program is loaded and executed If the program cannot be started e g because the s
49. e flow rate You can also enter a different text Here you can enter the format of each physical value Example F73 mbar min Unit of the physical value Number of decimal places for the value displayed Number of digits incl decimal point F incl leading zero f excl leading zero marks the beginning of the format specification The value entered here is subtracted mathematically from the measuring result This might be necessary if for example during a leakage test thermal effects or plastic deformation of the test piece cause a pressure change that is not due to a leak Take care to enter the correct algebraic sign Note For physical value leakage rate and physical value 3 this parameter is 32 Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual only accessed when offset nominator and denominator of the program parameters are set to 0 see chapter 14 1 Nominator This is one component used to generate a scaling factor When converting the pressure drop into a leakage rate the nominal value of the test leak used must be entered here see chapter 12 2 Note For physical value leakage rate and physical value 3 this parameter is only accessed when offset nominator and denominator of the program parameters are set to 0 see chapter 14 1 Denominator In the example o
50. e output This output can be used freely e g for controlling devices 251 X2 OUT 4 03 Reserve free output This output can be used freely e g for controlling devices 252 X2 OUT 4 04 Reserve free output This output can be used freely e g for controlling devices 253 X2 OUT 4 05 Reserve free output This output can be used freely e g for controlling devices 254 X2 OUT 4 06 Reserve free output This output can be used freely e g for controlling devices 255 X2 OUT 4 07 Reserve free output This output can be used freely e g for controlling devices 7 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de EC Declaration of Conformity steuerungstechnik as defined by EC Directive 2004 108 EEC 2006 95 EEC 93 68 EEC We confirm that the products defined below meet the EC directives above by design type and the version which are put into circulation by us In case of any product changes or use which does not comply with the instructions made without our approval this declaration will be avoid Designation of the product Leakage Testing System INTEGRA type RD RD1 RD4 RD6 RD10 RDV DD DD1 DD6 DD10 DDV DF DF1M DF2M DF1 and their versions Manufacturer Dr Wiesner Steuerungstechnik GmbH Weststrasse 4 D 73630 Remshalden Germany Phone 49 7151 9736 0 Fax 49 7151 9736 36 The followin
51. e place where neither heat nor mechanical shocks can influence the test results The test device should be as close to the test appliance as possible to keep the test volume as small as possible For multiple circuit systems where each test circuit has its own casing it is also advisable to keep the pressure pipes of the test circuits as short as possible The operating panel of the test device should be visible and accessible at any time Also ensure accessibility for maintenance purposes The test device should never be built into a closed cupboard without heat exchange or air conditioning Before the beginning of test cycles there should be await a warm up time of about 10 minutes after switching on the device Through this it will be avoided a minor drift of the measuring results caused by temperature 8 5 Test leak A test leak is suitable for adjust the limits and for quick check of the system If it s connected with the rapid action coupling on the front panel a leakage is simulated If the test leak is adapted to the allowed limit and a seal test specimen is connected to the system the pressure rise or decay generated by the test leak determines the limit for the evaluation in the relevant test methods It s recommended to adjust the limit so that the evaluation of a test with coupled test leak is NOK Test leaks are basically consisting of a glass capillary which allows a defined volume flow per time unit The test leaks should be stored t
52. e relative pressure absorber a capacitive differential pressure transmitter for differential pressure method and volume flow measurements amass flow sensor for mass flow measurements a Laminar Flow Element for volume flow measurement and various test valves 12 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 10 Interfaces All electrical and pneumatic outputs and interfaces are on the back panel Only the rapid action coupling for connecting a test leak is on the front panel The device will be switched on by the mains switch SO 3 at the back side u PK Programm 209 pDiff klassisch Erg UGW eee 9 mirMin rg OGW A Pr fergebnis 00 03 mI Min DD D SS MARNE or 2 Rnzeigemodus 3 Statistik T STARTI RESET N chstP MODUS MENU o 9 Oo o nn mn jun Cen 6 66666050 d d A d back side 13 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 17 18 19 20 21 Test Ref Test P1 Test P2 Test P3 Dr Wiesner Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de
53. e unusual flexibility of the INTEGRA is made possible last but not least because of a strict separation between the logical functional level and the physical level The assignment between logical signals and physical I O channels or flags is determined by the system configuration separately for each test circuit In the following description we will generally refer to the logical level and speak of signals no matter if a physical I O channel is assigned to a signal or which one The terms input and output are always used from the point of view of INTEGRA i e output always refers to an output of INTEGRA from the point of view of a superior control this would be an input The following list gives an overview of the signals used for sequence control and their functions Input signals PROGRAM BIT 1 to 8 Program pre selection START load and execute the selected program PAUSE execution of the program is stopped after the current step STOP abortion aborts the running program or resets the completed program ACKNOWLEDGE acknowledge a message NOK result disruption etc Output signals READY system ready for START TEST RUNNING a test program is active PAUSING paused the current test program was paused OK the test result is OK NOK the test result is NOK DONE test is completed the test has been completed ERROR an error or a system failure occurred during the test Report defects immediately to the approp
54. e variety of application possibilities we recommend the following default assignment of the interfaces COM1 For management and diagnostic tasks especially firmware updates remote maintenance and debug functions COM2 To connect external computers for requesting and recording test results and for sending and receiving parameter data If necessary this interface may be used for firmware updates and diagnostic functions also COMS3 To connect report devices printer computer with simple data logging function etc or for application specific special functions Basically it is possible to use a combination of operation modes e g automatic data exchange and command controlled data exchange using the same interface However the user or application software of the control computer must ensure that a collision of different data streams does not occur 2 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces 2 Interface assignments and data formats The interfaces use only the data connections TxD and RxD and ground Handshake connections are not supported To connect a standard PC use a so called null modem cable send and receive lines crossed The transfer format is generally 115 200 bps 8 data bits 1 stop bit no parity For text data the
55. elected program is not available the ERROR output is set After being started successfully the test program takes over control of the signal exchange The DONE signal is cleared and the TEST RUNNING signal is set 17 4 4 The PLC monitors the starting procedure Usually a successful start is checked using the set TEST RUNNING signal On rare occasions it can happen that this signal is set for a very brief period of time e g if the program is aborted because of a disruption This can cause the PLC not to recognize whether the signal has not yet been set or whether it has already been cleared again after the end of the check routine There are two ways to avoid this situation a the PLC uses an internal clock that initiates an appropriate error treatment after the monitoring time has passed Adequate monitoring time for standard routines is 200 ms for application specific extensions longer duration may be necessary b prior to the start the signals OK NOK and ERROR are checked for and if necessary cleared by a reset call After the start all 4 signals can be evaluated As soon as the PLC recognizes that the test program has been started or has already been terminated it can clear the START signal 17 4 5 Executing the test During the test procedure itself there is normally no further signal exchange It is however possible to pause the running test at certain points for a while or to request early termination of the test pro
56. eriod between start signal and beginning of the test procedure Time period between availability of evaluation result OK NOK and end of test run Lower limit value for start pressure monitoring relative pressure Start pressure monitoring ensures that a certain pressure is available at the beginning of a test usually atmospheric pressure gt 0 bar 10 of measuring range Upper limit value for start pressure monitoring relative pressure 11096 of measuring range Lower limit value for start pressure monitoring differential pressure 11096 of measuring range 30 info drwiesner de www drwiesner de Weststrasse 4 D 73630 Remshalden Germany Phone 49 0 7151 9736 0 Fax 49 0 7151 973636 Leakage Testing System INTEGRA Instruction Manual Initial pDif HiLimit Prefilling Prefill Time PrePressure Setpoint PrePressure LoLimit PrePressure HiLimit Prefill Hold Time Filling Pressure LoLimit Pressure HiLimit Fill Hold Time Test Pressure LoLimit Test Pressure HiLimit SeparValve Time Filter Interval Differential Pace Hesult as Deflate SetPoint Dr Wiesner Steuerungstechnik GmbH steuerungstechnik Upper limit value for start pressure monitoring differential pressure 11096 of measuring range Selection or deactivation of the pre filling function Here you can select whether pre filling is time controlled controlled by a pressure limit value
