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HBLT Software Version 1.93

1. 68 95 Return Pressure minimum 82 74 Return Pressure maximum 172 37 Return Pressure default 0 00 Increment Pressure minimum step 0 69 Increment Pressure maximum step 172 37 Increment Pressure default 34 47 Maximum Test Pressure minimum 6 89 Maximum Test Pressure maximum 172 37 Maximum Test Pressure default 68 95 Leak Rate minimum persecond 6 89 Leak Rate maximum second 327 67 Leak Rate default second 34 47 Up Burst Rate minimum per second 34 47 Up Burst Rate maximum per second 5 327 67 Up Burst Rate default persecond 5 17237 Down Burst Rate minimum per second 34 47 Down Burst Rate maximum per second 327 67 Down Burst Rate default per second 5 0 00 Leak Dip minimum Leak Dip maximum 172 37 Leak Dip defaut O 0 00 HBLT User s Manual page 36 moge Parameters Sr BAR era Up Ramp Rate minimum second 10 0 07 0 07 69 Up Ramp Rate maximum per second Up Ramp Rate default Down Ramp Rate minimum per secon Down Ramp Rate maximum per second Down Ramp Rate default Initial Pressure minimum Initial Pressure maximum Initial Pressure default Target Pressure minimum Target Pressure maximum Target Pressure default Return Pressure minimum Return Pressure maximum Return Pressure default
2. HBLT Invalid Calibration Please Recalibrate Aborting the test Location DOTEST C perform test The HBLT displays this alert message when attempting to run a test and the HBLT is not calibrated Calibrating the HBLT clears this problem User s Manual page 56 Alert Invalid test type aborting to main menu Location DOTEST C wait to start The HBLT displays this alert message when attempting to run a test and the process type is not one of the valid types This occurs only if there is a programming error or there is a memory fault If this alert repeats contact Crescent Design Inc for service Alert No pressure unit was present so the test will not be saved Location PDBASE C gt import_process The HBLT displays this alert message when an imported test does not contain a PRESSUNIT record or that record is invalid If the transfer is between HBLT s check the serial connections and try again If the transfer is between a PC and HBLT verify that the text file on the HBLT contains the PRESSUNIT record and that the record is correctly formatted If this problem persists contact Crescent Design Inc for service Alert Processes found with bad checksums will be erased Location BLTMAIN C gt init_hbltQ The HBLT displays this alert message at initialization if there are any bad checksums Alert System Overpressure Please verify that the outlet is clear Location gt StateSys
3. Touch the menu button next to the name of the test to be deleted Review the information about the test selected and touch OK if this is the test intended to Touch YES to confirm deletion of the test Printing a Test Ensure that a printer is connected to the HBLT and that it is turned on and paper is loaded Select Edit test information from the Engineering menu Select Print on the Test Editing Menu Touch the menu button next to the name of the test to print The test parameters will be immediately printed HBLT User s Manual page 27 Importing Test This feature allows you to send information that defines a given test from one similar HBLT instrument to another Using a Crescent Design customized serial cable connect two HBLT instruments together via their serial ports located on their back panels Next go to the HBLT instrument that is to receive test information and select Import from the Test Editing Menu Go to the HBLT instrument that is to send test information and select Export from the Test Editing Menu Follow the instructions under Exporting a Test Data transfer usually takes only one second If you attempt to import a test with the same name as an existing test you will be prompted as to whether to overwrite an existing test If you attempt to import a test and the test memory is already full you will be prompted to delete an existing test or to abandon the import If information is not rece
4. Time If no burst or leak occurs the pressure is decreased to the specified Return Pressure level This repeats a specified Repeat Cycle number of times Once the Repeat Cycles complete a new Target Pressure is computed by increasing the previous pressure by the Pressure Increment amount The test continues like this until a burst or leak or the Maximum Pressure is achieved Custom Custom P R E 5 5 U R E This is a custom pressurization profile It works like Incremental mode except that each successive Target Pressure is defined individually Up to 100 successive Target Pressures can be defined for a given test These custom target pressures need bear no relationship to each other one target may be greater than less than or equal to any of its neighboring targets HBLT User s Manual page 24 Editing Buttons When creating or editing test information most of the data entry screens feature a number of editing buttons along the bottom row These are editing buttons ESC The ESC escape button appears on screens enabling you to abort the process of entering or selecting information It is also used to close menus or submenus and return to a previous level of selection BACK The BACK button is used to step backwards in a multi step procedure such as entering or editing test information Pressing the BACK button permits you to step backwards and change a setting you just entered and the setting previous to that one a
5. The HBLT displays this alert message when the operator presses a button labeled Undefined when selecting a test for execution Select only defined tests on these panels Alert You must calibrate the HBLT before use Location CALIB C StateCalibFunctions The HBLT displays this alert message when it discovers that the calibration is invalid after the user presses ESC on the Calibration screen After closing the alert message calibrate the machine before use Alert You must choose a unique name for this test Try again Location PDBASE C edit process The HBLT displays this alert message when saving an edited test with a new name that is not unique After closing the alert message enter a new unique test name Alert You must define expiration days before warning days Location CALIB C StateCalibWarning The HBLT displays this alert message when the user attempts to set the calibration warning days before the calibration expiration days After closing the alert message set the calibration expiration days before setting the calibration warning days HBLT User s Manual page 61
6. accurately during FAST RAMP testing FAST RAMP pressurization is very much like trying to move a car between two points using a stop go switch as opposed to an accelerator and brake A side effect of FAST RAMP pressurization is pressure backlash If a product is brought to a target pressure and does not fail the rapid stopping of the pressurization process causes a kind of hiccup in the pressure curve which the tester may interpret as a mild burst It is recommended that the Burst Rate be set to higher values for FAST RAMP tests FAST RAMP pressurization consists of two phases full power pressurization and controlled target acquisition Full power pressurization starts immediately and runs for as long as it can without running risk of going over pressure Then a controlled ramp rate decelerates to goal Defining a New Test Select Edit test information from the Engineering Menu Select New on the Test Editing Menu Select the type of test see definitions above Enter the information requested at the prompts Each type of test uses a different number of settings The HBLT prompts you to enter each of the settings displaying minimum and maximum allowable values each time If you enter a value that is out of range for a test you will be prompted to correct the value If an incorrect value is entered there is no need to quit It is easy to go back and change values by Editing a test see below The test will be saved automatically when a
7. alert message when an imported test does not contain a TESTNAME record or that record is invalid If the transfer is between HBLT s check the serial connections and try again If the transfer is between a PC and HBLT verify that the text file on the HBLT contains the TESTNAME record and that the record is correctly formatted If this problem persists contact Crescent Design Inc for service Alert The streaming mode CPS is greater than the serial port CPS Location FORMAT C gt CheckCPS The HBLT displays this alert message when the operator selects streaming mode options and baud rates that result in more Character Per Second CPS than the serial transmission can handle For instance if the operator selected a baud rate of 1200 approximately 120 characters per second and a streaming mode of 100 data points per second 100 length of streaming message the HBLT would not be able to send the data without dropping many characters To prevent this from happening always use 38400 the maximum baud rate for the serial port If a slower baud rate is essential select a streaming data rate below 100 that does not cause this alert message HBLT User s Manual page 59 Alert The test record contains an unknown test type Location DOTEST C perform test The HBLT displays this alert message when beginning test execution and the test type is not one of the predefined types This message is a program diagnostic If this ale
8. carriage return or linefeed This command must follow the r command R ASCII code 82 decimal START button Tester will behave as if the on screen START button had been pressed If a test is already in progress or there is no START button currently being displayed this command is ignored lower case ASCII code 114 decimal execute process command The lower case must be immediately followed by the exact spaces punctuation and case sensitive test name and then a carriage return ASCII code 13 decimal If this test name matches one of the tests in the HBLT memory it will be loaded and ready The system should typically respond with an F waiting to start A response of followed by the test name happens when no match is found A non response within one or two seconds would indicate that the HBLT was busy running a test or in another mode purge or engineering menus for example and cannot accept run commands The test name need not be terminated with a carriage return if its length is exactly ten characters long NOTE Most tests contain no lower case characters Example TEST lt cr gt The command resets the operator id string and lot number string to null Use the 1 and o commands to set the lot number and operator id respectively after you issue the r command S ASCII code 83 decimal STOP button Tester will behave as if the on screen STOP button had been pressed If a test is not in progress or the
9. one Replace the hose clamps Replace the cover Sl Imo CUAL Attach the power cord 10 Tum on the instrument and purge it thoroughly Fault conditions Internal fans in the HBLT run when needed to keep certain components cool You may hear the fan cycling on and off while a test is running This is normal Overtemperature Temperature sensors inside the HBLT allow the computer to alert you in the case of over temperature conditions An error message will appear on the display if either the servomotor or HBLT User s Manual page 29 electronics get too hot In order to clear over temperature error you must turn off the HBLT and turn it back on again Motor Stalled The HBLT automatically adjusts for hard to pressurize conditions such as compliant products In the event that the HBLT cannot effect pressure increases after 5 seconds of effort it will assume that its motor has stopped working and will display a Motor stalled message In order to clear this error turn off the HBLT and after a moment turn it back on again Check to make sure that the product undergoing testing is properly attached to the outlet and that water flow is closed off Overpressure If the pressure exceeds a safe limit the HBLT displays an over pressure error message This typically cannot happen under normal test circumstances unless some outside force is applying extreme pressure back into the HBLT Another possible cause of over
10. per second 50 Up Burst Rate maximum per second 100 0 Up Burst Rate default per second 250 Down Burst Rate minimum per second 50 Down Burst Rate maximum per second 100 0 Down Burst Rate defaultpersecond 00 Leak Dip minimum 30 Leak Dip maximum 100 0 Leak Dip default 00 50 0 50 0 1 0 50 0 50 0 1 0 100 0 10 0 d 100 50 0 100 0 100 0 100 0 50 0 5 0 100 0 25 0 5 0 100 0 Co See the notes at the end of this appendix HBLT User s Manual eo OJN w INES AR o 12 0 ojoj 10 gt m Io Li eo Co ojo 0 o e e ho 3 40 0 45 344 7 EN 195 oo OJN 44 7 44 7 eo 6 ooo lt 0 o ojojo O N eo c d O O 195 EN ojojo w eT ES ojojo GRIES O Co O l o ojo o Qo o AA 3 19 EN eo O N N N to EN D O 0 6 Qo oio Qo 69 AJN o N Qo Oi N N o o Co page 37 ars moa wan we Up Ramp Rate default 125 0 Down Ramp Rate minimum per second 1 0 0 07 7 Down Ramp Rate max
