User Manual Micro-Cal™ Model 869
Contents
1. 15 6 32 Test P Switch 15 6 33 Test Dither Control Pages 16 6 4 Profile General eere 18 6 41 Profile Dial Gauge 19 6 42 Profile Pressure Switch 19 6 43 Profile Expert System 19 6 5 UUT SETUP General 20 6 51 UUT SETUP Dial Gauge 24 6 52 UUT SETUP P Switch 24 6 53 UUT SETUP Expert System 24 6 6 View a Reference Setup 25 DNA LUI 26 7 0 UNIT UNDER TEST 31 8 0 CALIBRATING TESTING A TRANSDUCER TRANSMITTER 31 3 9 0 MICRO CAL MANAGER INTERFACE 9 1 Setup for Pocket PC Connection 34 9 2 Graphical User Interface Setup 35 9 3 Test Results Data 39 10 0 GLOSSARY OF 5 42 11 0 SPECIFICATI0ONS 43 12 0 SPECIFICATION DERIV2. 40 F to 120 F Storage Temperature 40 F to 160 F Temperature Effect 7 none zero tare Temperature Effect Span radio eite 0 01 F NIST traceable certification for reference pressure sensors and voltage current meters 11 2 CONTROL Controlled Pressure Stability 0 0002 W C typical Minimum Controlled Pressure 0 00005 W C Dual Reference Pressure see order info Pressure ypeS tre Rit t etes gauge and differential Overpressure Limit rtt e 5 psid Control rte nier rtp e t pss user selectable 11 3 GENERAL SPECIFICATIONS Pressure Units Selectable in W C Pa kPa mbar cm W C AME 30 minutes Reading Rate nie mes 20 readings second typical Gravity Orientalion o ri e b ttes negligible Shock and Vibration 5g maximum Communications I n n n RS 232 Display 3 5 transflective type TFT color QVGA 64 k color Keypad pocket PC touch pad and external ASCII keyboard plug cra H 11 x 14 x 6 27 9 cm x 35 6cm x 15 2 cm LEE 16 Ibs 7 3kg
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6. Excitation Setting Warning Tum on excitation setting waming Miswire Warning Tun eri mining wiring Test Results Save Warning e Tum on test results save waming Sep Hrough test Manual Step Through Test v Add extra digit to pressure display Restore Factory Default Settings Restore Factory Defaults Edit Default AUTU DETELT Set Opens AUTO DETECT Default Settings Page Extra Digit Resolution Diagram 18 AUTO DETECT DEFAULT SETTINGS PAGE Used for Setra Expert System option Requires 869 with Expert System and 269 or SRPM Default Profile ID ID of default test profile to be used when automatically setting up an AUTO DETECT UUT Settling Time Settling time to be used when automatically setting up an AUTO DETECT UUT Req d Ctrl Stability Required control stability to be used when automati cally setting up an AUTO DETECT UUT Max Leak Rate Maximum leak rate to be used when automatically set ting up an AUTO DETECT UUT Re Cal Accuracy Re cal accuracy to be used when automatically setting up an AUTO DETECT UUT Note This value is used to determine if the 869 should adjust the unit despite a passing As Found test Default Accuracy Accuracy to be used when automatically setting up an AUTO DETECT UUT Note This value is used to program all AUTO DETECT units with the same Pass Fail specification Use Defaults For AUTO DETECT UUT s Checking this box allows the software to automatically program an AUTO DETECT UUT pr
7. Select UUT from list of available UUT ID s at the top of the screen Tap DELETE button at bottom of the page 13 More Press to access remaining UUT setup items LI UUT ID Box z t4 1DOTWETTT Le Profile Template ID to Copy From UUT Serial Number UUT Input Output UUT Accuracy Specs Ideal Accuracy Spec Where UUT Is Adjusted Access the UUT EN SUPPLEMENTAL PAGE Excitation Diagram 14 Delete UUT ID New UUT ID Setup 2 UUT ID Diagram 13 21 UUT SUPPLEMENTAL PAGE 1 Enter the UUT Part Number 2 Enter the UUT Model 3 Enter the UUT Manufacturer 4 Enter the required pressure Settling Time at target in milliseconds 99 999 max and 0 min 5 000 recommended Pressure settling time is time allowed at pressure point before data is acquired 5 ENTER MAXIMUM LEAK RATE in box This is PASS FAIL criteria for leak check function measured in change of pressure per second 6 Enter the required pressure stability for data acquisition in the Control Stability field T Enter the System Volume value cu in 64 is default To increase speed of pressure control increase this value The software automatically programs this value based on testing performed at Setra It is recommended that the preprogrammed values always be used 8 To accept the changes made tap OK To reject the changes made tap Cancel 22 UUT Part Number UUT Model UUT Manufacturer Setting Time for Data Acq Max Lea
8. Pressure clean dry non corrosive gases Power 120 240 AC 50 60Hz LITHIUM ION battery 8 hours operation Pressure Transducer Interface Pressure Fittings barbed plug in o ring quick connects nee ss q a M rM HR banana plug jacks Voltage Meter isses 0 005 FSO at 10 VDC Current Meter sss 0 005 FSO at 4 20mA Excitation 24 VDC nominal for 4 20 mA output 5 to 24 VDC for voltage output 3 3 43 12 0 SPECIFICATION DERIVATIONS Accuracy Expressed in 5 at constant temperature Accuracy as RSS non linearity hysteresis and non repeatability Root Sum Squares RSS Non linearity 40 1 z 0 0196 Hysteresis 0 05 0 0025 Non Repeatability 10 0296 0 000495 0 01298 30 012995 0 11 FS at constant temperature Charts do not reflect calibralor measurements Total Error Band Worst case over a temperature range of 10 F to 130 F Non Linearity 0 1 FS Hysteresis 0 05 FS Non Repeatability 0 02 FS Thermal Zero Shift lt 40 32 FS Thermal Span Shift lt 40 24 FS Zero Offset 0 2 FS Span Offset 40 2 FS Long term stability error not included Non Repeatability The ability of a transducer to reproduce output readings when the same pressure value is applied to it consecutively under the same conditions and from the same direction 5