57. erungstechnik Instruction Manual 11 3 8 Data Administration Data Administration Here you can create copy delete or edit new programs and base data sets In addition the various passwords can be changed Use the F1 key to edit all display texts and the F3 key to edit all format texts 5 Create New Data Base Set Duplicate Existing Base Data Set 7 Delete Existing Base Data Set Create New Program Duplicate Existing Program Delete Existing Program Dre ite DB WM H Program Directory 8 Special functions 9 Edit passwords Fl Edit display texts F3 Edit formatting texts Texts Formats BACK 11 3 8 1 Create new program Select Progr Type Test Method At first the desired testing method must be selected using the numerical keyboard or the cursor and the Enter key If the device does not have the option Volume measurement the key 7 is without function In the next display the program number and the desired corresponding base data set must be chosen By pressing the F1 key the new program is created Ifthe desired program is already allocated input is refused You either have to select a different program number or delete the existing program reet See also chapter 12 parameter setting pDif Classic pDif Differential pRel Classic pRel Differential Volume Flow vosauswm H Cat I he ey d 11 3 8 2 Duplicate delete existing program When duplicating
58. erungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces Contents 1 Data traffic via serial interface 4444444404nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn page 2 2 Interface assignments and data formats 44444440snnnnn nennen page 3 2 1 Automatically output test results in plain text page 3 2 2 Automatically output test results in a table 444400nnennnnnnnnnnnnnnnnnnnnnnnnnnnnn page 4 2 3 Format of data output upon request from the user interface nenn page 4 3 Command controlled data exchange eeeeeeeeeeereeeeesiirrrrtssserrrnnnnrssssrnnns page 5 3 1 EE eeler IG page 5 3 2 Symbols and abbreviations in Commande page 6 3 3 Commands for general device and communication control and status query page 6 3 4 Commands for transferring binary data page 8 3 5 Commands for managing logical data blocks uusssunsssnnnnnnnnnnnnnnnnnnnnnnnnnn page 10 3 6 Commands for control of keyboard screen and system IO page 12 3 7 Other COMMANAS t EP page 13 1 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces 1 Data tra
59. es should be checked in regular intervals approximately twice a year for wear and if necessary be replaced Since the test quality and test accuracy of the device depends on the dili gence of execution the valves must be opened by qualified maintenance personnel only To ensure the test quality it is absolutely necessary to check the test results of the device regularly in short intervals ideally on a daily basis using a test leak see accessories Furthermore the measurement display should be calibrated and adjusted once or twice a year Since the test quality and test accuracy of the device depend on the diligence when calibrating and adjusting this must be done by qualified maintenance personnel only The system is suitable for remote maintenance This requires connecting a modem or a PC with appro priate data transfer software to the serial interface COM1 This makes it possible to change parameters upload software updates or get help with problems from the manufacturer s plant For cleaning the keypad only use a soft and clean cloth with clear water or mild cleaning agent Never use solvent based or aggressive cleanser 42 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de steuerungstechnik Leakage Testing System Appendixes Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steu
60. esting storage execution INTEGRA executes the command and acknowledges These are the commands used for binary transfer RP read flash memory Format RP hhhhhhhh hhhh the first hexadecimal number defines the flash memory address the second the number of bytes Effect Preparation of storage area transfer The actual transfer must be started with the following RD command Response RP hhhhhhhh hhhh Note The firmware the operating system is stored in the flash memory of the device RE read eeprom memory Format effect and response in analogy to RP command Note The EEprom memory contains calibrating data user programs and settings RR read RAM memory Format effect and response in analogy to RP command Note The battery buffered RAM contains test results and statistics RB read the transfer buffer Format RB hhhh the hexadecimal number specifies the number of bytes to be transferred Effect Output of data from the transfer buffer Response RB hhhh After the terminator the binary data is transferred RD read number of transferred data bytes Effect The number of bytes to be transferred is read according to a prior transfer command Response RD hhhh with hhhh representing the number in hexadecimal format Note This command is redundant It is recommended not to use this command 8 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fa
61. esult NOK pRel Stable 6 7 of target pressure value but min 0 33 of measuring range Time period between end of stabilization period and test period This time period serves to tare a pressure jolt caused by the closing of the separation valve between test and reference circuit only for differential pressure test Flexible time window in which the measured values are averaged 0 6 sec Time window for differential calculation differential method only 1 2 sec Selection of the display mode of the test result e g flow leakage rate dp dt delta p etc Enter here the target pressure after deflating 31 info drwiesner de www drwiesner de Weststrasse 4 D 73630 Remshalden Germany Phone 49 0 7151 9736 0 Fax 49 0 7151 973636 Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 14 3 Base Data The following parameters can be entered in the Base Data submenu see chapter 11 3 6 Fail Ack required Volume data format Reference volume Dead volume Leak volume min Prg Active Output Physical Dim dp at Physical Dim Leakrate Physical Dim 1 Physical Dim 2 Physical Dim 3 Format Offset Dr Wiesner Steuerungstechnik GmbH Here you can activate or deactivate the function Acknowledge after NOK evaluation Here you can enter the desired volume unit usually ml volume testing Volume of the reference volume for volume testing wit
62. f converting the pressure drop into a leakage rate the measured drop rise in pressure with the test leak must be entered here see chapter 12 2 Note For physical value leakage rate and physical value 3 this parameter is only accessed when offset nominator and denominator of the program parameters are set to 0 see chapter 14 1 Special options Here you can activate special options for various test methods For flow and differential methods Pressure correction The actual pressure is compared to the target pressure during the test In case of a deviation the result is corrected linearly Analog output Here you can scale the proportional pressure control valve 15 Graphical display PK1 25 000 25 000 mbar 15 1 Display of the march of pressure In the basic display press the F4 key to browse the various display modes Press this key several times for the graphical display of the march of pressure of the last test The graphical display shows the march of the relative pressure 1 or the differential pressure 2 during the entire test run Press 3 to display the first differentiation of the relative pressure 4 for that of the differential pressure Press 5 to display the second differentiation of the relative pressure 6 for that of the differential 299 0 0 20 0 s ZoomX ZoomX FUNC MODE MENU pressure The upper row shows the display range of the Y axis in mbar the line under the graphics s
63. ffic via serial interface The following types of communication tasks can be carried out via the serial interface a Automatic output of test results at the end of a test For this the COM2 and COMG interfaces can be configured see System configuration menu item The output can be multiline plain text or a table CSV format simplifying reading editing of data in spreadsheet programs and databases Data traffic is text oriented and unidirectional b Output of data parameters statistics etc upon manual request from the user interface For this all 3 COM interfaces can be used The selected interface is requested from the user interface on a case by case basis Data traffic is text oriented and unidirectional c Command controlled data exchange In this case communication is controlled via an external computer The external computer sends commands and possibly parameters or data over the interface INTEGRA processes the received data and replies or sends requested data via the same interface For this all 3 COM interfaces can be used Data traffic is bi directional and usually text oriented only pure blocks of data e g parameter data are sent binary d Application specific special functions For tasks that cannot be accomplished with the standard functions INTEGRA can be equipped with customer specific extensions For this COMS3 is normally used but in some cases using COM1 or COM2 may be necessary With regard to th