11. problem persists contact Crescent Design Inc for service HBLT User s Manual page 55 Alert IMPORT ERROR lt var gt lt value gt Press units unknown Location PDBASE C gt import_process gt withinLimits The HBLT displays this alert message when importing a test and the PRESSUNIT record contains an unrecognized unit If this alert repeats contact Crescent Design Inc for service Alert IMPORT ERROR lt var gt lt value gt var min val max Location PDBASE C gt import process gt withinLimits The HBL T displays this alert message when importing a test and a record parameter is not within valid bounds If this alert repeats contact Crescent Design Inc for service Alert Imported process invalid therefore cannot be saved Location PDBASE C gt import process The HBLT displays this alert message when an imported test contains invalid parameters If the transfer is between two HBLT s insure both HBLT s are the same version If the transfer is between an HBLT and Pressure Manager insure that the HBLT version is 1 81 or later If the transfer 15 between an HBLT and a PC check the text file on the PC for correctness If this problem persists contact Crescent Design Inc for service Alert Invalid Calibration Please Recalibrate Location BLTMAIN C init hblt The HBLT displays this alert message at initialization Calibrate the HBLT before running tests Alert
12. rate choices are set above will enable Remote Control of HBLT tests as if an operator were pressing on screen buttons The optional Pressure Manager software also requires that this option be set to YES Please refer to Appendix A for an explanation of the remote control functions how they work and when they apply HBLT User s Manual page 12 Select Remote Output This option allows the operator to choose the Select Output Format menu This menu allows the user to alter the output format and data rate used during remote operation streaming mode Because of a serial port conflict this option is mutually exclusive with the Enable Gage Measurement option described below Download New Program This option allows the operator to start the download a new program procedure See the Download new program heading below Refill After Downramp This option enables the refill cylinder option when a downramp drops below 2 PSI This allows the testing of a leaky product This option applies to all tests When using this option make sure that each tests leak rate is high enough The cylinder does not refill after the last down ramp Enable Gage Measurement This option enables the gage data capture using the serial port Because of a serial port conflict this option is mutually exclusive with the Select Remote Output option described above If the response is YES the HBLT displays the current baud rate and asks the operator if the baud rate is corre
13. requires removal of any covers can expose parts that involve the risk of electric shock or personal injury Make sure that the power switch is turned off and the instrument is disconnected from the main power source and refer such servicing to qualified personnel Electrical Safety To reduce the risk of electrical shock this equipment uses a three wire electrical cord and plug to connect it Make sure that the matching wall outlet receptacle is properly wired and earth grounded HBLT User s Manual page 5 Safety Against Risk of Fire Fuses protect certain electrical circuits within this instrument against overcurrent conditions For continued protection against the risk of fire replace only with the same type and rating specified SAFETY MESSAGES Your safety and the safety of others is very important We have provided many important safety messages in this manual Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message is associated with a safety alert symbol These symbols are found in the manual and inside the instrument The definition of these symbols is described below gt gt General Warning Caution Refer to the instruction for details on specific danger Caution Hot Surface Caution Electrical Shock Hazard Caution The HBLT should be used for the purpose and in the manner described in this manual If you use the HB
14. respectively test aborted leak dip condition This response code is followed immediately by XXX YY Y ZZZ cr where XXX is the leak pressure in test units YYY the peak pressure in test units and ZZZ is the time elapsed since the pressure started ramping up in the current cycle Example DD360 500 4 2 lt cr gt Burst at 360 units peak 500 4 2 seconds The HBLT emits this message when a leak dip occurs However during streaming data mode the message is displayed after the test completes ASCII codes 68 and 75 decimal respectively test completed no errors This response code is followed immediately by XXX Y YY cr where XXX is the peak pressure in test units and YYY is the time elapsed since the pressure started ramping up in the current cycle Example DK1130 8 1 lt cr gt Peak at 1130 units 8 1 seconds ASCII codes 68 and 76 decimal respectively test aborted leak condition This response code is followed immediately by XXX YYY ZZZ cr where XXX is the leak pressure in test units YYY the peak pressure in test units and ZZ Z is the time in tenths of seconds into the current step Example DL25 29 7 2 lt cr gt The HBLT emits this message when leak occurs However during streaming data mode the message is displayed after the test completes ASCII codes 68 and 90 decimal respectively test not run due to lack of calibration Since the HBLT never starts the test there are no parameters Calibrating t
15. the current calibration is invalid due to check sum error or values outside limits the HBLT initializes the values using the default settings Calibration Password This function allows the user to set a password to protect the calibration This allows access to calibration functions without allowing access to the other engineering functions To set the calibration password first set the dual passwords option to YES using the engineering configuration screens The HBLT sets the calibration password to the same value as the engineering password The operator can then set the calibration password If the dual password is not set the HBLT displays an alert message advising the operator to set the dual password mode System configuration System configuration consists of setting the criteria for communication with the HBLT Below are the options and their definitions Most options have buttons that read YES or NO buttons or their prompts show their current settings for respective options To change an option touch its related button and then choose the new setting from the screen prompt Set the baud rate The baud rate is the serial data transfer rate into and out from the HBLT The Import and Export features under Edit Test Information use serial data transfer as well as the Remote control Pressure Manager and Download New Program functions When using Remote control be sure and select a baud rate high e
16. to expose the unit to temperatures much outside this range 2 Connect power AN The operating voltage on the HBLT is selectable between two voltage ranges Itis shipped with the proper voltage setting for the intended destination If necessary use the power selector on the back of the instrument to switch between the 105 130 Volts AC and 210 260 Volts AC settings This selector is located just under the power cord receptacle To change it remove the power cord and pry out the selector then replace it in the desired orientation Connect the HBLT to a suitable electrical outlet with the HBLT User s Manual page 7 power cord provided The HBLT consumes maximum of 400 Watts and operates any AC frequency between 47 to 63 Hz 3 Connect fluid A quick disconnect fitting with a built in shutoff valve is shipped with the HBLT Connect this fitting with a hose to a clean water reservoir Fill the reservoir with clean distilled water Connect the fitting to its mating half on the front of the HBLT A IMPORTANT Do not connect the HBLT to any kind of pressurized water source Use a clean distilled water source only 4 Connect the printer The HBLT uses a printer for printing the defined tests and for printing test results during test execution see the corresponding sections of this manual for more explanation of these printouts The printer must use a standard parallel interface Attach a parallel printer cable to the DB 25
17. 447 Leak Rate minimum per second Leak Rate maximum per second Leak Rate default per second Up Burst Rate minimum per second Up Burst Rate maximum per second Up Burst Rate default per second Down Burst Rate minimum per second Down Burst Rate maximum per second Down Burst Rate default per second Leak Dip minimum Leak Dip maximum Leak Dip default See the notes at the end of this appendix 100 68 07 10 0 7 0 00 345 138 3 1 1000 345 138 50 10 20 50 20 4 4 68 1 6895 4 4 1000 6895 00 00 2 100 6895 00 00 HBLT User s Manual page 40 rS oaa rer a Up Ramp Rate minimum per second 10 07 07 69 Down Ramp Rate minimum per second 10 071 07 69 Initial Pressure minimum 10 07 071 69 Initial Pressure defaut 100 68 69 689 Target Pressure minimum 1 4 RetumPressure defaut 0 oof oof 0 Increment Pressure default 25 147 17 172 Maximum Test Pressure minimum 10 07 07 Maximum Test Pressure maximum 13790 Maximum Test Pressure default 3447 Leak Rate minimum per second 10 100 Leak Rate maximum per second 100 Leak Rate default per second 10 25 10 7 0 7 10 7 0 7 10 ef 0 7 Up Burst Rate minimum per second 40 27 2 8 50 4 3 4 40 7 2 8 2 00 6 2 Up Burst Rate maximum per second 2000 136 1 137 9 13790 Up Burst Rate default per second 501 34 34 40 2 89
18. 76 5 Down Burst Rate minimum per second aera 76 21 0 0 0 3 Down Burst Rate maximum per second 2000 136 1 137 9 13790 2 Down Burst Rate default second o oo 2001 Leak Dip minimum 3 02 02 Leak Dip maximum 13790 Leak Dip default po qr 300 See the notes at the end of this appendix HBLT User s Manual page 41 S000 PSI Model Parameters Psi BAR KPa Ramp Rate minimum persecond 101 07 07 69 Down Ramp Rate minimum persecond 10 07 07 69 Initial Pressure minimum 10 07 07 69 Initial Pressure default 100 68 69 Target Pressure minimum 689 Retur Pressure defaut 00 oo Increment Pressure default Maximum Test Pressure minimum Maximum Test Pressure maximum Maximum Test Pressure default Leak Rate minimum per second Leak Rate maximum per second Leak Rate default per second Up Burst Rate minimum per second Up Burst Rate maximum per second Up Burst Rate default per second Down Burst Rate minimum per second Down Burst Rate maximum per second Down Burst Rate default per second Leak Dip minimum Leak Dip maximum Leak Dip default See the notes at the end of this appendix HBLT User s Manual 5 17 1007 a 32767 25 10 0 7 0 7 ol or i00 8 69 689 0 O07 69 oof 00 oof oo page 42 Notes This value is upper bounded b
19. CII codes 68 and 65 decimal respectively test aborted by operator safety door open RESET via remote control or front panel This response code is followed immediately by XXX lt cr gt where XXX is the peak pressure in test units Example DA1200 cr ASCII codes 68 and 66 decimal respectively test aborted up ramp burst condition This response code is followed immediately by XXX Y YY ZZZ cr where XXX is the burst pressure in test units YYY the peak pressure in test units and ZZZ is the time elapsed page 33 DC DD DK DL DZ since the pressure started ramping up in the current cycle Example DB360 500 4 2 lt cr gt Burst at 360 units peak 500 4 2 seconds The HBLT emits this message when an up ramp or dwell burst occurs However during streaming data mode the message is displayed after the test completes ASCII codes 68 and 67 decimal respectively test aborted down ramp burst condition This response code is followed immediately by XXX YYY ZZZ cr where XXX is the burst pressure in test units YY Y the peak pressure in test units and ZZZ is the time elapsed since the pressure started ramping down in the current cycle Example DC360 500 4 2 lt cr gt Burst at 360 units peak 500 4 2 seconds The HBLT emits this message when a down ramp or bottom maintain burst occurs However during streaming data mode the message is displayed after the test completes ASCII codes 68 and 68 decimal
20. E tnn EEE 10 PRINT CALIBRATION REPORT Su des or SKIP CALIBRATION EE rE E E EAEE EE AREE s ESTEE A a CALIBRATION PASSWORD 22 rtt rep ert ER REM I EEEN EI INEASA SYSTEM CONFIGURAT ION eerte eaten enn tnto tonta tan tania enses estas ueneno tenen esae sesta tan 11 SET THEBAUD RATE htm e PARENT UNE UPPER ERE FO HERI ERE RERO Fee MERE MAINTAIN BEEP OPTION m Sees gods PAGE EJECT OPTION 5 te outre sre teh e NOR ER Uer a she eee del aea opea ESO TAa IEOS EKEK EEE Orao Son E ES AERE PURGE SPEED ERAN IO DIE HIBERUM ENABLE SAFETY DOOR NEXT PAGE gt E M DIAGNOSTICS ttt oc irt te oe e REN Mo ERO nt E c RR ren rie fer ts ENABLE REMOTE CONTROL e SELECT REMOTE OUTPUT terrere erbe rte eee Roles estende DOWNLOAD NEW PROGRAM trecenti e den enel enean enean ehe d ENABLE GAGE MEASUREMENT dA ve ENABLE DUAL PASSWORDS rte ettet te etg ege es E a a etre eden DIAGNOSTIC MENU TOUCH SCREEN TEST PRESSURIZATION COUNT DOWNLOAD NEW PROGRAM eee eee nente ten ta tanane nent tanen ennt totes snas to tenens ses ea tonnes ense tenen sessios 14 SET THE amp TIME 14 BROWSE TESTS c sccssscsssssssssssssss
21. Hydraulic Burst Leak Tester Owner s Manual Software Version 1 93 Released June 4 2003 Crescent Design Inc 9932 Mesa Rim Road Suite B San Diego CA 92121 Voice 858 452 3240 FAX 858 452 3241 crescent abac com www crescentdesign com Revision July 7 2003 Table of Contents INTRODUCTION 2 5 INTRODUCTION P 5 SAFETY m A4A 5 SAFETY DURING INSTALLATION AND OR 5 ELECTRICAL SAFETY E E SAFETY AGAINST RISK OF FIRE NR REIR XR EN Ne PON EORR Ns 6 SAFETY MESSAGES T 6 SPECTBICATIONS 7 MACHINE SETUP 7 TURNING ON THE HBLT cscccsssssssssssssssssssssssssessssesssssssssssssssssssnsesessssessesssssessssssssnsessvsssessssssesssossssssssnseesses 8 MAIN MENU 9 ENGINEERING ID U X 9 EDIT TEST INFORMATION eene tette ennt ton tn tnn annona tanen enia soto estas nannte to tones seen es ta ton 9 PERFORM 9 PERFORM CALIBRATION i305 tratte RR OH RM FR oe oss eave Mtr te e I OR 9 SET CALIBRATION EXPIRATION serrar oar RAER ANAE eo eee pee e eee bes eere exe EE eMe 10 SET CALIBRATION WARNING porpre et tenente tiennent tinte ni ttn tnihi ttn tnihi E ne ttn EA E