9. for calibration purposes and test purposes acts as a digital indicator Applied Pressure Window Displays system pressure When Go To Pres is pushed the text will turn yellow while pressure is outside of tar get control band Required control stability for UUT Text will turn green when target pressure is reached Go to Pressure macro buttons are configured by UUT pressure range For all units the top most button will display the UUT s lowest Input Pres sure The bottom most button will display the UUT s highest input pres sure The middle button will display 0 0 for bidirectional units and 50 FS Full Scale of UUT range for unidirectional units Pressing any of the buttons enters the pressure value on the button into the target pressure window and calls the to Pressure function HOLD SAMPLE Will take a filtered reading and freeze the display with that reading To release press the same button Release Hold VENT Opens both positive and negative pressure ports to each other and atmosphere TARE Zeros out internal pressure standard and re zero s mechanical components in controller GO TO PRESSURE Calls controller to generate pressure point set in pressure target box HALT Stops any process in action MONITOR CONTROL Switches calibrator into monitoring mode This allows calibrator to be used as pressure measurement device Error Graph is an auto scaling display of the present error of the UUT s output as c
10. list and press Ok 7 Once you ve entered your new PROFILE ID select the number of data points box highlight the number and change it 8 Go to PROFILE TYPE drop down window press down arrow and select from the list of Ascending Descending Both or Custom Note When using both the number of data points MUST be odd it cannot be even 9 If leak test is required check PERFORM LEAK TEST box 10 To save press SAVE button Note Save will be grayed out when data has been saved 11 To delete a profile select PROFILE from list and push DELETE button 12 Custom test point profiles can be created To adjust a custom test point via the Custom Profile Editor Page Diagram 12 tap the test point number in the TP column of the profile display window 13 Ascending Descending and Both will set up a profile with evenly spaced points in the direction implied by the type For custom point spac ing see the Custom Profile Editor Page Prose vps 2 Number of Test Points Test Point FS Target Target Pressure 18 CUSTOM PROFILE EDITOR PAGE This page allows entry of target pressure target output or target 9o FS Full Scale to be stored for a test To change highlight value in any field and enter a new value The remaining fields will update automatically To accept changes press To ignore changes press Cancel Test Point Number Target FS Target in Pressure Units UUT Output Unit
11. 37 40 This will bring up a printer selection dialog Select printer from here and press Print button See Diagram 38 level To print an As Left As Found pair the test results must be selected manually 1 Select As Found file then while holding CTRL key select As Left file 2 Press Print button See Diagram 39 Before data can be sent to the printer the 2 selected files must be verified as a valid pair Data is validated as follows 1 Only 2 files being requested for print operation 2 Only one As Found and one As Left file 3 As Left data file s date time stamp comes after that of As Found data file 4 UUT Profiles amp Test Profiles for each test result s data file match 5 As Left data file date time stamp is within 24 hrs after that of As Found file Diagram 39 10 0 GLOSSARY OF TERMS Atmospheric Pressure Pressure of the atmosphere at the Earth s surface NIST standard atmospheric pressure 1 01325 bar Burst Pressure The mazimum pressure that may be applied to the posi tive pressure port without rupturing the sensing element Capacitive Sensing Detection and measurement of pressure through the change in voltage accross a capacitor one plate of which is a dia phragm which deflects slightly with changes in applied pressure Differential Pressure Pressure measurement relative to a reference pressure Referred to as pounds per square inch differential PSID or inch
12. 4 869920 869921 869901 869922 869923 869924 406731 869714 869969 06 869969 12 Item 269 terminal block security key accessory bag electro pnuematic harness 2 wire electro pnuematic harness 4 wire terminal fork 18AWG 6 mini alligator clip shrouded banana plug Pocket PC USB cradle Pocket PC power adapter universal harness cable end assy 2 wire harness cable end assy 4 wire Pocket PC screen protector pre programmed Pocket PC acessory kit stylus 3 pack Littlefuse 0218 063HXP 5 x 20 mm 0 63 ma time lag 250vAC rating Littlefuse H217004 5x20 mm fast acting 250vAC rating EPIC Cable 6 feet EPIC Cable 12 feet 48 14 0 WARRANTY amp LIMITATION OF LIABILITY SETRA warrants its products to be free from defects in materials and workmanship subject to the following terms and conditions Without charge SETRA will repair or replace products found to be defective in materials or workmanship within the warranty period provided that a The product has not been subjected to abuse neglect accident incorrect wiring not our own improper installation or servicing or use in violation of instructions furnished by SETRA b the product has not been repaired or altered by anyone except SETRA or its authorized service agencies the serial number or date code has not been removed defaced or otherwise changed and d examination discloses in the judgement of SETRA the defect in mat