64. first INTEGRA sets the READY signal and waits for the signaling time specified in the test program parameters Subsequently TEST RUNNING is cleared At this point at the latest the PLC must clear the START signal As soon as it has been cleared the test program is terminated and the supervisor takes over control of the signal exchange By setting READY the PLC is told that INTEGRA is ready for the next start 17 5 Special cases 17 5 1 Stop test program For set up and test purposes it is possible to stop the test procedure of the standard programs at pre defined points between test steps for a while by setting the input signal PAUSE As soon as the test procedure reaches such a break point and PAUSE has been set as a response to the PLC the output PAUSING stopped is set The test program then waits for the PAUSE signal to be cleared or for the program to be terminated by a stop or reset request Note if PAUSE is cleared before the next break point has been reached there will be no response 17 5 2 Abort test procedure prematurely By setting STOP the test procedure can be aborted prematurely As far as possible the test program tries to shut down the process in a defined way by for example venting the test piece Further signal exchange takes place as described in section End of program 17 5 3 Forced termination of test program Kill In some situations it may be desirable or necessary to force a running test program to
65. g EN standards were applied at the time of testing DIN EN 60204 1 Electrical Equipment for Industrial Machinery DIN EN 61000 6 2 Generic Standard Disturbance Immunity Industrial Sector DIN EN 61000 6 4 Generic Standard Disturbance Transmission Industrial Sector Remshalden January 01 2010 res Dipl Ing Frank Wiesner General Manager Pay attention to the safety instructions in the delivered documentation
66. gram For more information turn to section Special cases 17 4 6 Report of the test result As soon as the test result has been evaluated and all pertaining actions logging marking if necessary etc have been executed the test result is reported to the PLC using the signals OK NOK or ERROR Note on the difference between NOK and ERROR NOK is reported when the test procedure has been carried out properly but the result is outside the range between the limiting values The ERROR signal is set when the test procedure could not be carried out properly The cause can be a disruption but also a defective test piece etc therefore it is not possible to determine whether the test is OK or NOK and ERROR can thus occur by themselves or together The appropriate reaction of the PLC to NOK or ERROR depends on the application 17 4 7 Acknowledge NOK must only be acknowledged if this has been set in the basic data set of the test program executed ERROR must always be acknowledged To acknowledge the PLC has to set the ACKNOWLEDGE signal Subsequently INTEGRA clears the ERROR or NOK signal if both were set ERROR takes precedence Now the ACKNOWLEDGE signal must be cleared 38 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 17 4 8 End of program At
67. h reference volume see chapter 12 7 These parameters are only accessed when all 3 volume parameters of the program parameters are set to 0 see chapter 14 1 Device specific test circuit volume see appendix Technical data plus the connected tube volume or the volume of the fastening and sealing device for volume testing with reference volume If you enter 0 here these volumes are included for volume calculation see chapter 12 7 These parameters are only accessed when all 3 volume parameters of the program parameters are set to 0 see chapter 14 1 For volume measurements with a test leak the nominal value of the test leak must be entered Using this value and the measured pressure decay the volume is calculated see chapter 12 7 These parameters are only accessed when all 3 volume parameters of the program parameters are set to 0 see chapter 14 1 Here you can enter an I O bit that will be set during program execution This is useful when adding an external valve or a lamp etc For leakage tests the value is usually dp at You can also enter a different text For leakage tests the value entered is usually the leakage rate You can also enter a different text In most cases the relative pressure rel pressure is entered here You can also enter a different text In most cases the differential pressure Diff pressure is entered here You can also enter a different text For flow tests the value entered is usually th
68. hat way to protect them from shocks and dirt The best way is to store them in a optional available case If the Leakage Testing System INTEGRA is equipped with the option switchable test leak the test leak can remain permanent in the rapid action coupling 9 Setup The Leakage Testing System INTEGRA comes in a desktop casing that can be used as a desk casing or a 19 slot in combination with optionally available angle fixtures The casing dimensions are 450 x 180 x 380 mm width x height x depth The front panel contains all controls and a fully graphical color display In addition there is a rapid action coupling for connecting a test leak on the front panel On the back panel of the device are all pneumatic electrical and electronic connections and interfaces cf Chapter 10 The Leakage Testing System INTEGRA can be equipped for asynchronous multiple circuit tests Up to 3 test circuits can be connected altogether with one test circuit usually in the base device but it is also possible to house up to 3 test circuits in separate casings The external test circuits are supplied with test pressure by the base device optionally they can be equipped with their own manual pressure regulators Depending on the test method and configuration each test circuit contains an input filter test pressure regulation using a proportional pressure valve or manual precision pressure regulator optional for external test circuits apiezoresistiv
69. he plain text denomination of the value concerned 1 525 bar Format and physical unit of a value correspond to the display on the screen Most data formats can be freely configured in the set of basic data ok evaluation of the value concerned ok means OK IF means NOK or ERROR The character marks the end of a record 3 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces 2 2 Automatically output test results in a table Example 05 04 21 19 45 30 02 023 0k 077 000000001525 0k 098 00000000825 ok General structure All data is contained in one line fields within the line are separated by commas The first fields contain date time device ID and program number in analogy to the corresponding data of the plain text output The next field shows the overall result of the test ok or IF A test is considered ok only when all part and intermediate results have been OK Subsequently the values of the measurements are given in the same number and order as in the plain text output Each measured value consists of the fields register number value and evaluation 2 3 Format of data output upon request from the user interface Example Ck ckckckckckckck ck ckckck ck kckck kc kok LOG 2006 02 01 17 09 39 Ck c
70. hows the display range of the X axis in sec Use the F1 and F2 keys to enlarge or shrink the display range Thus it is possible to analyze parts of the pressure curve more easily and using a higher resolution Use the F3 key to switch the zoom function between the X and Y axis Furthermore you can switch to the Start or Stop function thus enabling an online view of the pressure Using the cursor keys the curve can be moved up down or to the left right by 1 10 of the display range 33 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA Instruction Manual 15 2 Statistics display Use the sub menu 3 of the main menu to access statistical evaluation see also chapter 11 3 3 Use the F4 key to display test results graphically The upper row shows the display range of the Y axis in mbar test results the line under the graphics shows the display range of the X axis number of tests Use the F1 and F2 keys to enlarge or shrink the display range This provides maximum clarity Use the F3 key to switch the zoom function between the X and Y axis Using the cursor keys the curve can be moved up down or to the left right by 1 10 of the display range steuerungstechnik Program 209 pDif Clasic Tests 0 Test Circuit 1 Attribute pDif Delta Count Total
71. ial evaluation are carried out automatically The operator only has to enter the so called optimization degree specifying the strictness for which the test parameters are to be set The system then automatically carries out a process optimization with a connected test volume and a test leak i e it sets the necessary process times for each test step The higher the optimization degree the longer the process times will usually be see also chapter 11 3 7 10 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 8 Conditions for optimal leak testing When testing for leakage or flow using air some basic prerequisites must be met to achieve the desired test significance This will be demonstrated using the components involved in the test process 8 1 Test piece First of all the test piece should be dry and as free of contaminants on the inside too as possible before itis inserted into the test device In addition it should have reached room temperature If the test piece was heated e g by a prior production process an intermediate storage must be available for the pieces to cool The areas where the test piece is sealed with the adaptation of the test device must not have any damages 8 2 Test appliance The test appliance should be set up in a place with l