22. Increment Pressure minimum step Increment Pressure maximum step Increment Pressure default Maximum Test Pressure minimum Maximum Test Pressure maximum Maximum Test Pressure default Leak Rate minimum per second Leak Rate maximum per second Leak Rate default per second Up Burst Rate minimum per second Up Burst Rate maximum per second Up Burst Rate default per second Down Burst Rate minimum per second Down Burst Rate maximum per second Down Burst Rate default per second Leak Dip minimum Leak Dip maximum Leak Dip default Up Ramp Rate maximum per second 500 Ramp Rate defaut 500 Down Ramp Rate minimum per second 10 Down Ramp Rate maximum per second _50 0 Down Ramp Rate default 50 0 Initial Pressure minimum 10 Initia Pressure maximum 100 0 _Initial Pressure defaut 10 0 Target Pressure minimum 10 Pressure maximum 100 Target Pressure default 50 0 Return Pressure minimum 120 Return Pressure maximum 100 0 Return Pressure defaut 00 Increment Pressure minimum step 0 1 Increment Pressure maximum step 100 0 Increment Pressure default 501 Maximum Test Pressure minimum 10 Maximum Test Pressure maximum 100 0 Maximum Test Pressure defaut 100 0 LeakRate minimum persecond 10 _Leak Rate maximum per second 500 Leak Rate default per second 5 0 Up Burst Rate minimum
23. LT in a manner other than that for which it was intended unpredictable behavior could ensue with possibly hazardous consequences CAUTION RISK OF ELECTRICAL SHOCK DISCONNECT POWER BEFORE PERFORMING THE FOLLOWING OPERATIONS THE OPERATIONS DESCRIBED IN THE FOLLOWING PARTS OF THIS MANUAL ARE TO BE PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLY HBLT User s Manual page 6 Specifications Operating Temperature Range 59 104 F 15 40 C Humidity Range Dimensions H x W x D Weight Power Environmental Conditions Maximum Operating Altitude Machine setup 35 85 RH Non Condensing 634 x 20 7 8 x 1734 17cm x 53cm x 45cm 65 Ib 29 5 kg 105 130V 2A 50 60HZ 210 260V 1A 50 60HZ Installation Category Overvoltage Category II Pollution Degree 2 6560 feet 2000 meters Perform following steps before using Read all steps before starting HBLT is a heavy instrument so keep in mind that wherever it is set up should be a permanent location 1 Remove from carton A Carefully remove the HBLT from its packing carton It contains electronic and mechanical components that can break if dropped Set it on a level operating surface where the height of the touch screen display is convenient for an operator The HBLT operates best in an environment where the temperature is between 15 26 C Since it operates on distilled water and has sensitive components care must be taken not
24. STOP button is not currently being displayed this command is ignored X ASCII code 88 decimal export currently loaded process When the HBLT is waiting for the START button sending an X causes the HBLT to export the process presently being HBLT User s Manual page 32 N lt run via the serial channel exactly as if it had been EXPORTed via the Engineering Menu Note that decimal points are omitted See Appendix B for units description ASCII code 89 decimal redirect parallel port output to serial port Used by Pressure Manager to redirect reports to the Windows application ASCII code 121 decimal restores parallel port output back to original port ASCII code 90 decimal resume a test stopped by S command burst or leak If a burst or leak stopped the test the cylinder is refilled If stopped in a pressurized state the HBLT is re pressurized Response codes The tester will send various codes indicating test status by itself when a test is in progress or just stopping The following are the codes and their meanings DA DB HBLT User s Manual ASCII code 61 decimal status report responding to remote query This response code is followed immediately by XXX Y YY cr where XXX is the current pressure in test units and YYY the peak pressure in test units ASCII code 126 decimal status report responding to remote query command This response code is followed immediately by XXX YY Y ZZ Z l
25. al Pressure maximum 172 37 Initial Pressure default 6 89 Target Pressure minimum Target Pressure maximum 172 37 Target Pressure default 68 95 Return Pressure minimum 82 74 Return Pressure maximum 172 37 Return Pressure default 0 00 0 000 0 000 Increment Pressure minimum step 0 007 0 007 Maximum Test Pressure minimum 6 89 Maximum Test Pressure maximum 72 37 Maximum Test Pressure default 68 95 Leak Rate minimum per second 6 89 Leak Rate maximum per second 327 67 Leak Rate default per second 34 47 Up Burst Rate minimum per second 34 47 Up Burst Rate maximum per second 27 67 Up Burst Rate default per second 172 37 Increment Pressure maximum step 25 00 1 701 1 724 172 37 Increment Pressure default 0 340 0 345 34 47 C2 Down Burst Rate minimum per second 34 47 Down Burst Rate maximum per second 327 67 Down Burst Rate default per second 0 00 0 000 0 000 Leak Dip minimum Leak Dip maximum 172 37 Leak Dip default 0 00 0 000 0 000 See the notes at the end of this appendix Up Ramp Rate default 34 47 Down Ramp Rate minimum per second 6 89 Down Ramp Rate maximum per second 327 67 Down Ramp Rate default _ 34 47 Initial Pressure minimum 6 89 Initial Pressure maximum 172 37 Initial Pressure default 6 89 Target Pressure minimum 0 69 Target Pressure maximum 172 37 Target Pressure default
26. alibration functions screen There the operator can change the calibration password To disable the dual password mode first set the calibration password to no characters null password Then set the Enable dual passwords option to NO Enable safety door The HBLT has an optional connection for a safety switch assumedly connected to an enclosure where products are hydraulically tested When this option is enabled set to YES no testing will commence until the safety switch indicates that the safety door of such an enclosure is closed Diagnostic Menu This menu allows you to perform diagnostics on the HBLT and analyze its performance Touch Screen Test This screen allows you to test all the buttons on the HBLT s touch sensitive front panel The screen is filled with buttons which when pressed change to OK Press each button to determine if the button is operable Press the ESC button to return to the Diagnostic Menu In the event the ESC button is inoperable turn off the HBLT and contact Crescent Design for assistance Pressurization Count In order to give Crescent Design s technicians an indication of the HBLT s level of usage a counter is incremented every time the HBLT is pressurized The pressurization count screen displays this counter Download new program This function permits the re programming of the HBLT by running the Crescent Design downloading program on your PC This program will be supplied to you with
27. any pressure at the sensor When Fill speed is enabled for a test it will attempt to pressurize a product to approximately eight PSI before starting the actual test Some very compliant products can burst at less than eight PSI as the sensor sees it since the actual weight of water inflating the product can apply much more than eight PSI to its sides seams etc HBLT User s Manual page 25 Highly compliant products may need special test considerations e g testing a product encased in a rugged constrictive enclosure that prevents it from consuming more than a fixed volume of water Of course once inside a constrictive enclosure the product will not experience the same stresses that it would see in normal use Ramp Pressurization Each of the five test types Linear Ramp Staircase Fatigue Incremental Custom ask for an Up Rate Most non destructive tests use a controlled pressurization rate that is entered on this screen in terms of engineering units per second PSI sec kPa sec Atm sec or Bars sec The Up Rate screen features a FAST button which when pressed changes the requested Up Rate to FAST RAMP Any test created with a FAST RAMP Up Rate will pressurize as fast as possible within the limitations of the unit The effective rate in this case can be as fast as 1000 PSI per second more in some cases depending on model FAST RAMP is intended for destructive testing Target pressures are not achieved
28. any software updates See Appendix E for more on downloading Set the date amp time This Engineering Menu displays the current time and date at the top of the screen Buttons allow you to adjust the MINute HOUR DATE MONth and YEAR by touching the up and down arrows next to these words New settings will appear at the top of the screen as you adjust Touch the OK button to save the new information or ESC to exit without changing the current settings HBLT User s Manual page 14 Browse Tests This function allows the operator to select and view a test parameters without the ability to change the test This allows operators to verify a test prior to testing without having the password to the engineering edit menu Purging Purging is the first of the choices appearing on the Main Menu The object of purging is to remove air bubbles from the fluid path inside the machine The HBLT should be purged prior to each use Water will exit from the outlet when purging so it is advisable to set it up so that it may drain into a suitable container Select Purge the tester from the Main Menu There are two purge modes available The first purge mode is continuous purge This purge mode is useful when filling the HBLT for the first time and for filling test fixtures The second purge mode is single cycle purge This purge mode uses a syringe and a graphic display to purge trapped bubbles from the system Check for proper water reservoir
29. at the top In the event that hydraulic pressure exists at the outlet at the onset of the test the system will attempt to depressurize Part of this function may include burping clicking noises as the inlet valve switches on and off in an attempt to equalize pressure between the HBLT cylinder and the atmosphere Compliant products in particular can cause this kind of activity When the outlet pressure has been equalized the HBLT will put up a wait message while its cylinder refills with water it will then be ready to go showing a START button Pressing START will either begin the test or start the Fill function depending on the test s Fill speed setting In the event that the test has a Fill speed specified the words Press to fill will appear beside the START button Pressing START will then pump water slowly into the product being tested until 8 PSI of backpressure exists and then the Cylinder will refill itself This refilling may again cause burping as mentioned above especially with compliant products The words Press to fill will be erased and the word START will appear on the screen Pressing START will then commence testing Tests run to completion unless a fault burst or leak is detected During the test the screen displays what state the machine is in what cycle it is on and the current and target pressures The only other way to interrupt a test is to either press the on screen STOP button or to open the safety
30. ays this alert message when it receives an invalid parameter to a PRESSUNIT record during remote import mode If this alert repeats contact Crescent Design Inc for service Alert IMPORT ERROR TESTTYPE lt val gt RAM STA FAT INC CUS Location PDBASE C gt valid The HBLT displays this alert message when it receives an invalid parameter to a TESTTYPE record during remote import mode If this alert repeats contact Crescent Design Inc for service Alert IMPORT ERROR lt val gt at least one item out of range Location PDBASE C gt valid The HBLT displays this alert message when it receives an incorrectly formatted creation or update date during remote import mode If this alert repeats contact Crescent Design Inc for service Alert IMPORT ERROR lt var gt undefined or missing Location PDBASE C gt scrutenize_bad_msg The HBLT displays this alert message when a required variable is missing in an imported test The most likely cause is an invalid test variable record If the transfer is between two HBLT s insure that both HBLT s have the same application version If the transfer 15 between Pressure Manager and an HBLT insure that the HBLT version is 1 81 or later If the transfer is between a PROCOMM or similar program and an HBLT check the format of the test for correctness Do this by exporting a test to PROCOMM and compare the two tests In rare cases there may be a problem with the serial port If the
31. by venting the outlet Excessive pressure can damage the pressure transducer One cause of this problem is mis calibration If it reoccurs soon after a calibration contact Crescent Design for assistance The motor is overheating The motor that generates hydraulic pressure has overheated Turn off the machine and contact Crescent Design for assistance Motor stalled Five seconds elapsed without any pressure change Check for proper attachment of product to be tested to the outlet and that water flow 1s cut off Switch off the HBLT and after a few moments switch on again and retry The motor driver is too hot The circuits that power the motor that generates hydraulic pressure have overheated Continued operation would risk damage Let the system cool for five minutes with the power off If the problem re appears contact Crescent Design HBLT User s Manual page 49 Can t configure machine Ver mismatch x xx y yy Transducer not installed Unknown press config xxx Invalid exhaust intake limits Error code HBLT User s Manual Option switches or internal setup is incorrect Contact Crescent Design for assistance in solving this problem The Kernel version y yy is incompatible with the Application version x xx Contact Crescent Design for assistance in solving this problem The pressure transducer is disconnected or malfunctioning Contact Crescent Design for assistance in solving this problem The pressure l