13. ATI0NS 44 13 0 SPARE PARTS amp ACCESSORIES ne 48 14 0 WARRANTY amp LIMITATION OF LIABILITY 49 1 0 SAFETY INSTRUCTIONS Use the calibrator only as specified in the manual otherwise the protec tion provided may be impaired Do not operate the calibrator in explosive gas vapor or dust environ ments The calibrator is designed to operate from 14 4 VDC internal Lithium lon battery source or from the AC adaptor that is included Do not use AC adapters or chargers other than those supplied with the unit If supplying external excitation to the Unit Under Test in a measure mode do not exceed 30 VDC There are no user serviceable parts internally removing the internal cover Will void warranty Return the unit to the factory for re certification or repair BEST PRACTICES FOR CALIBRATOR OPERATION Use the shortest length of tubing from the calibrator to the Unit Under Test during pressure testing avoid vibration of the tubing Avoid movement of the calibrator during operation avoid locating in a high vibration environment Allow the calibrator to warm up for one 1 hour before use The calibrator can be turned on during transport 2 0 INTRODUCTION DOCUMENTING PROCESS CALIBRATOR The Setra Micro Cal Model 869 is a pressure generating very low pres sure documenting calibrator The calibrator has been designed and optimized to m
14. Lines 869 Expert System EPIC Cable Plug UUT End Unit Under Test Model 269 EPIC Cable Plug Calibrator End EPIC Cable Diagram 22 EXC 24VDC EXC 24VDC SIG 6 P Switch SPST External Power Supply EXC 24VDC SIG SIG O OF Current External Excitation COM Diagram 23 COM SIG SIG SIG o 9 o Current Internal Excitation External Power 32 EXC COM EXC COM 24VDC SIG 3 Wire Internal Excitation 3 Wire External Excitation 4 Wire Internal Excitation External Power Supply 4 Wire External Excitation EXPERT SYSTEM TEST 1 Select UUT Test Tab 2 Select Auto Detect from UUT ID dropdown box Wait for software prompt to plug EPIC cable into Transducer 3 Remove Process Head from pressure sensor and plug in EPIC connector Epic must also be connected to 869 top panel header FIRST TIME UUT AUTO DETECT The 869 will automatically down load and save a new UUT Profile from a Setra 269 or SRPM A UUT ID Selection Screen will appear B Enter tag number or UUT ID number C Tap OK D UUT Part Number Screen will appear Complete part and tap OK E All setup data for UUT will be automatically downloaded and stored under new UUT ID Number F Ready to initiate test 4 Select Test Tab 5 Press Do Test and wait for completion A If As Found data is within the user selected Re Cal Accuracy The 869 saves the test da
15. User Manual Micro Cal Model 869 Very Low Pressure Generating and Documenting Calibrator Software Version V3 02 q mpl aa 800 257 3872 Toll Free pressure transducers setra com Web Site Table of Contents 1 0 SAFETY INSTRUCTI0NS 5 2 0 INTRODUCTI0N I 6 3 0 STANDARD EQUIPMENT 7 4 0 OPERATING FEATURES 4 1 Pocket PU rre nets 8 4 2 ta uu 8 5 0 CALIBRATOR SETUP 5 1 Battery Charging 9 5 2 Pocket PC Charging 9 5 3 User Interface Panel 10 5 4 Getting Started 11 6 0 POCKET INTERFACE SCREENS 6 1 Application Definitions 12 6 2 Real Time General 12 6 21 Real Time Dial Gauge 13 6 22 Real Time P Switch 13 6 23 Real Time Expert System 13 6 3 Test General 14 6 31 Test Dial Gauge
16. VDC lt 0 02 FS Hysteresis The maximum difference in output at any pressure value within the specified range when the value is approached with increasing and decreasing pressure 5 VDC lt 0 05 FS 100 PSI Long Term Stabilit The ability of a transducer to reproduce output readings obtained during its original calibration at room conditions for a specified period of time 5 VDC 70 F 21 C Example 0 1 FS Over 6 Months at Original Calibration After 6 Months 100 PSI 45 Zero Offset Zero output is factory set to within a certain 96 shi 29 68 ast The change in zero and span output thal occurs due to temperature changes Thermal Zero Shift lt 0 4 FSHOO F Thermal Span Shift lt 0 3 FSM00 F Example Temp Range 10 F to 130 F Max Temp Change from 70 F 80 F 60 F x 4 32 FS DZIDT 80 F x 3 24 FS DZ DT Z Shift lt 0 32 FS 5 Shift lt 0 24 FS 46 Non Linearity Relationship of a calibration curve to a specified straight line Best Fit Straight Line BFSL Method Example 0 1 FS 9 5 100 PSI Relationship of a calibration curve to a specified straight line with end points at zero and full scale Terminal Method RS232 OUTPUT Example 0 12 FS 100 PSI 47 13 0 SPARE PARTS amp ACCESSORIES Part 269701 269425 02 869902 869904 xx 869905 xx 869909 869910 869912 xx 869913 86991
17. e DATA SETS UUT Unit Under Test Profiles These define a transducer so the 869 knows what it s working with See Diagram 26 Portion outlined in red Test Profiles Determines how a test is performed See Diagram 26 Portion outlined in blue Test Results Actual data files created when a test is recorded on the Pocket PC See Diagram 26 Portion outlined in green Diagram 26 Profile Selection With each profile set there are two list windows for existing profiles One is labeled PC DataBase the other Pocket PC Database See Diagram 27 Mara mus m kim _i else E es zm p pee t Erb Loa qe Free re arm uon x misis Diagram 27 35 Pocket PC Database This list shows what test profiles are currently on the Pocket PC After editing any profile said profile will automatically download to the Pocket PC This ensures that the list window always ac curately reflects what is on the Pocket PC See Diagram 28 Diagram 28 Profile Quick Display Below the database list is a window which will display the properties of the selected profile Once a profile is selected from either database it is loaded from its database and the data is then displayed in this window See Diagram 29 1 To select a profile simply click on the ID in the lis