72. ial pressure method parameter setting is done using manual setup of program parameters according to chapter 11 3 5 The meaning of the parameters is explained in chapter 14 When setting the various process time periods e g filling damping testing deflating the conditions for an optimal leakage test according to chapter 7 must be observed The best way to visualize the pressure value profiles is to use the graphical display according to chapter 15 To simplify setting the time periods use the optional self optimization auto Tune see chapter 11 3 7 Usually the test result is displayed in ml min leakage rate or mbar min pressure rise or decay To set the limit values a test leak should be inserted into the fast coupling of the front panel after setting the parameters and a known tight test piece connected If possible the test leak should be adjusted to a leakage rate close to the permissible limit value The first test will display a fictitious leakage rate To display the correct leakage rate the parameters must be changed in the base data set or program specific under local conversion Proceed as follows example set of base data Base Data Set 001 Press the F5 key to enter the main menu eae E Press the 6 key to access the base data set Physical Dim In the base data set the following parameters must be set AES E select using the cursor keys Physical Dim Leakrate set to Leak rate ms M Format set to ml min format
73. input can be used freely e g for controlling devices 223 X2 IN 4 07 Reserve free input This input can be used freely e g for controlling devices 224 X2 OUT 7 00 Reserve free output This output can be used freely e g for controlling devices 225 X2 OUT 7 01 Reserve free output This output can be used freely e g for controlling devices 226 X2 OUT 7 02 Reserve free output This output can be used freely e g for controlling devices 227 X2 OUT 7 03 Reserve free output This output can be used freely e g for controlling devices 6 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix I O bit number assignment table 228 X2 OUT 7 04 Reserve free output This output can be used freely e g for controlling devices 229 X2 OUT 7 05 Reserve free output This output can be used freely e g for controlling devices 230 X2 OUT 7 06 Reserve free output This output can be used freely e g for controlling devices 231 X2 OUT 7 07 Reserve free output This output can be used freely e g for controlling devices 232 X2 OUT 6 00 Reserve free output This output can be used freely e g for controlling devices Reserve free output This output can be used freely e g for controlling devices Eu pee Reserve free output This outpu
74. ith a test leak If the test leak is adjusted to the permitted limit value NOK must be returned after inserting the test leak 7 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 5 Test methods 5 1 Relative pressure method With the relative pressure method the test piece is filled with compressed air or vacuum during an ad justable filling time The filling process is followed by a damping period During this time the temperature between test piece and test medium equalizes Before the subsequent test period the measurement display must be tared If the test piece is leaking the pressure will be different at the beginning and end of the test period which can be measured and evaluated Since this method measures the absolute change of pressure measuring accuracy is directly dependent on the test pressure By connecting to a test leak an equivalent volume flow can be assigned to the resulting pressure difference 5 2 Differential pressure method With the differential pressure method the test piece and a comparison volume are filled with compressed air or vacuum during the filling time The filling process is followed by a damping period During this time the temperature between test piece and test medium equalizes At the end of the damping period test
75. ittle temperature variation Avoid places that can be exposed to direct sunlight or close to machines radiating strong heat Drafty spots next to doors or floor conveyor passages should be avoided as well If necessary shields must be installed A pipe conduct is the optimal connection of test device and test appliance If this is not possible a hose of sufficient stability should be used This avoids bursting under test pressure and flexible distortions of the test volume which would affect the test results The pipe should be as short as possible to minimize the test volume The pipe should be laid in such a way that it cannot be damaged or bent In the case of vacuum testing a filter with mesh size lt 50um should be mounted in this pipe to prevent the absorption of dust into the inside of the test device The test appliance should be constructed in such a way that the test piece cannot be damaged during insertion or adaptation Furthermore the sealing materials must conform to the conditions at the sealing spots of the test piece It must be ensured that the adaptation does not exert forces onto the test piece which may seal possible leakage The forces should be adapted to the given test pressure 8 3 Test medium The test medium to be used testing for leakage with the Leakage Testing System INTEGRA is mainly compressed air vacuum or less frequently nitrogen When using compressed air it should conform to quality class 4 acc DIN ISO 8573 1
76. ivated using the keyboard or input channel IN 11 For this the following assignments must be made iof Start 24 bit no for connection IN 9 iof Stop 26 bit no for connection IN 11 Kb Start O 0 no Start via keyboard Kb Stop 7 bit no of the flag for Press Stop button for test circuit 1 Which test program is loaded and executed at the next Start is also determined by appropriate signal assignment To select the desired program manually the least significant program selection bit must be set to O If this signal is assigned a bit number not equal to 0 the manually set program number is ignored and the program is selected according to the given I O signals 8 program selection bits are available but not all need to be assigned It can happen that the available physical inputs are needed for other purposes and only a few are used as program selection bits In such cases the signals with the lower values must be assigned while those with higher values are set to 0 The assigned program bits beginning with program bit 1 as the least significant bit up to the last assigned program bit as the most significant one give the program number as a binary number 17 4 Exchange of signals in normal test operation 17 4 1 Switch on mode After switching on the device or after a reset all output signals are cleared As soon as INTEGRA is ready to start the test program the output is set to READY If there is a system malfunction th
77. k volume min in the base data set or program specific in local conversion Using this value and the measured pressure decay the volume is calculated Note For the parameters Reference volume and dead volume 0 must be entered lest volume measurement with reference volume see chapter 12 7 2 is activated If no reference volume is connected activating the volume measurement with reference volume leads to wrong calculations 12 7 2 Volume testing with reference volume When doing volume measurements with reference volume you must enter the following parameter in the base data set Volume Data Format The desired volume unit usually ml Reference Volume The volume of the reference volume Dead Volume The device specific test circuit volume cf appendix Technical data plus the connected tube volume or the volume of the fastening and sealing device If you enter 0 these volumes are included for volume calculation 12 8 Flow test method mass flow or volume flow Setting parameters for the mass flow test method is done similarly to the differential pressure method described in chapter 12 1 With flow test methods it is possible to select a pressure correction in the base data set under Special Options If pressure correction is active the actual pressure is compared to the target pressure during the test In case of a deviation the result is corrected linearly 12 9 Automatic adding of test leak connection option For devices e
78. kckckckckckck ck ckckck ck ckckck ck kck Data Block PRGOO5 01 02 06 17 11 00 Program Type pRel Different Base Data Set 001 Pressure Setpoint 15000 0 Pa Fill Time T1 s Stabiliz Time 120 0 s Testing Time 120 0 s Result LoLimit 0 00 mbar mi Result HiLimit 0 00 mbar mi Deflating No Deflating Deflate Time 0 0 s Marking No Marking Marking Time 0 0 s Local Conversion Offset 0 00 mbar mi Nominator 0 00 ml min Denominator 0 00 mbar mi Extended Parameter Chain if PASS 000 Chain if FAIL 000 Chain if ERROR 000 Call at Beg End 0000 Call when Testing 0000 Call synchronized 0000 Startup delay 0 1 s Signaling delay 0 0 s Initial pRel LoLimit 9999 0 Pa Initial pRel HiLimit 99999 0 Pa Initial pDif LoLimit 0 0 Pa Initial pDif HiLimit 0 0 Pa 4 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces Prefilling No PreFilling Prefill Time 0 0 s PrePressure Setpoint 0 0 Pa PrePressure LoLimit 0 0 Pa PrePressure HiLimit 0 0 Pa Prefill Hold Time 0 0 s Filling Time Controlled Pressure LoLimit 9999 0 Pa Pressure HiLimit 99999 0 Pa Fill Hold Time 0 0 s TestPress LoLimit 9999 0 Pa TestPress
79. ling devices Reserve free output This output can be used freely e g for controlling devices Reserve free output This output can be used freely e g for controlling devices Reserve free output This output can be used freely e g for controlling devices Reserve free output This output can be used freely e g for controlling devices Reserve free output This output can be used freely e g for controlling devices Reserve free output This output can be used freely e g for controlling devices Reserve free output This output can be used freely e g for controlling devices Reserve free output This output can be used freely e g for controlling devices Test circuit 3 Ready The test device is switched on and the test circuit is ready for testing Test circuit 3 Test is running This output is set from receiving the start signal until the very end of the test run including periods of interruption after Stop during the waiting period for Acknowledge bad part and during the marking and signaling period The test procedure was paused Test circuit 3 OK The measured values of all steps of the test were within the set ranges the test piece is OK Test circuit 3 NOK The measured values of at least one step of the test were outside the set ranges the test piece is NOK Test circuit 3 Test done This signal is set at the end of the test run and stays active until the next start or until the test re