32. compliance is a problem try constraining the product to limit its compliance If the HBLT itself is leaking contact Crescent Design Inc for service Alert Bad import line record label record value Location PDBASE C gt remote import process The HBLT displays this alert message when importing a test that has an unrecognized record Write down the record label and the record value Then contact Crescent Design Inc for service Alert Calibration expired on date Please recalibrate Locations BLTMAIN C init hblt BLTMAIN C CheckCalibExpiration The HBL T displays this alert message when the user defined calibration expires Contact your metrology group vendor to recalibrate the HBLT The HBLT resets the expiration date upon successful calibration HBLT User s Manual page 52 Alert Calibration expires in 99 days Schedule recalibration now Locations BLTMAIN C gt hblt BLTMAIN C CheckCalibExpiration The HBLT displays this alert message when the warning period defined by the calibration occurs This is only a warning The HBLT will function after closing the alert panel Contact your metrology group vendor to schedule calibration This message appears each time the HBLT powers up until the next calibration The HBLT resets the expiration date upon successful calibration and this warning ceases to appear Alert Calibration warning days not defined Set days first Loca
33. connector on the back of the HBLT Connect the other 36 pin Centronics connector to the printer The printer must be an ASCII printer Do not use printers that require an operating system driver Make sure that the printer is turned on on line and has paper properly loaded before you attempt any printouts If the printer is not selected reports will be buffered up to a maximum of 6000 characters An optional page eject can be sent after each report When the HBLT is switched off or no longer connected buffering is canceled 5 Prepare the machine must be calibrated and purged before its first use It is not calibrated prior to shipment Please refer to the instructions about purging the HBLT and about calibrating the sensor Engineering Menu Calibration section later in this manual Pressure calibration is not accurate until the system has been purged of air Turning on the HBLT When the HBLT is turned on it will beep and then prompt you to proceed with calibration Once calibration is performed switching it on will then beep two long three short and show the greeting screen with the Crescent Design logo the software versions kernel and application and maximum pressure for your particular machine Press on screen GO to proceed to the main menu HBLT User s Manual page 8 Menu This screen allows user to go to the purging screen perform test or access engineering menu screen T
34. creen prompts and buttons make selecting running and viewing results of tests simple Name and Lot Code information are entered by on screen keyboard which includes alphanumeric some punctuation backspace and erase clear keys To prepare for testing attach an item product to be tested to the pressure outlet on the front of the HBLT Touch the menu button next to Run a test on the Main Menu The next prompt asks for Operator Name This 15 optional meant to identify who ran the test on its report if printed Touch the OK button in the lower right hand corner once this information has been entered HBLT User s Manual page 17 The next screen prompts you to enter a Lot code This is optional information that will appear on printed test reports Touch the OK button once entered A menu of currently stored tests will then appear Ten test names fit onto the display up to forty tests may be defined Undefined tests are listed as undefined Touch the PAGE button to switch between the screens of test names Touch the menu button next to the name of the test to be run A new screen appears showing the information about the test selected Touch the OK button if the information displayed corresponds to the test intended to run Touch the ESC button if you decide not to run this test If OK was pressed the machine will ready itself When this action is complete the test screen will appear saying BURST LEAK TESTER READY
35. ct If the response is NO the HBLT displays the baud rate screen to change the baud rate This option collects snap gage data from the serial port at the end of the maintain period The HBLT then prints the target pressure the current pressure and the gage reading on the line printer attached to the HBLT parallel port To connect the gage follow these instructions 1 Attach the serial port adapter directly to the HBLT DB9 serial port connector located on the back of the HBLT 2 Connect the Mitutoyo serial port adapter to the Crescent Design adapter 3 Connect the gage to the Mitutoyo serial port adapter 4 Use the configuration menu to set the serial port baud rate to 2400 baud Test the setup by running a staircase test The HBLT should print a line of data at each plateau Remember to return the serial port baud rate to 38 400 when downloading a new HBLT program or attaching to Pressure Manager Enable dual passwords This option enables the dual password mode This mode allows the operator to set a password for the engineering functions and to set a password for the calibration functions When set to NO the single password protects both engineering and calibration functions When set to YES the passwords are split between engineering and calibration HBLT User s Manual page 13 When enabling dual passwords the HBLT initially copies the engineering password to calibration password Then the operator can navigate to the c
36. ctioning smoothly the new application will be ready to run in a matter of minutes Receiving last block The application data has been completely received and the end of data message is being checked for validity The system will automatically progress to another status message almost instantly Title record err The HBLT received the initial data but that data does not correspond with the expected values Typically the screen will show Download BLT and next to Received ID will be something other than BLT What appears next to Received ID may be useful information for diagnosing problems if this occurs frequently The system will automatically progress to another status message if the correct initial data does not come in within a certain amount of time HBLT User s Manual page 47 Waiting for record Application data is received in bursts of information known as records A certain minimum amount of time has elapsed without a subsequent record coming in The system will automatically progress to another status message if another record does not come in within a certain amount of time Waiting for start This indicates that the initial data has yet to come in Typically the screen will show Download ID BLT and Received ID shows a blank The system will automatically progress to another status message if the initial data does not come in within a certain amount of time Write failed The memory circuits inside the HBLT did not prog
37. door assuming that a safety door switch is enabled After the test 15 stopped you may resume the test by touching the Resume button end the test by touching the OK button or cancel testing and return to the main menu by touching the ESC button Resuming refills the cylinder re pressurizes the system depending on the state the test was stopped in and then continues with the test The results of each test are sent to the printer port at the end of each test The printout includes Test name specified test name Test Type Product specified product name Operator operator name lot lot name or number Start at date time snap gage data appears here if enabled End at date time Result If no burst or leak occurs No failure HBLT User s Manual page 18 If a burst or leak occurs time elapsed burst cycle number burst pressure and maximum pressure attained In order for results to be printed a printer must be connected turned on on line and ready before the test begins This is optional The HBLT will run through tests with or without a printer connected Test Definition and Management Definition of Terms Maintain pressure time Dwell time Pressure increment P H E o o U H E Initial target pressure Return pressure Ramp rate TIME Burping This is the process of opening and closing the HBLT water inlet in order to equalize pressure between the hydraulic cylinder and the atmosphere Burping cause
38. eed for large passage devices Please note that this option adjusts the purge function only Individual tests have a separate and different setting for filling On the 2000 PSI HBLT and 5000 PSI HBLT the maximum purge speed is lower than the other models because the motor running at max speed can only deliver 2 0 cc sec maximum Purge intake speed The Main Menu contains an option for purging Purging is the process of pumping water through a product and whatever interconnected tubing with the goal of removing any air that may be trapped inside The purge intake speed option allows you to specify at what rate water will be draw in the intake when purging or filling Use lower purging when using higher viscosity fluids such as diluted glycerin This option controls the intake speed for both purge and fill operations On the 2000 PSI HBLT and 5000 PSI HBLT the maximum purge intake speed is lower than the other models because the motor running at max speed can only deliver 2 0 cc sec maximum Next page gt gt The Configuration Menu has three screens one with the settings mentioned above and a second screen with the five options mentioned below The Next Page button switches between these Diagnostics This option allows the operator to choose the Diagnostics Menu See the Diagnostics Menu heading below Enable remote control When this option is set to YES special characters received on the serial channel obeying whatever baud
39. eii Download succeeded HT 2 2 Er sing dalabase eiie e RR USC ER van e TAN RAP EROR eee iat Erasing unused EEPROM iet RR n eH OR e ARE REN ERER EUER 47 Last block err TN 47 NO APPLICATION Sead zn TIE 47 Receiving 47 Receiving last block ae sits deste eed 47 Title record err be i ie De 47 Waiting for record Veste ie et 46 Waiting for start s S cuianest 48 Write failed tenore ens sus bie 48 APPENDIX ALERT MESSAGES tete ta ten enn tnto tonta tata nes ton en nene tenen 51 HBLT User s Manual page 4 Introduction The Crescent Design Hydraulic Burst Leak Tester HBLT system uses distilled water to accurately pressurize an item according to programmable profiles These programmed profiles are referred to as tests The HBLT features simple yet extensive menus for defining saving and running up to 40 different tests as well as special functions The HBLT has a backlit LCD screen with a touch sensitive front for user input Pressurization is achieved using a hydraulic cylinder A motor connected to a linear actuator drives its piston The system is controlled using Crescent Design Inc proprietary electronics and firmware With optional Pressure Manager software PC compa
40. features that apply to the specific model HBLT you have There are no jumpers intended for customer use they are for factory use only and should not be changed or removed HBLT User s Manual page 45 Appendix E Downloading Downloading is the process of programming the HBLT with a new application or software that permits operation running and defining tests and so forth Usually downloading is invoked by requesting it via the System Configuration menu In the event that the re programmable memory circuits inside the HBLT lose their information a message will be displayed similar to NO APPLICATION PRESENT Please begin downloading new application Downloading requires that a computer usually a PC compatible be attached to the serial port and a special application run on the PC that downloads application data into the HBLT When downloading is invoked via the System Configuration menu the screen indicates that it is waiting for download data to begin This screen also features a STOP button that you may use to abort the downloading before it begins and large numerals counting down minutes and seconds The minutes and seconds indicate how much time remains before the download request is automatically canceled usually starting from five minutes Once downloading begins the screen will show a Download ID and Received ID These both should read BLT for standard software versions Below this information will be a Record Addr short
41. for record address This displays hexadecimal numbers that count up as the application data comes into the system At the bottom of the screen will be status messages The normal status should read Receiving data Download Status Messages The following is a list of status messages and their meanings that may appear on the bottom of the downloading screen All messages are informational the downloader automatically makes whatever corrections and retries if it can After a number of consecutive errors occur the process will abort and the screen will indicate the problem and or prompt to begin downloading again Address err The application data was received with an improper programming address The system will automatically progress to another status message if correct data does not come in within a certain amount of time Character timeout A generous amount of time has elapsed since any data was received If this message lingers it may suggest a poor connection between the HBLT and the PC compatible performing the transfer After successive failures to communicate the system will progress to show an abort message Data CRC err The application data was received with improper formatting or checksum The system will automatically progress to another status message if correct data does not come in within a certain amount of time HBLT User s Manual page 46 Download aborted The download process had too many problems in receiving da