18. e wait for completion User will hear operation of solenoid valves and stepper motor 4 Look for orange light flashing or solid on PDA if light does not come Oh see section on battery charging 5 Tum on PDA power button in upper right corner of the PDA 6 After powering up tap the icon labeled Calibrator tap START Menu icon tap on programs folder and tap on CALIBRATOR icon Also the lower right button is programmed at the factory to start Calibrator soft ware T Software will startup with UUT selection Page see Diagram 6 Select desired UUT and press or press Cancel Cancel will setup UUT as 0 25 in W C transmitter Keyboard Button Pressing this button calls up an on screen keyboard for inputting data Sect LLFT to start wr fram Keyboard Button Diagam6 1 111 11 6 0 6 1 6 2 POCKET PC INTERFACE SCREENS The Pocket PC Interface is tab based split into 6 major sections at the bottom of the screen APPLICATION DEFINITIONS General This describes operation for the broadest range of applications Dial Gauge Departures from general operation for Dial Gauge calibration P Switch Departures from general operation for Pressure Switch calibration Expert System Departures from general operation for Expert System calibration REAL TIME General Screen Instructions Diagram 7 Real Time page is constantly updating and is used to see the output and pressure being applied
19. eet the needs of our customers for a capable system for the calibration troubleshooting and documentation of very low pressure measuring sensors The design of the Model 869 exploits years of experience in the calibra tion of Setra transducers as well as NASA patented and Setra exclusive licensed technology The Pocket PC user interface provides a familiar state of the art application of computer technology and an upgrade path for future developments Major Features Pocket PC user interface capable of storing thousands of Units Under Test UUT data files Portable battery powered system capable of full operation for up to eight 8 hours Closed loop pressure control which is immune to the effects of ambient pressure perturbations doors closing people moving around Very low internal reference pressure standards which are selectable to match customer needs Auto zero pressure tare function Ability to source power to the UUT or use external power supply Strip chart capability for troubleshooting drift conditions High resolution pressure control capable of precise generation and pressure control in the micro inch of water column pressure ranges Leak testing Expert Equipped 869 Standard 869 Diagram 1 6 3 0 STANDARD EQUIPMENT BREAKOUT THE ITEMS BELOW ARE INCLUDED IN YOUR CALIBRATOR Calibration Certificate User Manual Calibrator Accessories Bag Diagram 2 Electronic Test Lead Kit Pneumatic Fittin
20. erials or workmanship developed under normal installation use and service e SETRAis notified in advance of and the product is returned to SETRA transportation prepaid Unless otherwise specified in a manual or warranty card or agreed to in writing and signed by a SETRA officer SETRA pressure and accelera tion products shall be warranted for one year from date of sale The foregoing warranty is in lieu of all warranties express implied or statutory including but not limited to any implied warranty of merchant ability for a particular purpose SETRAs Liability for breach of warranty is limited to repair or replace ment or if the goods cannot be repaired or replaced to a refund of the purchase price In no instance shall SETRA be liable for incidental or consequential damages arising from a breach of warranty or from the use or installation of its products No representative or person is authorized to give any warranty other than as set out above or to assume SETRA any other liability in connec tion with the sale of its products 49 50 61 10 py 66 suiejs s ees ed 60 rc t 0 69855 ueeJos qi LNN uwopdoup eq sql LNN Jo paea Ajmeu de pue yew uses0s uwopdoup LAN p s LAN e Ajlpow esn SI iJo1d 159 Meu pue uonnq
21. es of water column differential WCD FS Full Span or Full Scale The range of measured values over which a transducer is intended to measure specified by the upper and lower limits Ex 0 to 100 PSIG FS is 100 PSIG O to 5 VDC 800 1100 MB FS is 300 MB P I Term common to process industries meaning pressure in current out Ex 3 15 PSIG Input to 4 20 mA DC Output Pressure Transducer An electromechanical device for translating fluid pressure values into voltages across a high impedence 5k ohms or greater load Pressure Transmitter An electromechanical device for translating fluid pressure values into currents generally 4 20 mA into a low impedence load Proof Pressure The maximum pressure that may be applied without changing performance beyond specifications typically 0 5 FS zero shift Range The spread between the maximum and minimum pressures between which the transducer has been designed to operate Span The algebraic difference between the limits of the range Ex 0 1 to 5 1 Volts DC span is 5VDC Sometimes used to designate full scale output i e 5 VDC 42 11 0 SPECIFICATIONS 11 1 MEASUREMENT ze MTS HE 0 04 FS iud eiit eese 0 0002 W C Calibration Stability oce 0 2 FSlyr Calibration Adjustment eae ites zero tare Resolution mn edem up to 1 ppm Compensated Temperature Range