80. lues are zeroised the values will be determined by the base data set too Nominator The evaluation is carried out by the formula Y X Offset x Denominator X Actual value Y Target value The value entered here is subtracted mathematically from the measuring result This might be necessary if for example during a leakage test thermal effects or plastic deformation of the test piece cause a pressure change that is not due to a leak Take care to enter the correct algebraic sign 29 info drwiesner de www drwiesner de Weststrasse 4 D 73630 Remshalden Germany Phone 49 0 7151 9736 0 Fax 49 0 7151 973636 Leakage Testing System INTEGRA Instruction Manual Nominator Denominator Reference volume Dead volume Leak volume min steuerungstechnik This is one component used to generate a scaling factor When converting the pressure drop into a leakage rate the nominal value of the test leak used must be entered here see chapter 12 2 In the example of converting the pressure drop into a leakage rate the measured drop rise in pressure with the test leak must be entered here see chapter 12 2 Volume of the reference volume for volume testing with reference volume see chapter 12 7 Device specific test circuit volume see appendix Technical data plus the connected tube volume or the volume of the fastening and sealing device for volume testing with reference volume
81. nd the manufacturer s serial number The other settings are used mostly by the manufacturer s service personnel Use the F1 key to print the system configuration To print select the appropriate interface COM COMO from the selection dialog using the F1 F3 keys 12 Parameter setting After switching on the leakage testing system the basic screen chapter 11 2 is displayed Press the 1 key to activate program selection and to select a program as described in chapter 1 1 3 1 When setting system parameters for a new test task it is recommended to create a new program Proceed as follows Select Progr Type Test Method As described in chapter 11 3 8 1 the depicted display can be reached via data management pDif Classic pDif Differential pDif autoTune pRel Classic First select the test method or program type classic or differential In the next display the program number desired and the corresponding base data set must be entered confirm by pressing F1 For all test methods or program types the function Acknowledge NOK can be activated or de activated in the base data set 0 Custom tests pRel Differential pRel autoTune Volume Flow o 0 100 bro BOR upon o Pow The following test methods or program types can be created 12 1 Differential pressure test method classic pDiff classic With the classic differential pressure method parameter setting is done using manual
82. nfo drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Digital I O Interface Outputs X1 9 24V DC voltage supply for outputs X1 10 24V DC voltage supply for outputs x1 1 OUT 1 Ready system output The test device is switched on and ready for testing X1 20 OUT 2 Test is running pre set output This output is set from receiving the start signal until the very end of the test run including periods of interruption after Stop during the waiting period for Acknowledge bad part and during the marking and signal period X1 2 OUT 3 Pause system output The test run is interrupted by pressing the Pause button once or by setting the Stop input X1 21 OUT 4 OK pre set output The measured values of all steps of the test were within the set ranges the test piece is OK X1 3 OUT 5 NOK pre set output The measured values of at least one step of the test were outside the set ranges the test piece is NOK X1 22 OUT 6 Test done pre set output This signal is set at the end of the test run and stays active until the next start or until the test results are cleared by Stop X1 4 OUT 7 Error system output The test device encountered an error caused by a violation of limiting values at the start or end of the filling process or because of an electronic error X1 23 OUT 8 Reserve free out
83. nput u This input can be used freely e g for controlling devices 141 X2 IN 2 05 Reserve free input This input can be used freely e g for controlling devices 142 X2 IN 2 06 Reserve free input This input can be used freely e g for controlling devices X2 IN 2 07 Reserve free input This input can be used freely e g for controlling devices Setting this input starts the test procedure Setting this input stops the test procedure 154 X2 IN 0 02 Test circuit 1 Abort Setting this input aborts the test procedure Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de 3 Leakage Testing System INTEGRA steuerungstechnik Appendix I O bit number assignment table I O bit no 155 X2 IN 0 03 Test circuit 1 Acknowledge bad part This input must be set for NOK test results 156 X2 IN 0 04 159 X2 IN 0 07 163 X2 OUT 3 03 164 X2 OUT 3 04 167 X2 OUT 3 07 E d X2 OUT 2 00 X2 OUT 2 01 m X2 OUT 2 03 X2 OUT 2 04 168 169 E 171 172 173 X2 OUT 2 05 X2 OUT 2 06 X2 OUT 2 07 Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for control
84. nts The Leakage Testing System INTEGRA is equipped with the following control and display elements Fully graphical LCD display Soft keys F1 F5 Keypad with alphanumerical keys Cursor keys Dm DO D gt Contrast control of display E1 darker E2 lighter PK1 289 pDiff klassisch gt 99 99 mi Min Pr fergebnis 00 03 mi Min EEE A 2 Anzeigemodus 3 Statistik STARTI RESET1 N chstF MODUS MENU steuerungstechnik Note Use the keypad only manually Never use spiky or hard things for pressing the keys Don t use the keypad with dirty fingers especially in contact with solvent based substances oils or fats 16 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA Instruction Manual 11 2 Basic screen standard steuerungstechnik After switching on the device using the mains switch SO the basic screen is displayed see also chapter 11 3 2 The program that was active when switching off the device and the upper and lower limiting values are displayed In the middle the release number of the integrated software is displayed By pressing the cursor keys D and then confirming with the Enter key or by using the alphanumerical keypad C the main menu 0 the program selection 1 display mode 2 or statistics 3 can be selected Use the F5
85. ock type and block number are in hexadecimal form The following block types are possible A1 application specific texts A2 application specific format texts A3 system configuration data A5 calibration data A6 sets of basic data AT program specific parameter descriptors 10 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces A8 normal test programs with numbers 0 to 255 that can be created edited and called up in the INTEGRA interface A9 special programs AA empty block at the end of the memory AB user specific program name FF empty erased data block Note Data blocks that haven t been written back to the EEprom are marked by the missing most significant bit in the block type IBLDEL block delete Format BLDEL lt BlockType gt lt BlockNumber gt Both numbers are decimal Effect The specified data block will be marked as erased in the block list and the RAM Response BLDEL lt BlockType gt lt BlockNumber gt If the command is not accepted e g syntax error block not existing etc the command is returned with an added question mark BLPUT block put Effect A data block that was transferred using the WD command and which is now in the data transfer buffer is written as data block to the RAM Type
86. ped Use the F1 key to restart a test and the F2 key to abort it Weststrasse 4 D 73630 Remshalden Germany Dr Wiesner Steuerungstechnik GmbH PK1 Program Result LoLimit Result HiLimit Result of Test 123 209 pDif Differential 99 99 ml min k 099 99 ml min o kW 000 00 ml min 0 Main Menu 1 Select Program 2 Change Display Mode 3 Statistics START1 STOP1 NextPro MODE MENU 0 Default Display Mode Short Menu Prg Window 1 1 Program Window 1 as Full Screen 2 2 Program Windows stacked 3 3 Program Windows stacked 4 Curve Most Recent Test PK1 Program Result LoLimit Result HiLimit Result of Test pRel at Filling pRel Stable pDif at Separation pRel Tara pDif Tara dpRel dt dp dt 209 pDif Classic 99 99 ml min o k 099 99 ml min 000 00 ml min 500 00 mbar 1499 00 mbar 0 032 mbar 498 00 mbar 0 031 mbar 0007 750 mbar min 0001 750 mbar min START1 STOP1 NextPro MODE MENU Phone 49 0 7151 9736 0 Fax 49 0 7151 973636 19 info drwiesner de www drwiesner de Leakage Testing System INTEGRA Instruction Manual steuerungstechnik Use the F3 key to switch between different test circuits for multiple circuit systems Use the F4 key to switch between different display modes In display mode 2 only the limit values set for evaluation and the
87. put This output can be used e g for controlling the device appliance X1 5 OUT 9 Mark good part pre set output This output can be programmed using the Marking time of the measuring electronic It is only set when the test result is OK and a marking period gt 0 s is programmed It can be used for controlling a marking device X1 24 OUT 10 Reserve free output This output can be used e g for controlling the device appliance X1 6 OUT 11 Reserve free output This output can be used e g for controlling the device appliance X1 25 OUT 12 Reserve free output This output can be used e g for controlling the device appliance X1 7 OUT 13 Reserve free output This output can be used e g for controlling the device appliance X1 26 OUT 14 Reserve free output This output can be used e g for controlling the device appliance X1 8 OUT 15 Reserve free output This output can be used e g for controlling the device appliance X1 27 OUT 16 Reserve free output This output can be used e g for controlling the device appliance 2 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix I O bit number assignment table This table shows the assignment between external E A and internal bit numbers GE Een D Maso KDSTART