42. he HBLT clears this condition ASCII code 70 decimal waiting for start button This character is transmitted after a test is prepared and ready to run and also after 8 PSI of back pressure is detected during the Fill pre testing process The latter only occurs when the Fill speed setting is enabled ASCII code 77 decimal maintain cycle ending This character is transmitted after any applicable pressure maintenance during a test If a test s Maintain pressure time setting is zero this character is transmitted each time the hydraulic pressure reaches its next goal If a test has a non zero Maintain pressure time then this character is sent after the Maintain Time expires However the HBLT does not emit this character when streaming mode is active ASCII code 91 decimal starts a quoted text string when transmitting redirected parallel port output out the serial port HBLT User s Manual page 34 ASCII code 93 decimal ends a quoted text string when transmitting redirected parallel port output out the serial port A ASCII code 126 decimal quotes a single character when transmitting redirected parallel port output out the serial port HBLT User s Manual page 35 Appendix B Model Parameters 28 PS1 Model Parameters Psi Amm Ban Up Ramp Rate default 34 47 Down Ramp Rate minimum per second 6 89 Down Ramp Rate maximum per second 327 67 Down Ramp Rate default 34 47 Initial Pressure minimum 6 89 Initi
43. he engineering menu allows tests to be created and edited Engineering Menu This screen offers the choices described below as well as the means to jump back up to the main menu Edit test information This takes the user to the screen where tests are created changed printed deleted imported and exported It is also where the engineering password is changed Perform calibration This choice comes up automatically when the HBLT is first installed and also may be accessed by touching the menu button labeled Perform calibration on the Engineering Menu The following functions are available on the Calibrations Functions menu This choice is now password protected by its own password This choice was previous protected by use of the engineering password This change allows both engineers and calibration staff to have protected access to their respective areas while protecting the other area Perform Calibration Prior to performing a calibration set the calibration expiration days and options then set the calibration warning days and options This is necessary because performing the calibration calculates the expiration date and warning date The first action is to select the pressure units to perform the calibration Select PSI atmospheres kilopascals or bars from the displayed panel As the next screen prompt instructs open the pressure outlet to the atmosphere Touch the ESC escape button to abandon the calibration or OK
44. hen in streaming mode See description of command character D below for details on streaming HBLT User s Manual page 31 ASCII code 67 decimal Streaming mode CANCEL This is a software function that has no on screen button equivalent See description of command character D below for details on streaming D ASCII code 68 decimal Streaming mode ENABLE This is a software function that has no button equivalent Streaming mode causes a continuous flow of data to be sent by the HBLT during test operation See the description of the colon response code for details on the data packets G ASCII code 71 decimal GO button Tester will behave as if the on screen GO button had been pressed The GO button in question is the button that appears on screen after initial power up of the HBLT K ASCII code 75 decimal OK button Tester will behave as if the on screen OK button had been pressed If a test is not in progress or the OK button is not currently being displayed this command is ignored 1 lower case ASCII code 108 decimal Lot number string Tester will behave as if a string were typed in response to the lot number request Type up to 14 characters followed by a carriage return or linefeed This command must follow the r command o lower case ASCII code 111 decimal Operator string id Tester will behave as if a string were typed in response to the operator id request Type up to 14 characters followed by a
45. imit xxx in PSI is unknown to the software This can also be caused by improper option settings or setup Contact Crescent Design for assistance in solving this problem Both the intake limit switch and the exhaust limit switch are on at the same time Contact Crescent Design for assistance in solving this problem An internal software error xxx was detected Contact Crescent Design for assistance in solving this problem page 50 Appendix Alert Messages The HBLT displays Alert messages to inform the operator of recoverable program error conditions and recoverable machine error states After reading the message press the OK button to continue operation Each Alert message described below includes the full alert text a description of the cause and resolution of the alert and the location s of the alert call for customer support reference only Alert IMPORT TIMEOUT No data was received in the time allowed Location PDBASE C import process The HBLT displays this alert message when the import test text fails to arrive within 3 minutes if initiating the import The long time allows the user to begin the export process from another HBLT After closing the alert message begin a new import attempt without distractions Alert A fill timeout has occurred Please call for service Location FILL C HillStateError The HBLT displays this alert message when the fill operation times out without encounter
46. imum Test Pressure default 500 0 34 03 34 47 3447 Leak Rate minimum per second Leak Rate maximum per second 4 7 5 4 34 Leak Rate default per second 3 Up Burst Rate minimum per second 1001 0 68 0 69 Up Burst Rate maximum per second 500 0 3447 Up Burst Rate default per second 172 Down Burst Rate minimum per second 10 0 0 68 0 69 Down Burst Rate maximum per second 500 0 34 03 34 47 3447 Down Burst Rate default per second 0 00 00 0 00 Leak Dip minimum 21 Leak Dip maximum 500 0 3447 Leak Dip default 00 0 00 0 00 See the notes at the end of this appendix HBLT User s Manual page 39 aars moa aano sam wa Up Ramp Rate minimum persecond 10 07 07 69 Up Ramp Rate default 250 Down Ramp Rate minimum per second 1 7 Down Ramp Rate maximum per second 500 34 5 3447 1724 0 34 8 6895 0 689 0 0 Down Ramp Rate default 250 17 0 17 2 Initial Pressure minimum 5 0 3 1 7 03 Initial Pressure maximum 1000 68 9 Initial Pressure default Target Pressure minimum 69 Target Pressure maximum 1000 Target Pressure default 250 Return Pressure minimum Return Pressure maximum 1000 Return Pressure default oo oof ol Increment Pressure minimum step 1 Increment Pressure maximum step 1000 Increment Pressure default 25 Maximum Test Pressure minimum 5 Maximum Test Pressure maximum 1000 6895 Maximum Test Pressure default 500 340 3
47. imum per second 125 0 8 51 862 Down Ramp Rate default 125 0 8 51 862 Initial Pressure minimum 1 0 0 07 7 Initial Pressure maximum 17 01 1724 250 0 Initial Pressure default 1 70 25 0 Target Pressure minimum 2 5 Target Pressure maximum Target Pressure default Return Pressure minimum Return Pressure maximum Return Pressure default 0 0 0 00 0 00 0 Increment Pressure minimum step Increment Pressure maximum step Increment Pressure default 1001 0 68 0691 69 Maximum Test Pressure minimum Maximum Test Pressure maximum 250 0 17 01 17 24 1724 Maximum Test Pressure default 250 0 17 01 17 24 1724 Leak Rate minimum per second Leak Rate maximum per second 34 Leak Rate default per second Up Burst Rate minimum per second Up Burst Rate maximum per second 250 0 1724 Up Burst Rate default per second 172 Down Burst Rate minimum per second 3 Down Burst Rate maximum per second 250 0 17 01 17 24 1724 Down Burst Rate default per second 00 0 00 0 00 Leak Dip minimum Leak Dip maximum 1724 Leak Dip default 00 000 0 00 See the notes at the end of this appendix 7 5 34 34 4 21 HBLT User s Manual page 38 500 Parameters Psi BAR Retur Pressure default 00 000 0001000 Increment Pressure default 1001 0 68 0 691 69 Maximum Test Pressure minimum 3 Maximum Test Pressure maximum 500 0 34 03 34 47 3447 Max
48. ing a limit switch The timeout value varies depending on the cylinder volume If this alert repeats contact Crescent Design Inc for service Either the HBLT needs adjustment or there is a faulty component Alert A purge timeout has occurred Please call for service Location PURGE gt StateSystemPurge The HBLT displays this alert message when the purge operation times out without encountering a limit switch The timeout value varies depending on the cylinder volume If this alert repeats contact Crescent Design Inc for service Either the HBLT needs adjustment or there is a faulty component HBLT User s Manual page 51 Alert An intake timeout has occurred Please call for service Location DO TEST C refill cylinder The HBLT displays this alert message when the refill operation times out without encountering a limit switch The timeout value varies depending on the cylinder volume If this alert repeats contact Crescent Design Inc for service Either the HBLT needs adjustment or there is a faulty component Alert At intake limit Check for leaks Locations DOTEST C sent at intake message The HBLT displays this alert message when the intake limit switch turns on during a test This can occur if the product leaks is very compliant is compliant and large The cylinder does not have enough volume If the product leaked during an up ramp try lowering the burst rate parameter to detect the leak If the
49. installation to the HBLT and that the reservoir contains clean distilled water Then select either single cycle purge or continuous purge by touching the button to the left of the desired mode Touch the OK button If you select continuous purge the HBLT displays a text screen that shows exhaust or intake status There is a STOP button to exit continuous purging If you select single cycle purge a graphic display guides you through the purging process Use the syringe and follow the instructions on the HBLT display The use of the syringe is the best method for removing trapped bubbles from the system Be sure and pull a hard vacuum when directed by the display The last option is volume correction This option directs the HBLT to calibrate itself to remove the HBLT internal compliance when reporting total or incremental volume to Pressure Manager Using this option replaces the default volume correction table Use this option only when using the Pressure Manager Protocol Calibrate and purge the HBLT prior to volume calibration If you select Volume Correction the HBLT displays a text screen prompting you to close the outlet with a steel not plastic plug Press the OK button to continue or the ESC button to cancel Pressing OK opens a status screen that displays the current pressure and goal pressure Wait until the HBLT displays the finished message and then press the ESC button Pressing the ESC button during the volume calibration lea
50. ived within three minutes the Import screen will automatically time out returns to a menu Once a test has been successfully imported a button appears on screen that enables you to Quick Start it This button appears with the language Run Process MYPROC where is the name of the test recently received Exporting a Test Select Export a test from the Test Editing Menu Touch the menu button next to the name of the test you d like to export The data for that test is automatically sent out the serial port in ASCII form The data is formatted to be intelligible by another HBLT instrument and may not be obvious to the operator It is possible to use a terminal program to record exported tests edit and later upload them into HBLT using ASCII data transfer Any unacceptable settings will be brought to your attention as well as related error messages should an imported test have problems Changing the engineering password Tests and other Engineering Menu items may be protected with a password When a password is applied access is restricted To enter or change a password press the Change password button on the Edit Test Information screen off the Engineering Menu If an existing password is in place you must enter the previous password before proceeding If you choose to change the password you must enter it twice the second time for confirmation If the confirming entry matches the initial entry the new pas