22. ew ID then press OK If the number entered is a valid configurable number the UUT will be automatically setup Enter the UUT s Serial Number in the field provided In the Accuracy field enter the pass fail accuracy for the UUT In the ReCal Accuracy field enter an accuracy less than the one entered in the Accuracy field at which you would like the calibrator to ReCal the transducer in spite of a passing result Note Only used with Setra 269 and RPM This feature is for automated calibrations is optional and can be useful for transducers that have drifted but are not yet failing by avoiding a failing result at the next calibration Enter the transducer s lowest and highest pressure in the LO and HI boxes in the Input column Enter the transducers corresponding lowest and highest output in the LO and HI boxes in the Output column Select DEFAULT TEST PROFILE some default profiles are already listed select which one you want or create a new one save UUT go to PROFILE page and create NEW return to UUT and select newly created profile for default profile and press SAVE Select Excitation Level from drop down list 10 Select UUT Type from drop down list Select one 3 WIRE VOLAGE 4 WIRE VOLTAGE CURRENT 4 20 mA PRESS SWITCH DIAL GAGE 20 11 Save Once all parameters have been changed tap the SAVE button at bottom Note Save button will be grayed out when data has been saved 12 Delete
23. gs Pocket PC amp Tubing Documentation and Cables 4 0 OPERATING FEATURES 4 1 THE POCKET PC PERFORMS THE FOLLOWING MAJOR FUNCTIONS User interface for setups display and storage Data transfer to and from Micro Cal Manager Database Communications with internal data acquisition and control microprocessor board Monitors battery voltage Stores data for UUT test profiles and test results 4 2 PORTABILITY CALIBRATOR IS FULLY PORTABLE AND POWERED BY 120 240 VAC to 24 VDC power adaptor external Using the internal 14 4 VDC battery which has been designed for eight 8 hours of continuous operation after a full charging cycle The Li lon battery is rated at 14 4 VDC 6 6 Amp hour AH See Diagrams 3A 3B and 4 User Interface Panel urrent Loop Fuse 63 mA Littlefuse 0218 063HXP See Spare Parts amp Accessories Battery Jack Located on back of case Diagram 3A Diagram 3B Pocket PC Power Fuse 4A Littlefuse H217004 See Spare Parts amp Accessories i Serial Port On Off 8 Switch Diagram 4 5 0 CALIBRATOR SETUP 5 1 BATTERY CHARGING The Calibrator is assembled calibrated and tested at the factory The battery as received will be in a partially charged state Before operation please be sure to fully charge the battery to get maximum portable use of the device TO CHARGE THE BATTERY If calibrator is not in use for more than one month Pocket PC should be
24. ith dither control Diagram 10 Output columns removed from Test Profile Results window 6 32 TEST P Switch Differences from General Diagrams 8 amp 9 Pressing DO TEST button brings up separate test page with dither control See 6 33 Dither Control Page Diagram 10 Output columns removed from Test Profile Results window O C column added to indicate the state of the pressure switch O Open C Closed 15 6 33 TEST Dither Control Page Manual Pressure Incrementing Screen Instructions Diagram 10 Test Point Indicator Displays present test point number Target Pressure Displays present test point target pressure Eng Units Display Displays pressure units Pressure Display Window Displays present pressure during test OPEN CLOSE Indicator Available only with P Switch indicates open closed status of switch Take Data Button Forces data collection for Dial Gauge Tells software that the UUT is indicating the present target pressure Vent Button Stops the test in progress and vents 869 pressure ports to atmosphere Halt Pauses pressure control Leaves system closed to allow for quick re acquisition of target pressure Set Point Window Displays present set point for the 869 pressure controller Updates when test point number is changed or when dither controls are used Also allows user entry GO Button Updates pressure target within 869 to that displayed in the set point window Starts pressure control FINE Bu
25. k Rate Allowable for Pass Fail Accept Changes 23 Adjust Pressure Control Sensitivity Pressure Stability Required for Data Acquisition Cancel and Reject Changes 6 51 UUT UNIT UNDER TEST SETUP Dial Gauge Differences from General Diagram 13 Output fields hidden Excitation field hidden 6 52 UUT UNIT UNDER TEST SETUP P Switch Differences from General Diagram 13 Output fields converted to Manual Reset check boxes Excitation field hidden LOHI labels changed to OPEN CLOSE Profile selection locked out P SWITCH amp DIAL GAUGE UUT PAGE P Switch shown UUT ID Box Profile Template ID i to Copy From Manual Reset Check Boxes P Switch OPEN CLOSE Input P Switch UUT Accuracy Recalibration Accuracy Delete UUT ID Save New UUT ID New UUT ID Setup Diagram 15 6 53 UUT UNIT UNDER TEST SETUP Expert System No Differences from General Diagram 13 24 6 6 VIEW A REFERENCE SETUP Screen Instructions Diagram 16 1 Tap the REF tab to view the different reference data 2 Tap on REF 1 or REF 2 radio button Reference Setup The Model 869 is shipped with either one or two inter nal reference transducers and are referred to as REF 1 or REF 2 respec tively REF 1 is the lowest range and REF 2 is the highest range If only one reference is installed it will be located in REF 1 REF ID the serial number of the reference unit Input Output Parameters This section
26. ofile using the values stored on this page Note Not checking this box will cause the software to prompt the operator to enter these values during the initial setup Automatically Recalibrate Checking this box allows the software to automatically recalibrate a unit if its highest error is outside the re cal ac curacy and or pass fail accuracy Note Not checking this box will cause the software to prompt the operator to OK CANCEL recalibration Default Profle IO Default Profile ID Settling Time Input Required Control Stability Input Maximum Leak Rate Input Re Cal Accuracy Input Default Accuracy Input Use Defauts For AUTO DETECT UUT s Check Box Use Defaults For AUJITO DETECT Automatically Recalibrate Check Box Automata recalibrate Diagram 19 ENGINEERING UNITS SCREEN This page is used to convert the displayed engineering units on the Pocket PC All values are stored as a default in WC Displayed values are then converted using conversion values below Press to exit w out changing units Press to set units to presently selected Units Selector Radio Buttons Diagram 20 Conversions Unit Abbr UnitName inWC Value UnitValue psa 30 7 0 UNIT UNDER TEST CONNECTION 8 0 STANDARD 869 See Diagram 22 1 Attach the unit in a secure location Two 8 32 threaded inserts are pro vided in the area above the USER INTERFACE PANEL to install the UUT A custom bracket ma