88. question mark The protocol is usually case insensitive Exceptions are noted with the corresponding command Please note that acknowledgements and other responses may differ in form from the command character string upper lower case letters normalization of address and other numerical data Before the commands given by the controlling computer are accepted by INTEGRA a special command to establish communication must be used Only after this command has been received and acknowledged can further commands be executed This prevents character strings sent inadvertently 5 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces over the data line by software e g automatic modem recognition with Plug amp Play operating systems or hardware impulses at switching on and off of being misinterpreted by INTEGRA A number of commands is compatible to the predecessor series LTS 670 Because of the considerably extended functional range of INTEGRA there are several commands that are no longer supported require more other parameters or that are wholly new in INTEGRA 3 2 Symbols and abbreviations in commands hh or hhhh means two or four digit hexadecimal number n or nn or nnnn etc means a one two four etc digit decimal number with a fixed number of
89. quipped with the option to add test leaks automatically the sub program 318 add test leak or 319 switch off test leak must be included via the parameter Call at Beg Endfor the creation of the relevant check program in the extended parameters area see chapter 14 27 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 13 Test procedure The following flowchart shows the standard test procedure for a leakage test Start pressure OK no Pre filling pressure OK Pre filling Stabilization 28 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA Instruction Manual 14 Parameters steuerungstechnik 14 1 Program Parameters The following parameters can be entered in the Program Parameters submenu cf chapter 11 3 5 Pressure Setpoint Fill Time Stabiliz Time Testing Time Result LoLimit Result HiLimit Deflating Deflate Time Marking Marking Time Local Conversion Offset Dr Wiesner Steuerungstechnik GmbH Enter here the target value of the filling pressure Time period between beginning and end of the filling procedure Time period between beginning and en
90. r safety is at stake The manual must be available at the device 1 2 Safety measures in this manual In this manual the following symbol is used to indicate descriptions of danger Danger Signals an immediate danger If not avoided the result can be death or serious injuries 1 3 Intended use The device must only be used in technically perfect condition The operations and maintenance instructions given in this manual must be followed For safety reasons unauthorized alterations and conversions of the device are prohibited If the device is integrated into a machine operation of the device is prohibited until it has been confirmed that the machine conforms to the applicable EU regulations Spare parts must conform to the technical requirements defined by the manufacturer This can only be guaranteed for original spare parts The operator must take care that the working order of the device is checked in appropriate intervals using suitable tools Although this instruction manual was made with greatest care mistakes or failures are possible Dr Wiesner Steuerungstechnik GmbH is not responsible for damages even any kind caused by them 5 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 2 Safety 2 1 Sources of danger The following haza
91. rasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix I O bit number assignment table 09 3 3 X8OUT205 PO 110 XSOUT206 PT 111 X8OUT207 PO 112 2 XSOUT100 TI 3 XSOUT101 TI 114 3 XSOUT102 TI 115 Joao PO 116 X38OUT104 TI III XSOUT105 TI 118 XSOUT106 TI 119 XSOUT107 PO 120 XSOUTOO0 TI 21 XSOUTOOD TI 122 XBOUT 0 02 TI H23 XSOUTOO8 PO 124 XSOUT 0 04 TI i25 XSOUTOOD TI 126 X3SOUTOO8 TI 127 X3OUTOO7 128 X2IN3 00 X Testciuit2programbit 1 S y 129 X2IN3 01 X Test circuit 2 program bit2 130 X2IN3 02 X Testciuit2programbit3 131 X21N3 03 X Testcimuit2programbit4 132 X2IN304 X Testcicuit2programbito S O 133 X2IN305 X Testciuit2programbitG 134 X2 IN3 06___ Testcircuit2 program bit7 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 35 X2 IN 3 07 Test circuit 2 program bit 8 Setting this input starts the test procedure Setting this input stops the test procedure 138 X2 IN 2 02 Test circuit 2 Abort Setting this input aborts the test procedure This input must be set for NOK test results 140 X2 IN 2 04 Reserve free i
92. rds can be connected with operating the device Because of these hazards caution must be exercised when operating the device Bursting parts can cause serious injuries When filling hollow bodies with compressed air all valid regulations must be observed The device operates on 230 V AC supply voltage Before opening the device disconnect the power and compressed air supply The device may only be opened by appropriate and trained personnel 2 2 Admissible persons Responsibilities for operation and service must be clearly defined Unclear responsibilities could endan ger the safety of the operating personnel Operating personnel must have a contact person or institution in case of problems with the device The operating personnel must be trained in using the device by the operator and must have read and understood the operating instructions Operating personnel must be of legal minimum age Service personnel must consist of qualified people Only a trained specialist for electrical installations may be allowed to work on electric parts of the device 2 3 Safety measures at the place of installation Make sure that the device and the surroundings are clean and orderly Check the device at least once per shift for visible damages and defects Report defects immediately to the appropriate contact 6 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0
93. riate contact 36 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 17 3 Configuration of control signals Every test circuit has its own set of logical virtual control signals In the system configuration the assignment between the virtual control signals and the physical I O channels or device internal flag bits is determined To every logical signal of each test circuit e Start test circuit 1 the desired physical WO bit must be assigned in the system configuration The physical I O bits including the internal flag bits are identified by a unique number 1 255 A table of the digital I O bits can be found in the manual s appendix For example the pin IN 1 of the X1 connector has the bit number 16 If bit number 0 is given for a signal the function of the corresponding signal is deactivated It is possible to assign the same physical bit number to various logical signals Therefore it is possible to set the same digital input channel as start signal for all 3 test circuits Appropriate assignment of the signals also determines whether control of the device is possible via keyboard and or digital I O signals or not Configuration can determine for example that Start can only be initiated via input channel IN 9 while Stop can be act
94. s follows 1 top left not used 2 top right green module is online 3 down right red module is offline 4 down left red flash error 10 4 INTERBUS interface option The leakage testing system INTEGRA can optionally be equipped with a INTERBUS coupling module thus allowing for the operation in an automated manufacturing facility too The installation of the module in slot X2 is standard Caution Special applications could necessitate a differing assignment of the slots The baudrate is selected by jumper 500 kbit s or 2 Mbit s In the INTEGRA 8 bytes process data and further 20 bytes PCP data are provided In the PCP array e g the numerical measuring result could pass see also chapter 18 The correlation between the Interbus data and the internal INTEGRA dataports is indicated in the list of chapter 18 4 From Interbus side the PCP output data could be read via PCP data index 0x6040 20 bytes The status LEDs 11 indicates as follows 1 top left green cable connection is good and the Interbus master is not in reset mode 2 top right green bus active 3 down left yellow remote bus disabled 4 down right green PCP communication is active 15 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 11 Operation 11 1 Control and display eleme
95. serve free input This input can be used freely e g for controlling devices 207 X2 IN 6 07 Reserve free input This input can be used freely e g for controlling devices 208 X2 IN 5 00 Reserve free input This input can be used freely e g for controlling devices X2 IN 5 01 Reserve free input This input can be used freely e g for controlling devices X2 IN 5 02 Reserve free input BE This input can be used freely e g for controlling devices 209 210 Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices 219 Reserve free input This input can be used freely e g for controlling devices 220 X2 IN 4 04 Reserve free input Seet This input can be used freely e g for controlling devices Reserve free input This input can be used freely e g for controlling devices 222 X2 IN 4 06 Reserve free input This