51. l modes Pliant Product Flexible tubing or other plastic products that will stretch or grow under pressure before failure Example vinyl tubing Pressure Manager Optional PC compatible Windows software that allows you to edit store recall print and run complex HBLT tests that may take several hundred steps Pressure Manager is an integrated editing and testing application that makes the HBLT act as a slave to the PC Pressure Increment This is the amount of additional pressure added to the Target Pressure of the previous cycle to obtain the Target Pressure for the next cycle This is used in Staircase and Incremental modes see the section on Pressurization Modes Pressure Units The HBLT works with four different engineering units Pounds per Square Inch PSI atmospheres kilopascals KPA and bars BAR Pressure units are selected when a test is defined and apply to almost all data displayed or printed by that test including via remote control Once pressure units have been selected they cannot be changed when editing a test Purge The process of emptying air out of fluid pathways There is an option on the Main Menu to perform this function Also see Fill Purge speed The rate at which water is pumped through the outlet during the Purge function This is one of the System Configuration settings in the Engineering Menu Ramp Rate This is the rate at which the HBLT achieves pressure expressed in Pressure Uni
52. ll parameters have been entered Once a test has been created a button appears on screen that enables you to Quick Start it This button appears with the language Run Process where is the name of the test recently created HBLT User s Manual page 26 Editing an Existing Test Select Edit test information from the Engineering menu Note that all test settings except for the Type of test its name and the Pressure Units may be edited Select Edit on the Test Editing Menu Touch the menu button next to the name of the test to be changed Press OK Each of the settings beginning with Product ID will be presented just as when entering a new test You may change any of these Simply touch the OK button on screens that do not require changes The new values are automatically saved after the last screen has been optionally edited If any settings change the HBLT will ask what to do with these changes You may choose to save the changes into the original test updating it save the edited test under a new name or discard the changes Once a test has been edited a button appears on screen to enable the Quick Start function This button appears with the language Run Process MYPROC where is the name of the test recently edited delete Deleting a Test Select Edit test information from the Engineering menu Select Delete on the Test Editing Menu
53. mum Pressure Up Rate The speed at which pressure is applied during a test cycle This is expressed in terms of Pressure Units per second See also Down Rate Ramp Rate Vacuum Any state of negative pressure typically a small number of Pressure Units below Zero severe vacuum many Pressure Units below zero usually cannot be achieved by the HBLT Pressurization Modes or Types of Tests Linear Ramp Linear Ramp P R E 5 5 U R E Continuously increasing pressure is applied to a product until it reaches its Target Pressure then stays at that pressure for the Dwell Time or until a burst or leak is detected HBLT User s Manual page 22 Staircase Slaircase m zu c o ornzu Pressure increases to programmed Target Pressure and remains for the Dwell Time If no burst or leak occurs pressure is then increased by the Pressure Increment amount The test continues until a burst or leak is detected or until Maximum Pressure is achieved Fatigue P R E 5 5 U R E The Fatigue mode repeats a single defined pressurization cycle Pressure increases to a programmed Target Pressure Product will remain at pressure for the specified Dwell Time and then de pressurized to the Return Pressure This repeats for the Repeat Cycles defined for the test HBLT User s Manual page 23 Incremental Incremental m 290 c o ormzu Pressure increases to programmed Target Pressure and stays there for the specified Dwell
54. nd so on Arrow Buttons When entering numeric values a right pointing arrow button appears When entering alphanumeric information a left pointing arrow button appears These are backspace keys used to erase the last digit or character just entered SPACE The SPACE button inserts a blank space when typing in alphanumeric information 1 test name product ID operator name and so forth CLEAR The CLEAR button erases all alphanumeric information entered on a given screen or sets a numeric entry to zero OK The OK button acts as an enter key accepting the presently displayed setting Compliance Setting When defining a test a prompt appears asking for product compliance offering choices from 1 Rigid Product to 10 Rubbery Product Controlled pressurization requires special tuning in order to achieve goals accurately The means by which pressure is achieved when a product stretches under pressure differs from when a product does not stretch Valves usually are tested best at a Compliance Setting of 1 Rigid Catheters at 2 Firm Tubing at 3 Pliant bags at 4 Stretchy and latex at 5 10 Rubbery Certain products may be manufactured to be less compliant than their component materials may suggest Irradiated plastics usually increase in rigidity decrease in compliance for example Highly compliant products those best fit for settings 4 through 10 consume large volumes of water before showing
55. nough to accommodate the CPS characters per second that are output during streaming mode See Appendix A for details From the Configuration Menu touch the on screen menu button next to the words Set the baud rate Eight rates are shown in bits per second Touch the menu button next to the rate required to change the current baud rate Touch the ESC button to return to the previous menu without changing the baud rate Maintain beep option This option selects whether or not a beep is generated when the Maintain Pressure Time ends see below It is useful to cue operators on when to take a measurement after pressure has been applied to a product for a certain amount of time HBLT User s Manual page 11 Page eject option If you want a page eject command to be sent after printed reports select this option It is handy for cut sheet printers like lasers and inkjets Ejects apply to test summaries as well as process program printouts Purge exhaust speed The Main Menu contains an option for purging Purging is the process of pumping water through a product and whatever interconnected tubing with the goal of removing any air that may be trapped inside The purge exhaust speed option allows you to specify at what rate water will be pumped out the exhaust when purging Some products have a very small passage for fluid and others have relatively large passages Use lower purging speeds for small passage devices Use higher purging sp
56. pressure is incorrect calibration Always insure the HBLT is correctly calibrated HBLT User s Manual page 30 Appendix A Serial Remote Control Serial Remote Control is an option found on the second page of the Configuration Menu Enable remote control and Select Remote Output When set to YES this option will permit remote operation of the tester as if an operator were pressing buttons on its touch screen The baud rate at which remote operations commence is whatever rate is set in the Configuration Menu page 6 Set the baud rate Available baud rates are 300 600 1200 2400 4800 9600 19200 or 38400 Selecting a test The tester s Main Menu offers an option for Run a test An operator must use the touch screen to choose this option enter their Operator ID and Lot Code information and then select the test to run After selecting a test the screen shows test information and the operator must press OK to confirm the test selection See also the remote command code for a remote control method of selecting tests Remote Control Features The main test screen which shows BURST LEAK TESTER READY at the top may be controlled either by an operator or by characters coming in the serial channel The following describe characters and their function NOTE In the descriptions below cr stands for an ASCII carriage return code 13 decimal If stands for an ASCII linefeed code 10 decimal Examples in quotes
57. r Initial Pressure This is the first and lowest target programmed pressure the HBLT will achieve during a test Leak Dip This is the pressure drop in absolute pressure from the end of the maintain portion of the dwell cycle A leak dip will be reported during the Dwell Time of test when the Dwell Time exceeds the Maintain Time Leak Dips during this period are defined as an absolute pressure drop See also Burst Rate and Leak Rate Leak Rate This is the pressure drop rate for leak detection expressed in Pressure Units per second A leak will be reported during the Dwell Time of a test when the Dwell Time exceeds the Maintain Time Leaks during this period are defined as pressure drops at a rate that equals or exceeds the Leak Rate See also Burst Rate Maintain Time This is a period of time seconds during the Dwell Time when the HBLT actively maintains the Target Pressure in the product under test This means that any pressure drops that occur due to compliance or small leaks will be compensated for by further HBLT User s Manual page 20 pressurization Maintain Time begins concurrently with Dwell Time Bursts may be detected during the Maintain Time but leaks are not Maintain Time may be set anywhere from Zero which cancels any pressure maintenance to the total amount of Dwell Time which cancels leak detection Maximum Pressure The highest pressure achieved via two or more cycles in a test such as the Staircase or Incrementa
58. ram and verify properly The system will automatically progress to another status message if subsequent retries fail HBLT User s Manual page 48 Appendix F Troubleshooting If the HBLT will not operate when the power switch is turned on the most likely fault is the line cord pulling out of the wall plug or the IEC receptacle on the back of the machine If the machine still won t work check the fuse To gain access to it remove the line cord from the back of the machine and pry out the fuse carrier below it There are two fuses a two amp fuse for use in 230 volt locations and a four amp fuse for use with 115 volts Both are 5 x 20 millimeter SLO BLO types Do not use an ordinary fast acting fuse as the start up surge will blow it within a few power cycles WARNING When replacing the fuse carrier observe the markings to be certain you are installing it for the correct line voltage Below are shown a list of messages displayed by the HBLT under conditions in which operation is interrupted These messages are displayed on a special screen indicating ERROR ERROR ERROR at the top and bottom In some circumstances mentioned below you must take steps to correct the fault condition turn the HBLT off and then on again If you have successfully corrected the error condition you will be allowed to proceed Pressure limit exceeded The hydraulic pressure exceeded operational limits Remove pressure from the system manually
59. ration settings do not take effect until the next complete calibration Set Calibration Warning This option opens the Calibration Warning screen Use this screen to select the number of warning days before the calibration expires Press the Set Warning days button to enter the number of warning days The value must be between 1 and 1 less than the expiration days The HBLT warns you if the number entered is out of range In addition the expiration days must be non zero in order to set the warning days After setting the warning days select one of the warning actions The warning actions are Warn at Power On Warn Before Testing or No Warning Remember that the waning settings do not take effect until the next complete calibration Print Calibration Report This function prints the current calibration expiration and warning information along with the pressure transducer scale and offset values to the printer port parallel port After each calibration HBLT User s Manual page 10 print this report and file it in a safe place A history of the scale and offset values changes can give an indication of how frequently calibrations should be done Skip Calibration This function allows the user to skip an initial calibration to perform another function such as purge The HBLT will not allow test execution or remote tests or scripts until the HBLT is calibrated If the current calibration is valid the HBLT leaves the setting as they were If
60. remove pressure during the Ramp Down part of a testing cycle The speed is expressed in terms of Pressure Units per second Dwell Time This is the maximum amount of time in seconds for which an item under test will be pressurized at the Target Pressure Dwell Time begins when the Target Pressure is first attained Dwell Time includes within it the Maintain Time Fast Ramp This is pressurization method that can be applied to any test type intended to maximize pressurization stress at the cost of target pressure achievement accuracy The hydraulic pressurizing system runs at maximum possible speed throughout most of the upward pressurization cycle Fill Speed This is the rate at which water is pumped into a product before a test begins Each test contains its own fill speed specified in terms of cubic centimeters per second Select from 4 00 to 01 cc sec in 01 cc sec increments for 1000 PSI or less HBLTs Select from 2 00 to 0 1 cc sec in 01 cc sec increments for 2000 PSI or greater HBLTSs When this is enabled for a particular test e g reads some value other than NO FILL water is pumped through the outlet at this rate until a back pressure of 8 PSI is achieved then the test waits to begin its programmed pressure cycle s Firm Product A part made from plastic or other material which will expand very slightly under pressure before failure Examples certain balloon catheters junctions fittings HBLT Hydraulic Burst and Leak Teste