27. ompared to the applied pressure The red bars on the graph represent the UUT s accuracy specification limits The labels will display 12 the present range of the graph The arrow showing the error will turn red when the error is outside of tolerance Excitation to Unit UnderTest UUT Tares Internal Pressure Standard Applied Pressure FGo To Pressure Macro buttons UUT Output Current Pressure Target Terminal Based Monitor Mode Error FS Snapshot of An Includes Zero Displayed Condition and Span Errors Vents Pressure to Atmosphere Bar Graph of Halts Operation Error FS 6 21 REAL TIME Dial Gauge Differences from General Diagram 7 Output and Error windows hidden Bar Graph of Error is hidden 6 22 REAL TIME P Switch Differences from General Diagram 7 Output window changes to OPEN CLOSE indicator Error window changes to OPEN CLOSE capture window Bar Graph of Error is hidden 6 23 REAL TIME Expert System Differences from General Diagram 7 Monitor Only Control button locked out automatically controlled by the process head connection disconnection 13 6 3 TEST General Screen Instructions Diagram 8 1 Tap the TEST tab at the bottom of the page 2 Select desired UUT ID from the drop down box at the top of the page If desired UUT is not there see section on creating a new UUT 3 View the PROFILE ID drop down box and confirm that profile selected is the desired pressure test profile if not selec
28. overed so a verification dialog box will pop up asking operator to verify that delete is really desired See Diagram 33 Diagram 33 38 9 3 TEST RESULTS DATA 1 At bottom of screen there is a list box showing all the test results data files stored in memory 2 On connect all the data files from the Pocket PC are copied to the main PC database If a file already exists with the same name the file will not be copied 3 If a new data file is created while connected the new files can be up loaded by pressing the Refresh Test Results button This will repeat the file upload procedure performed on connect See Diagram 34 To review a particular test See Diagram 35 1 Select the ID of the Unit Under Test from the dropdown list above the test results list just below the Refresh Test Results button 2 Press dropdown arrow at the right of the ID box 3 Click on ID in box 15 1 tan zw Diagram 35 39 Once a UUT ID is selected the test results list will update to display only the test results from that UUT See Diagram 36 The test results for each UUT can be distinguished using date time of test and As Left As Found status Diagram 36 To print As Left or As Found data only 1 Select any profile desired from the list of test results 2 Press Print button See Diagram 37 Diagram
29. plugged into HP supplied power cable or be left connected to AC power supply Connect the AC power adaptor to AC supply connector on back of unit shown in Diagram 3B Battery charging will take approximately 6 8 hours 5 2 POCKET PC CHARGING TO CHARGE THE POCKET PC Pocket PC will only charge from calibrator when the unit is on or A C adapter is plugged in Pocket PC must remain charged Drained to the point that the Pocket PC is at zero the Pocket PC will need to be plugged into a 5V adapter and charged to a minimum of 596 before starting calibrator software Battery charge can be checked by going to Start Menu gt Settings gt System gt Power 5 3 USER INTERFACE PANEL The user interface panel includes the pressure and electrical connections to the unit under test See Diagrams 5A amp 5B Standard 869 Optional UUT Mounting i 8 32 UNF Threaded Inserts 2 Power Switch Pocket PC Power Switch High Pressure Port Low Pressure Port Electrical Connections for Unit Under Test Diagram 5A Expert Equipped 869 Optional UUT Mounting 8 32 UNF Threaded Inserts 2 Power Switch Pocket PC EPIC Connection Point Power Switch High Pressure Port Low Pressure Port Electrical Connections for Unit Under Test Diagram 5B 10 5 4 GETTING STARTED 1 Open calibrator top 2 Turn on calibrator power power switch on right side of the calibrator 3 Once calibrator is powered up re zero function begins automatically Pleas
30. s Exit and Save Changes Exit Without Saving Changes Digrami2lL 6 41 PROFILE Dial Gauge Differences from General Diagram 11 Output column removed from test preview window 6 42 PROFILE P Switch Differences from General Diagram 11 Output column changes to O C column to indicate expected switch status OPEN CLOSE Profile selection locked out Profile type selection locked out Test point entry window locked out Leak Test selection locked out 6 43 PROFILE Expert System No Differences from General Diagram 11 19 6 5 UUT UNIT UNDER TEST SETUP General Screen Instructions Diagram 13 UUT setup screeen is used for inputting UUT profiles into the UUT database The calibrator is supplied with many default instrument templates which may be copied modified and saved as new UUT 1 2 1 8 9 Select an Existing Profile Go to the UUT ID drop down box click the down arrow and select your unit from the list Create a New Profile Tap NEW button at bottom of page a dialog box will appear prompting user to enter new UUT ID Enter new ID in the box and select UUT to copy if desired from drop down list below Press OK to create the new profile or CANCEL to cancel action Note If you don t want to copy an existing UUT you may select DEFAULT from the drop down menu Note To automatically setup a UUT using Setra s configurable part number simply enter the Setra part number as the n