96. set Nominator Denominator 001 No f61 ml Format 25 6 ml 11 4 ml 2 0 ml 000 Rel Pressure Dim f73 bar Format 0 00000bar 0 001 bar 0 00100bar Voltage Dim f63 V Format 0 000 bar 0 001 V 0 001 bar PRINT Phone 449 0 7151 9736 0 Fax 49 0 7151 973636 21 info drwiesner de www drwiesner de Leakage Testing System INTEGRA Instruction Manual 11 3 7 Self Optimization autoTune optional Here you can optimize the program parameters of the selected program automatically The following parameters must be entered first Tuning Factor Enter the degree of test process optimization quality with regard to gauge capability in between 1 99 Pressure Setpoint Enter here the target value of the filling pressure The default equals the filling pressure entry in the program parameter set If the filling pressure is changed here it will be transferred to the program parameters after optimization is done Deflating steuerungstechnik PK1 Program 209 pDif Classic Tuning Factor 85 Pressure Setpoint 0 500 bar Time Controlled 2 0 s Deflating Deflate Time Start Cancel Selection or deactivation of deflating of test piece Here you can select whether deflating of the test piece is time controlled controlled by a pressure limit value or deactivated Deflate Time Time period between beginning and end of the deflating procedure The default
97. setup of program parameters according to chapter 11 3 5 The meaning of the parameters is explained in chapter 14 When setting the various process time periods e g filling damping testing deflating manually the conditions for an optimal leakage test according to chapter 7 must be observed The best way to visualize the pressure value profiles is to use the graphical display according to chapter 15 To simplify setting the time periods use the optional self optimization auto Tune see chapter 1 1 3 7 Usually the test result is displayed in mbar pressure rise or decay To set the limit values of the test results a test leak should be inserted into the fast coupling of the front panel after setting the parameters and a known tight test piece connected If possible the test leak should be adjusted to a leakage rate close to the permissible limit value The pressure rise or decay thus caused can then be taken as the limit value 25 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 12 2 Differential pressure test method with differential evaluation pDiff differential The difference between the differential pressure method with differential evaluation and the classic differential pressure method is the evaluation see chapter 6 As with the classic different
98. sner de www drwiesner de Leakage Testing System INTEGRA Instruction Manual In this mode press the F1 key to delete all data from the cyclic buffer thus all statistical data is deleted also Press the F2 key to delete only the data referring to the selected program To delete the data you must enter a password After entering the password a second confirmation is necessary before deletion takes place steuerungstechnik Program Tests Tests Pass Tests Fail Test Circuit Attribute Count Total Count Pass Count Fail Min Max Mean 209 pDif Classic 0 0 0 1 pDif Delta 0 0 0 000 00 mbar 000 00 mbar 000 00 mbar Del All Del Po FUNC GRAPH BACK 11 3 5 Program Parameters Program 209 pDif Classic Pressure Setpoint 0 000 bar Here you can enter or change the most important program Fill Time 5 05 parameters The meaning of each parameter is explained o n ups in chapter 14 1 Result LoLimit 40 000 1 For input the cursor must be moved to the selected ond uro LN MARRE parameter After pressing the Enter key enter the Deflating Time Controlled password and press the Enter key again Then you can wer NC enter the parameter value If the password has already Vide Ser a been activated data can be entered directly For input use EE the alphanumerical keypad or press the cursor key for ter E E cut i given selections Confirm by pressing the Enter key Dead
99. st piece has a leak the air will escape into the piece or from the test piece into the surrounding vacuum This will lead to a pressure rise or decay in the surrounding enclosure that can be measured Most of the time however it is necessary to take the test pressure or vacuum from a pre volume to check for big leaks A big leak would cause the test piece to be emptied or filled so quickly that no decay rise in pressure would take place during the actual testing pe riod and the test piece would falsely be rated OK 8 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 5 5 Flow test method 5 5 1 Mass flow measurement For this method the test piece is filled via a bypass pipe with a large cross section At the end of the filling process the bypass valve is closed The air escaping from the test piece is led to a mass flow sensor In a heated measuring canal the temperature difference between input and output is measured and used as a proportional measuring value for the flow Measuring the mass flow is largely independent of the tem perature and the medium s pressure however negative effects to the leakage test because of changes in temperature during the test period or because of flexible deformation of the test piece cannot be avoided with this method either
100. steuerungstechnik leakage testing gt flow testing gt functional testing Leakage Testing System at RD RD1 RD4 RD6 RD10 RDV DD DD1 DD6 DD10 DDV DF DF1M DF2M DF1 Instruction Manual Version 1 45e Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual Contents 1 ForeWord innra ee ER EEE TEE page 5 1 1 Contents of this manual page 5 1 2 Safety measures in this manual page 5 1 3 Intended use ee ere page 5 2 ELSE page 6 2 1 Sources of E E page 6 2 2 Admissible persons ursennsneeemaneenennpenmen mens page 6 2 3 Safety measures at the place of installation page 6 3 EE page 7 4 RTR E page 7 4 1 Recommended accessories uuuessssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn page 7 5 Test OU NOLO Ke PAANS ANEA NA VESE AN ouo Duce ont page 8 5 1 Relative pressure test meibod nnns page 8 5 2 Differential pressure test method ssssssssssssseeeeeeeeneennnn nnns page 8 5 3 Pressure rise method AAA page 8 5 4 Test of hermetically sealed componerte cece eeeeeeee eee eeeeeettaeeeeeeeeeeeeeteaeeeeeees page 8 5 5 Elowitest MEthOd EE DELE UELLE I es re page 9 5 5 1 Mass flow measurement nennen nnne nnns page 9 5 5 2 Volume flow measurement sss nnns page 9 5 6
101. sults are cleared by Stop Test circuit 3 Error The test device recognized an error caused by a violation of limit values at the start or end of the filling process or an internal electronic error has been detected Test circuit 3 Mark good part This output can be programmed using the Marking time of the measuring electronic It is only set when the test result is OK and a marking period gt 0 S is programmed It can be used for controlling a marking device 176 X2 OUT 1 00 Test circuit 2 Ready The test device is switched on and the test circuit is ready for testing Dr Wiesner W A eststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix I O bit number assignment table JO bit no 177 X2 OUT 1 01 Test circuit 2 Test is running This output is set from receiving the start signal until the very end of the test run including periods of interruption after Stop during the waiting period for Acknowledge bad part and during the marking and signaling period The test procedure was paused 179 X2 OUT 1 03 Test circuit 2 OK The measured values of all steps of the test were within the set ranges the test piece is OK 180 X2 OUT 1 04 Test circuit 2 NOK The measured values of at least one step of the test were outside the set ranges the test piece is NOK 181 X2 OUT 1
102. t can be used freely e g for controlling devices 233 234 235 Reserve free output This output can be used freely e g for controlling devices 236 Reserve free output This output can be used freely e g for controlling devices 237 Reserve free output This output can be used freely e g for controlling devices 238 Reserve free output This output can be used freely e g for controlling devices 239 Reserve free output This output can be used freely e g for controlling devices Reserve free output This output can be used freely e g for controlling devices 241 Reserve free output This output can be used freely e g for controlling devices 242 Reserve free output This output can be used freely e g for controlling devices 243 Reserve free output This output can be used freely e g for controlling devices 244 Reserve free output This output can be used freely e g for controlling devices 245 Reserve free output This output can be used freely e g for controlling devices 246 Reserve free output This output can be used freely e g for controlling devices 247 X2 OUT 5 07 Reserve free output This output can be used freely e g for controlling devices 248 X2 OUT 4 00 Reserve free output This output can be used freely e g for controlling devices 249 X2 OUT 4 01 Reserve free output This output can be used freely e g for controlling devices 250 X2 OUT 4 02 Reserve fre
103. t circuit For single circuit systems the various test circuits can be Window 2 PK2 Program 210 pDif Classic used to allocate different programs With multiple circuit systems each test circuit is allocated an actual physical test circuit By moving the cursor to the corresponding program line Window 3 PK3 Program 211 pDif Classic and pressing the Enter key the desired program number can be entered and confirmed by pressing the Enter key again If the program hasn t been saved it is not accepted Program 210 Program 211 Prg Dir SAVE NextPro BACK Use the F1 key to call up the program directory where all programs are listed see also chapter 11 3 8 3 Besides the program number the corresponding base data set BDS the program name and 18 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA Instruction Manual steuerungstechnik the type of program are given By moving the cursor to the desired program the program can be edited Enter key the program parameters see also chapter 11 3 5 F3 key or the corresponding base data set F4 key can be called up If you press the F2 key to leave the submenu selections are saved permanently If you leave the submenu by pressing the F5 key the selections are retained only until the device is switched off