61. rt appears contact Crescent Design Inc for service Alert There are no more free test memories You must delete one Location PDBASE C save process The HBLT displays this alert message when the operator attempts to save a new test when there is no Undefined test position To save the test the operator must first cancel the current operation Then select and delete a test Finally perform the original operation again Alert Warning Pressure is too low Check outlet Location CALIB C StateCalibration The HBLT displays this alert message when the applied pressure at the outlet is too low After closing the alert message apply more pressure and complete calibration Alert Warning Pressure at outlet is too low Location CALIB C StateCalibration The HBLT displays this alert message when the pressure at the open outlet is too low The transducer may be faulty If this alert message persists contact Crescent Design Inc for service Alert Warning You must press an arrow to complete calibration Location CALIB C StateCalibration The HBLT displays this alert message when the user presses OK without first pressing an arrow button i e bypassing calibration After closing the alert message correctly calibrate the HBLT before pressing the OK button HBLT User s Manual page 60 Alert You can t select an undefined test Please try another Location PDBASE C select process
62. s outside of valid bounds Contact your metrology group vendor to recalibrate the HBLT If the problem persists after calibration contact Crescent Design Inc for service Alert The cylinder is out of water Check for leaks or a starved inlet Locations DOTEST C sent at exhaust message The HBLT displays this alert message when the exhaust limit switch turns on during a test This can occur if the product leaks is very compliant is compliant and large The cylinder does not have enough volume If the product leaked during an up ramp try lowering the burst rate parameter to detect the leak If the compliance is a problem try constraining the product to limit its compliance If the HBLT itself is leaking contact Crescent Design Inc for service HBLT User s Manual page 58 Alert The import file has no process type and will not be saved Location PDBASE C gt import process The HBLT displays this alert message when an imported test does not contain a TESTTYPE record or that record is invalid If the transfer is between HBLT s check the serial connections and try again If the transfer is between a PC and HBLT verify that the text file on the HBLT contains the TESTTYPE record and that the record is correctly formatted If this problem persists contact Crescent Design Inc for service Alert The imported test has no name and will not be saved Location PDBASE C import process The HBLT displays this
63. s the HBLT to make clicking sounds and can repeat several times before pressure equalizes Compliant products in particular cause a lot of burping when starting a test because of their elastic nature Burst Rate This is the pressure drop rate expressed in Pressure Units per second A burst will be reported during Ramp Up or Dwell Time and optionally during Ramp Down when pressure drops at a rate that equals or exceeds this Burst Rate Burst Rates must be higher than the Leak Rate specified for the same test There are two burst rates The first up burst rate is active during ramp up and during maintain dwell The second down burst rate is active during ramp down and bottom maintain Compliance This is tendency of a product some plastics and rubber mostly to stretch or grow under pressure Compliant products seem to be leaking whereas in reality they are HBLT User s Manual page 19 growing to accommodate larger volume of water Long Maintain Times are recommended for testing compliant products as well as generous Leak Rate settings Typically compliant products can only be practically tested for burst conditions Cycle A Cycle is a pressurization and corresponding de pressurization of an item under test Cycle Repeat This is the number of times the HBLT will repeat a cycle with its specific programmed Target and Return Pressures before proceeding to the next programmed Target Pressure Down Rate The HBLT uses this speed to
64. sanssucsasesecsucsatesessuesancsuesueeaeene 29 MOTOR STALLED oF OVERPBESSURE 2 EE A E EET T I LU APPENDIX SERIAL REMOTE CONTROOL ccccssscsscsssssssssosscssssssscssssossessssoscessscossessesesssssssessossssssees 31 SELECTING A TES e eddie Ae et a d e ERAS 31 REMOTE CONTROL FEATURES cccscssecsssssessuessccsscsecsscsucseccsecsucsaccsscsuessucescsusssussuceasssecsucsatssesuessecsscsetsaseene 31 RESPONSE CODES ccssecsscsssssuessecsscsecsocssucssccueesucsuccescsucsssssucsuccssesucsasessssuessucssesursanssucsasesecsuesatescsuessectucsueeaeeese 33 APPENDIX MODEL PARAMETERS ccccssssssssssssssscescssscssscosscssesssscscssossessssoscessssosssssscesssssssessosssossees 36 E elie ene ete E sett i E 43 APPENDIX C SPECIAL NOTE ABOUT RAMP RATES cccssssssssssscssssosscssssoscossssessssssscsssssssessscssssees 44 APPENDIX D OPTION JUMPERS ei sis coe esee boe ec aene esa Le ten reae un des Feb pao os ee eee ce Eve 45 APPENDIX E DOWNLOADING 4 aereo dep ree eo aeri eie eroe vh e aeo e eo es Se tro EP ae pP eese eS Yan sep Qs eU pde eC NER eS ain REO 46 DOWNLOAD STATUS MESSAGES ertet ttt 46 HBLT User s Manual A AUS Si ZEE Character timeout GH 54 Osa Download aboried sr e sas a aa ar a a
65. ssnssssssssessssssssnsessssesessssssssessssssssesesessesessessnsssossssssnsesessssessessnssessssssssssnsevecs 15 HBLT User s Manual page 2 uU eh erm 15 SELECT OUTPUT FORMAT eere esten nen ta tanen snnt totes es ananas to ton tonta esas nens tanen enses 16 SELECTING AND RUNNING TEST eese eee tenen to tona ssa toes sessios sisosiso sesono 17 TEST DEFINITION AND MANAGEMIENT eese eee te tenen ennt testata an ansa ento tanen sse tenen esas nena tanen enses 19 DEFINITION OF TERMS tive PRESSURIZATION MODES OR TYPES OF TESTS Linear Ramp Fatigue Incremental DELETING A FEST tht c RR ERRUR NUR Or USt UR AATE PRINTING ASDEST Mi DE peo Mel at LA IMPORTING A TEST EXPORTING A TEST CHANGING THE ENGINEERING PASSWORD ertet ttt tette tet oess 28 PREVENTIVE MAINTENANG E ce eue eon bea epo eL ea boe ae DUREE ELSE E PED Pa De re Use Up 29 TOUCH SCREEN cccssssecsocsssssossoescesssessescossssessesosenessssvesacsessucssesessscsssesossavssassvesanssussssesesassassaesnesnessecsveesseens 29 WATER FILTER RM 29 FAULT CONDITIONS Qua Cera ste eese evt ETE URN EUR 29 OVERTEMPERATURE csccscsseessessccsucssessucssccusssucsuccesesucsusssucsusssecsuceascesesussecesesus
66. sword mode Alert Confirming entry did not match initial entry Try again Location PASSWORD C gt new password The HBLT displays this alert message when entering the confirmation to a new password After closing the alert panel enter the correct password Alert Each test must have a unique name Please enter one Location PDBASE C gt new process The HBLT displays this alert message when saving a new test After closing the alert message select a new unique test name to complete the save test operation Alert Enable the dual password option first Location CALIB C StateCalibFunctions The HBLT displays this alert message when the operator attempts to set the calibration password before enabling the dual password option on the engineering configuration screen Alert Import data had errors and therefor cannot be saved Location PDBASE C import process The HBLT displays this alert message when an import error occurs If the transfer is between two HBLT s insure both HBLT s are the same version If the transfer 1s between an HBLT and Pressure Manager insure that the HBLT version is 1 81 or later If the transfer is between an HBLT and a PC check the text file on the PC for correctness If this problem persists contact Crescent Design Inc for service HBLT User s Manual page 54 Alert IMPORT ERROR PRESSUNIT lt val gt PSI ATM KPA BAR Location PDBASE C gt valid The HBLT displ
67. sword will take effect and further attempts to access certain functions will require passwords When entering the password the HBLT displays asterisks instead of the entered characters This feature helps secure the password HBLT User s Manual page 28 To disable password go to Change Password and enter a blank password by pressing Clear then OK Confirm this and the password will be deleted The calibration function is now protected by its own password Read the section on calibration for instructions on setting that password Preventive Maintenance Except for the touch screen display no special external cleaning of the HBLT instrument is necessary If general cleaning is needed use a damp cloth to clean the exterior surfaces Touch Screen It is important that only a soft damp cloth be used to clean the touch screen on the HBLT Nothing sharp or potentially abrasive should be used Do not use paper towels to clean the screen as they can be abrasive to the touch screen surface Water Filter The water filter should be replaced every 3 months Follow these steps to change out the water filter 1 Remove the power cord from the back of the HBLT Remove the eight screws that hold the cover on Carefully remove the cover of the instrument Locate the water filter Clamps in the center of the hydraulic subassembly hold it down Release the hose clamps Remove the hose from the filter and replace the filter with a new
68. t cr gt where XXX is the current pressure in test units YYY the peak pressure in test units and ZZ Z is the time in tenths of seconds into the current step ASCII code 58 decimal streaming data report This character is followed by a sequence of digits as many as four representing current pressure including a preceding minus sign if appropriate a comma and another sequence of digits as many as five again with preceding minus if appropriate representing the number of steps the actuator took since the last sampling period then a carriage return The pressure will be in the type of engineering units specified for the test Example data responses would be without quotes 50 5 cr and 5 100 lt gt ASCII code 63 decimal remote test name rejected This character is followed by the test name up to 10 characters long and lt lf gt lt cr gt sequence This is always in response to a remote command followed by a test name that does not match any in memory Since test names are punctuation case and space sensitive common errors can be having an unintentional space or other character follow command or in sending lower case test name when most all tests contain no lower case ASCII code 66 decimal maintain cycle starting This character is transmitted before any applicable pressure maintenance during a test The HBLT does not emit this character when streaming mode is active AS
69. t point Adjust the setting using the on screen up and down arrows located on the center of the screen The arrows move the onscreen value toward the pressure gage value The small arrows are for fine adjustments and the large arrows for coarse adjustments Press the on screen OK button to complete the calibration or ESC to abandon it If performing the calibration for the first time first calibrate at a pressure 2096 below the HBLT maximum to set an approximate calibration This prevents the HBLT from detecting an overpressure condition and entering a fatal error condition state Then do the final calibration When calibration is complete new offset and span values are saved in non volatile memory The HBLT uses these critical values to correct the raw pressure from the transducer to the corrected pressure These values will be in force until the next calibration is performed Set Calibration Expiration This option opens the Calibration Expiration screen Use this screen to select the number of days for the calibration to expire The options are 30 days 91 days 183 days 365 days custom or none The Next Screen button uses the currently defined days and changes to the When Calibration Expires screen After selecting the days option the HBLT prompts for the action to perform when the calibration expires The action options are Alert at Power On Alert Before Testing Do Not Allow Testing or Take No action Remember that the expi
70. ta including the lack of data Several attempts have been made to recover and retry without success Usually an button appears on screen After pressing OK the download will start over from the beginning Download succeeded The application has been received initialized and is about to be launched The application s main greeting screen should appear almost instantly Erasing database The application has been received and the end of data message was correct The application is being invoked with the express purpose of erasing any process database information left over from the previous version This is done because process data structure differs from version to version The system will automatically progress to another status message Erasing unused EEPROM The download process received all application data without error Unused memory locations are being erased for safety The system should progress beyond this step in a matter of seconds Last block err The end of data message was formatted improperly The system will automatically progress to another status message almost instantly NO APPLICATION PRESENT This message indicates that the application memory contains no data or whatever data it once contained lost integrity You must begin running the download program on a PC compatible before the HBLT can function Receiving data Application data is presently being received and programmed When things are fun