31. s allows Pocket PC to be removed from base and still allow UUT test profile and system configuration changes Disabling Comm prevents testing and calibration from being performed Edit Defaults Brings up default settings page for more see Diagram 18 pg 28 Engineering Units Opens the Engineering Units Selection Page for more see Diagram 20 pg 30 Leak Test System Initiates leak test pressure decay test function This function should only be performed in a closed system The number returned is a rate of pressure decay 26 aie in Calibrator Com Software Version Pictiware Veron 1202 on Firmware Version trriesture Versone V8 1 Serial Number Serial Kumbar A033 Next Calibration Cu Due Due Date Curent Gabe 1 15 2009 rrm ddhnrmi Current Date Filter Length rites Length samples Default System Setting Lied anal Eng Units Setting eng Units leak Test System lt Leak Test System Excitation PEnritation aS Battery Level pBattery Level 2425 05 Reems es Profle ur eer vem Diagram 17 E 27 EDIT DEFAULTS PAGE Display trend graph on UUT warm up box will make a graph appear when the DoTest Button is pressed on test page The graph will show UUT output vs time to allow the operator to see if the UUT has a warm up drif
32. t 2 Only one profile can be selected at a time from both PC and Pocket PC database lists Diagram 29 36 Transfer Buttons gt amp lt These buttons will copy a selected profile from the database it currently exists within to the other remaining data base I E if a profile is selected in the PC database and Transfer gt but ton is pressed the profile will now be copied to the Pocket PC database 1 When transfering profiles if a profile of the same ID exists in the Copy To database the profile will be overwritten on the Copy To database See Diagram 30 Diagram 30 Edit Button This button opens a dialog box containing the informa tion for the selected file At this point the data may be manipulated and saved ID cannot be changed with this function To change ID copy the profile See New Button section following giving it a new ID then delete the old version See Diagram 31 New Button This button opens a dialog box to create a unique profile Profile ID must be entered into the ID box on the dialog 1 To copy a profile simply highlight the desired profile within the list win dow and then press NEW The data from the selected profile will appear in the edit window 2 The new profile will be copied to the database from which the profile to be copied was selected See Diagram 32 Delete Button This button will delete a profile from the database it exists within Data cannot be rec
33. t and output has been stabilized This feature is not likely to be required if the units to be tested are normally connected to a power supply Display test results in graph will make a graph appear at the end of the automated test Graph will show the UUT output error seen during test vs applied pressure Turn on excitation warning setting will make a dialog box appear on screen anytime the excitation is about to be changed to a higher level This is used to help prevent damage to unit If all units to be tested can accept 24VDC excitation feature will not likely be required Turn on miswire warning will make a dialog box pop up when it appears the UUT wiring or plumbing has been reversed or if the UUT pressure range appears to be set incorrectly Turn on test results save warning will make a dialog box appear at any point where unsaved test results could be deleted Manual step through test will stop a test in progress at each pressure point and require user to press OK on pop up dialog Add extra digit to pressure display increases pressure resolution shown on real time page Adds one digit to the end Restore Factory Default Settings resets default settings to factory programming Edit Default AUTO DETECT Settings opens a page to access settings for AUTO DETECT units 269 RPM See Diagram 19 pg 29 Display Trend Graph on UUT Warm up Display trend graph on WT warm up Display Test Results hist run dis in
34. t desired profile from drop down list 4 Select AS FOUND or AS LEFT radio button 5 Tap TARE and wait until completed This zeroes the ref unit 6 Tap DO TEST button T To stop a test in process tap the STOP button This will stop and cancel the test 8 Target pressure will be generated and data will be automatically recorded at each pressure point Note If the Display Test Results in Graph Option is selected see Edit Defaults page a graph will appear displaying pressure vs error after the pressure sequence has been completed Diagram 9 9 To record data Tap RECORD TEST RESULTS button Note Record Test Results Button has 3 states indicating the save status of test results When no test results are available to save the button reads No Results To Save When results on screen have been saved the button will change to Test Results Saved After a test is complete and before the data is saved the button will read Record Test Results 10 To review data Tap REVIEW TEST RESULTS button 11 To expand collapse the Test Profile Results window double tap Test Profile Results window Unit Under Test UUT Identity Profile ID Stop Do Test Re Zero Record Data As Found As Left Review Data Test Selection Target Pressure Test Profile Results Window Test Tab Diagram 8 Diagram 9 LL 6 31 TEST Dial Gauge Differences from General Diagrams 8 amp 9 Pressing DO TEST button brings up separate test page w