104. t the basic settings of the system EE By moving the cursor to the appropriate row and pressing Display Mode Default Tun H H Auto Reset An Output Yes Enter it is possible to enter text using the alphanumerical SE ar ane keyboard or by selecting text using the cursor keys Ser Port2 Mode Table Ser Port3 Mode Text TC Interlock No The following entries can be edited Serial No 5 1234 Circutt ee Set language Main Program 209 Format of the system date iof PrgSelect 1 000 iof PrgSelect 2 000 e g YY MM DD Y year M month D day M utut rui Set display mode when system is switched on iof PrgSelect 4 000 iof PrgSelect 5 000 Activate automatic reset of analog output test dot be eio vu uen pressure for resetting the built in pressure proportional PRINT BACK regulating valve to zero after each test 24 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual Setting a device identification number when using several leakage test systems a device assignation can be achieved e g when printing statistical data Setting the output format of the serial interface COM2 and COM3 Activating mutual locking of individual test circuits prevents simultaneous starts of test circuits when they can affect each other Serial no here you can fi
105. test pressure range 0 6 bar measuring range 20 mbar INTEGRA DD10 Differential pressure method test pressure range 0 10 bar measuring range 20 mbar INTEGRA DF1M Flow test method mass flow measuring range 0 1 10 ml min test pressure range 0 1 bar 0 6 bar or 0 10 bar INTEGRA DF2M Flow test method mass flow measuring range 2 200 ml min test pressure range 0 1 bar 0 6 bar or 0 10 bar INTEGRA DEI Flow test method volume flow test pressure range 0 1 bar manual regulation measuring ranges from 0 3 3 l min 1 5 15 l min 5 50 l min or 12 5 125 l min separate housing 19 3U high 4 1 Recommended accessories Besides the leakage test system we recommend using a test leak as accessory A test leak is helpful for setting up and checking the system Test leaks basically consist of a glass capil lary permitting a defined volume flow per unit of time If such a test leak is inserted into the fast coupling in the front panel of the leakage test system a leak is simulated Test leaks can be adjusted to almost any leakage rate common in the industry If an additional test piece known to be tight is connected to the system the drop or rise in pressure caused by the test leak can be used to determine the limiting value for the test evaluation Also the optional integrated automatic test process optimization autoTune see also chapter 7 is possible with a test leak A quick check of the system is also possible w
106. test result are displayed Two program windows are visible In display mode 3 only the limit values set for evaluation and the test result are displayed However three program windows are visible Use the cursor keys to browse up or down through the parameters Use the F1 F3 keys to start each test circuit Use the F4 key to switch between different display modes In display mode 4 the march of the various pressures for the prior test is displayed as a curve Especially the march of the test pressure and that of the differential pressure differential pressure method only Refer to chapter 15 on how to operate the graphics display 11 3 3 Statistics Here the statistical evaluation of the test results is displayed The second to fourth line displays the number of all started tests totaled and spared in pass and fail including the tests that did not yield any results e g because they were aborted In the lower part of the display the tests related to the test circuit or attribute are indicated Count Total displays the tests that yielded an OK or NOK result The minimum maximum and mean values refer only to tests that resulted in OK Press the F1 key to display the statistics for the active test circuit the F2 key for the statistics of all test circuits Use the F4 key to display statistics graphically cf chapter 15 Use the F3 key to switch the functions of the F1 and F2 keys as follows
107. urs minutes and seconds WU read RTC date time Format WU ddmmyyHHMMSS the letters represent day month year hours minutes and seconds Effect sets the real time clock to the given values The settings are NOT checked for validity or plausibility Subsequently the real time clock is read out Response WU ddmmyyHHMMSS date and time data is not read out from the parameters of the command line but the result after the readout of the real time clock DATETIME query formatted date and time Effect output of date and time in plain text Response DATETIME date and time gt The output format equals the one in the user interface in contrast to the RU command WV set bitrate Format WV 115200 Effect only for compatibility with predecessor series With INTEGRA the data transfer rate is always set to 115200 Response WV 115200 WX show connection msg No function only for compatibility with predecessor series Response WX query command list Effect Query for command list Output command list The list is in English and serves as mnemonic DIAG query diagnostic buffer This command helps to support technical service and enables the query of diagnostic messages 7 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfa
108. ve the changes by pressing the F1 key delete them by pressing the F5 key reset without save 11 3 8 9 Password management Three password hierarchies are provided Password 1 is the lowest hierarchical level e g for head of shift Password 2 is for example for set up personnel and password 3 for system administrators To create or change a password the new password has to be entered and repeated in the following line as confirmation 11 3 9 Diagnostics amp Setup 1 Set Date Time Use sub menu 1 to change date and time Enter in this order year month day hour minutes and seconds By pressing F1 the newly entered date and time are accepted 5 Check COM Interfaces Besides deleting the fixed value memory and data buffer MULT d b memory all interfaces can be tested in this menu e 8 Analog I O Enter sub menu 0 to set a calibrating time stamp showing SE 1 6 the date of the last calibration 0 Set Calibration Timestamp The Program Debug mode is intended for checking special MSIE MG M ee programs and mostly used by manufacturer s service personnel 2 Erase Permanent Memory 4 Erase Data Buffer Memory IF 1 Program Debug View SAVE Boot BootRom BACK Use the F2 key to save system data manually and F3 to reboot the entire system F4 is reserved for the manufacturer s service personnel 11 3 10 System Configuration System Configuration Use this menu to se
109. x 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Appendix Serial Interfaces RC read checksum of last transfer Effect Read checksum of the last transfer Response RC hhhh the hexadecimal number represents a checksum that is made up as follows the higher value byte is the 8 bit checksum of the binary data the lower value byte is its XOR operation RS calculate checksum Format RS hhhhhhhh hhhhhhhh the two hexadecimal numbers specify the beginning and end address of the desired memory area The addresses are inclusive Effect From the memory area defined the 32 bit checksum is calculated Output RS hhhhhhhh hhhhhhhh hhhhhhhh The three hexadecimal numbers are start address end address and the 32 bit checksum of the memory area Notes This command enables you to check the consistency of larger memory areas without having to read out and transfer the entire memory area The relevant memory areas are from F0000000 2MB size flash memory firmware from F1000000 128KB size battery buffered RAM measuring value memory from F2000000 128KB size EEprom calibrating and setting data WD write transfer buffer Format WD hhhh the hexadecimal number specifies the number of bytes to be transferred Effect After acknowledging the command INTEGRA waits for the specified amount of data to be transferred The data is stored in the transfer buffer Response WD hhhh WN er
110. ystem INTEGRA steuerungstechnik Instruction Manual 17 5 3 Forced termination of test program KI page 39 17 5 4 Acknowledge and clear message 44sss4ssssnnnnnnnnannnnnnnnnnnnnnnnnnnnnnnnnnen page 39 17 5 5 at Le E page 39 18 Test result output in digital UO are page 40 18 1 General description rn et ete e page 40 18 2 Data elt E page 40 18 3 Ets e EE page 40 18 4 Re e Ee e ek hen ek en hk tok ae page 40 19 Maintenance and ceanimg nnn page 42 Appendixes Serial interface Digital I O interface I O bit number assignment table Declaration of conformity Associated documents Custom built design and technical data Circuit diagrams Pneumatic plan Parameter setting print out of final configuration 4 Dr Wiesner Weststrasse 4 Phone 49 0 7151 9736 0 info drwiesner de Steuerungstechnik GmbH D 73630 Remshalden Germany Fax 49 0 7151 973636 www drwiesner de Leakage Testing System INTEGRA steuerungstechnik Instruction Manual 1 Foreword 1 1 Contents of this manual This operating manual contains the necessary instructions for the proper operation of the described device It explains the procedure for using the device and can be used to train operating personnel Nevertheless operating mistakes or improper use can endanger the operator and the device Every person concerned with setting up operating or servicing this device must therefore read this manual before starting to work with the device You

Leakage Testing System - Dr. Wiesner Steuerungstechnik GmbH

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