35. ta as both As Found and As Left and the calibration testing is complete B If As Found data is outside the user selected Re Cal Accuracy The 869 initiates automatic zero and span adjustments Auto Re Cal The 869 will perform the re cal process up to three times to meet the designated Re Cal Accuracy One correction is usually sufficient to re cal a UUT however if re cal is not achieved then the 869 displays the following message UNABLE TO ADJUST UNIT TO SPECIFIED RE CAL ACCURACY C Any Re Cal process will result in test data being saved in As Found and As Left data files 6 Remove EPIC Connector from UUT and replace UUT Process Head UUT is returned to service operation 33 9 0 MICRO CAL MANAGER INTERFACE The MICRO CAL MANAGER INTERFACE provides a central location for all data within a given facility database management and easy data entry and manipulation 9 1 SETUP FOR POCKET PC CONNECTION 1 Install Microsoft ActiveSync Please follow ActiveSync setup instructions 2 Select GUEST partnership 3 Verify device is connected on Microsoft ActiveSync CONNECTED should now appear in ActiveSync window 4 Run Micro Cal Manager software Diagram 24 5 Press CONNECT button See Diagram 25 6 Screen will update with data from both PC and Pocket PC Diagram 25 34 9 2 GRAPHICAL USER INTERFACE SETUP The interface is divided into sections corresponding to the pages on the Pocket PC softwar
36. tells you the pressure range and the output of the reference transducer Tare Button Allows the user to zero the reference unit Reference Location Shows the high and low ranges of the reference unit the Model 869 automatically selects the proper reference sensor according to the full scale range of the presently selected UUT Select Reference Number cc Diagram 16 25 6 7 SYSTEM Screen Instructions Diagram 17 Data and system values Software Version Version of software on Pocket PC Firmware Version Version of firmware on calibrator microprocessor board Serial Number Serial number of device Next Calibration Due Date Calibration due date set at factory when calibrated set for one year after latest calibration Current Date System Date Time Display This must be set through Pocket PC settings Date should be set accurately to notify operators of upcoming calibration due date Filter Length The number of samples taken when a data point is collected during an automated test It is also the number of samples taken when HOLD SAMPLE button is pressed on Real Time page The software will read this number of samples and return the average as the data value Excitation This value is the current excitation being provided to EXC Battery Level This value is the current battery voltage level Comm On Check box allows interruption of communication stream between Pocket PC and 869 base Thi
37. tton Decreases pressure set point by 0 1 of UUT span FINE Button Increases pressure set point by 0 1 of UUT span COARSE Decreases pressure set point by 1 of UUT span COARSE Increases pressure set point by 1 of UUT span Cancel Button Stops test in progress and dumps any data taken Leaves unit in vented state Test Type Test Point Indicator Target Pressure Eng Units Display Pressure Display Window OPEN CLOSED Indicator P Switch Only Vent Button 1 Halt Button Set Point Window GO Button FINE Button FINE Button COARSE Button COARSE Button Target Cancel Button Diagram 10 16 6 34 TEST Expert System Differences from General Diagrams 8 amp 9 Automatically starts test in As Found condition records As Found data Automatically performs recal if As Found data is found to be outside limits on UUT page Performs recal maximum of three tries before flagging UUT as No Records successful recal As Left Test data available as As Found and As Left data pair 17 6 4 PROFILE General Setting up Test Profiles Database Diagram 11 1 Profiles are pressure settings used during testing 2 Program has capability of creating additional test profiles besides the default test profiles that are installed 3 If a new profile setup is required tap the PROFILE tab 4 Select NEW button 5 Type new PROFILE ID in box 6 Select PROFILE to copy if desired from drop down
38. y be created to mount to these inserts for testing the UUT in a desired location 2 Hook up the pneumatic lines attaching the high port HI on the cali brator to the high port on the UUT and the low port LO on the calibrator to the low port on the UUT 3 Hook up electrical See Diagram 23 pg 32 EXPERT SYSTEM See Page 33 CALIBRATING TESTING A TRANSDUCER TRANSMITTER MANUAL CALIBRATION 1 Select UUT tab Select UUT ID from list and verify 2 Select REAL TIME tab 3 Connect UUT according to UUT Connection Guide Above 4 Press the FS button will be updated in the target pressure window it will generate the lowest pressure of the UUT range wait until pressure is achieved 5 At this point you may adjust the zero adjustment on the UUT until the output is within desired tolerance 6 Once zero is adjusted press the FS button target pressure will again update in window wait until pressure is achieved You may adjust the span potentiometer until within desired specification 7 Unit should be calibrated at this point To verify select TEST tab AUTOMATED TEST 1 Select TEST tab 2 Select UUT from list if not available follow instructions for creating new 3 If selected test profile is not desired test then select NEW test from list 4 Press DO TEST button and wait for completion EXPERT SYSTEM TEST see page 33 31 Standard 869 Unit Under Test Model 260 Electrical Lines Pneumatic
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