71. temPurge The HBLT displays this alert message when the pressure is too high This usually means that the outlet is blocked capped or the operator did not pull the syringe soon enough Insure the outlet is clear and attempt the purge again Alert That number exceeds a maximum of lt val gt Please re enter Location UTILS C gt edit_numeric The HBLT displays this alert message when entering a test parameter After closing the alert message enter a value within the bounds HBLT User s Manual page 57 Alert That number is below a minimum of val Please re enter Location UTILS C edit numeric The HBLT displays this alert message when entering a test parameter After closing the alert message enter a value within the bounds Alert That password is incorrect Please try again Location PASSWORD C gt get password The HBLT displays this alert message when the password the user enters is incorrect After closing the alert message enter the correct password Alert That test name is already used Please select another one Location PDBASE C new process The HBLT displays this alert message when selecting a test name for a new test After closing the alert message select a new unique name Alert The Calibration values are not reliable Please recalibrate Location BLTMAIN C gt hblt The HBLT displays this alert message during initialization when it finds calibration value
72. tible computer systems can be used to edit store recall print and run complex tests of several hundred steps The HBLT may therefore run as a slave to a PC compatible system or stand alone switching back and forth between these modes Leaks detected by the HBLT are defined in terms of drop in pressure over 1 second or by absolute drop in pressure from the end of maintain Bursts also known as ruptures are essentially dramatic rapid leaks In order to detect these hydraulic faults the HBLT checks for pressure drops every one tenth 0 1 second This manual contains complete instructions for setting up and using the HBLT SAFETY NOTICE This safety notice summarizes information basic to the safe operation of the equipment described in this manual The international symbols displayed on the below are a reminder that all safety instructions should be read and understood before installation operation maintenance or repair of this instrument is attempted When you see the symbol on other pages pay special attention to the safety information presented Observance of safety precautions and the instructions for proper instrument operation will also help to avoid actions that could damage or adversely affect the performance of the instrument Other symbols may also be displayed on the equipment These are reproduced and described under CONVENTIONS below Safety During Installation and or Maintenance Any servicing of the equipment that
73. tion CALIB C StateCalibWarning The HBLT displays this alert message when the user selects warn at power on or warn before test options without first setting the warning days After closing the alert message set the calibration warning days before selecting the warning location Alert Cannot build volume correction table unless HBLT is calibrated Location PURGE C wait to purge The HBLT displays this alert message when the user selects Volume Correction from the purge type selection screen The HBLT is not properly calibrated First calibrate the HBLT Then build the volume correction table Alert Check Sum Error Select another test Location ENGR C gt StateBrowseTests The HBLT displays this alert message when the user selects a test that has a checksum error If this alert persists contact Crescent Design Inc for service Alert Check Sum Error Will continue delete Location PDBASE C gt delete_process The HBLT displays this alert message when the check sums do not match while deleting a test If this alert persists contact Crescent Design Inc for service HBLT User s Manual page 53 Alert Clear the calibration password before changing this option Location CONFIG C gt make dual password choice The HBLT displays this alert message while changing from dual password to single password mode The user must clear the calibration password before the HBLT allows the change to single pas
74. to continue There are now two methods of applying pressure to the HBLT The first is the conventional method of attaching a pressure source to the outlet and using the arrows on the screen to match the HBLT reading to the pressure source The second is the new method of using the HBLT to provide the pressure source for calibration To use the first method attach a calibrated pressure source to the output port of the HBLT This source should be capable of generating precise pressures near to the top of the HBLT s range Apply pressure and adjust the displayed pressure on the HBLT screen so it matches your calibrated pressure source Adjust the setting using the on screen up and down arrows located on the center of the screen The small arrows are for fine adjustments and the large arrows for coarse adjustments Press the on screen OK button to complete the calibration or ESC to abandon it HBLT User s Manual page 9 Note that pressurizing the outlet to more than 596 of maximum pressure disables set point buttons To use the second method attach a pressure gage to the HBLT outlet Press the up arrow on the left of the screen and wait until the pressure matches the set point The set points start at 3090 of maximum pressure and increments by 1090 of maximum pressure for each up arrow press The HBLT truncates the set points in an attempt to match dial gage scales Do this repeatedly until the pressure reaches the desired calibration se
75. tom maintain paused by operator Z Last record of test 2 Sequence number of data followed by a comma This also corresponds to the time frequency count 3 Current Pressure followed by a comma 4 Peak Pressure followed by a comma 5 One of four volume options followed by a comma If this option is selected the operator has a choice of encoder counts from start of test encoder counts since last data item volume in milliliters since beginning of test or volume in milliliters since last data item The last delimiter of the items selected is replaced by a single carriage return The rate of data output is also selectable Choices are 100 50 20 10 5 2 1 samples per second If the CPS characters per second based on characters to be sent and the serial port baud rate is such that overrun is likely to occur a warning window is displayed HBLT User s Manual page 16 During streaming operation the HBLT suspends burst and leak reporting until the end of the run This allows simpler data cleanup when data is imported into spreadsheet programs The user has the option of including a headings record This allows headings for charts and tables in spreadsheets To get to the screens do the following steps l Touch the Engineering menu button on the main menu 2 Touch System configuration button on engineering menu 3 Touch PAGE button to get second page of system configuration menu 4 5 Touch Select remote ou
76. tput button on second page of system configuration menu You are now at the Output Format Menu The first five options are the fields in order of appearance that may be selected A YES or NO button is displayed depending upon the current state of that field To change a state touch the corresponding button A confirming message with a YES NO response is displayed Make your choice The volume field is a special case If this field is selected another menu appears so that you may choose volume units of encoder count total encoder count increment volume in milliliters total or volume in milliliters increment Touch the button next to the units desired A YES NO window appears to confirm When you have selected the units you want touch the ESC button to return to previous menu Touch PAGE to view the second page of the Output Format menu Here you may select the data rate or optional column headings Touch the button for Set the data rate and a new screen appears with the values of 100 50 20 10 5 2 or 1 Touch one of the rates to select Touch the Output column heading button to select column headings A YES NO window confirms your choice Only headings for the columns you requested on page one are output Selecting and Running a Test Run a test is the second option shown on the Main Menu This will permit you to recall previously specified test profiles and run them Test results will be sent to the printer if attached On s
77. ts per second There are two ramp rates specified in a given test These are called Up Rate and Down Rate Ramp Down The part of a cycle in which pressure decreases Also see Up Rate Ramp Up The part of a cycle in which pressure increases Also see Down Rate Ramp Rate Repeat Cycle A test setting that controls how many times a particular cycle will repeat until the next step Return Pressure This is the programmed pressure that the HBLT will depressurize to at the end of a given cycle This may be set to VACUUM or other negative pressures See the parameter tables for the lowest pressure Rigid Product Metal or stiff plastic parts undergoing hydraulic testing Such parts virtually never stretch under pressure only fracture Examples are end caps and valves HBLT User s Manual page 21 Rubbery Product Products that easily inflate when pressurized and can conform to enormous increases in hydraulic volume before failure Large volume vinyl and latex products fall into this category Stretchy Product Flexible products that stretch significantly when undergoing pressure Large volume vinyl products bags may fall into this category Target Pressure This is the programmed pressure that the HBLT will achieve during a given cycle Total Cycles This is the computed total number of pressurization de pressurization cycles performed during a test taking into account Repeat Cycles and how many steps may be required to achieve Maxi
78. use the quotes to delimit the message the quote characters themselves are not part of any message ESC ASCII code 27 decimal Return to main menu Once the main menu is displayed no further serial input is accepted until an operator selects another test as described above If a test is already in progress or there is no ESC button currently being displayed this command is ignored T ASCII code 42 decimal HBLT RESET command This command cancels a test during the fill operation or the test execution The HBLT returns to the main menu after resetting 2 ASCII code 63 decimal status query During most test states this command causes the tester to echo back a message formatted like XXX Y YY lt cr gt where XXX is the current pressure reading in applicable test units and Y Y Y the peak pressure reading again in test units Example 20 200 lt cr gt and 1130 1200 lt cr gt This command is ignored when in streaming mode See description of command character D below for details on streaming ASCII code 33 decimal status query During most test states this command causes the tester to echo back a message formatted like Y YY ZZZ Z cr where XXX is the current pressure reading in applicable test units YY Y the peak pressure reading again in test units and ZZZ Z is the time in tenths of seconds into the current step Example 20 200 2 2 lt cr gt and 1130 1200 3 1 lt cr gt This command is ignored w
79. ves the HBLT with the default volume correction table To check the calibration run Pressure Manager and execute a ramp test that ramps up slowly to the maximum psi and back down to zero Make sure the volume is set to Volume Total The resulting volume trace blue line should appear flat with a variation less that 0 1 cc The trace may not be flat near zero psi and maximum psi due to lash in the HBLT hardware Touch the DONE button when you are finished purging the machine Do not allow air to be pushed or pulled into the machine HBLT User s Manual page 15 Select Output Format This menu allows the operator to select the items and data rate that the HBLT sends out the serial port during remote operation with streaming mode enabled There are five options for items transmitted Machine state followed by a colon The states are op R Refill state after a burst or leak is resumed U Ramp up Ramp up paused by operator M Maintain m Maintain paused by operator W Dwell w Dwell paused by operator D Ramp down d Ramp down paused by operator L Last ramp down 1 Last ramp down paused by operator 1 Burst during ramp up 2 Burst during maintain or dwell 3 Leak during dwell 4 Leak dip during dwell 5 Burst during ramp down 6 Burst during last ramp down 7 Burst during bottom maintain B Bottom maintain b Bot
80. y the initial pressure setting 1 This value is lower bounded by the initial pressure setting This value is lower bounded by the leak rate setting 15 PSI 208 Items with gray backgrounds bounded the limit of their data types These values are lower than the maximum HBLT User s Manual page 43 Appendix C Special note about ramp rates Under certain conditions the HBLT may not be able to make a pressure jump at the requested ramp rate This typically occurs when small jumps are requested particularly at low pressures An example would be going from zero to 25 PSI at 250 PSI per second Theoretically this should take 1 10 of a second In practice the motor has to begin decelerating almost as soon as it starts accelerating To manage this the HBLT program applies rules to bound the actual rates used internally to achievable values This is generally invisible to a user It is important to realize that what the HBLT does is attempt to accelerate to the operating ramp rate and then decelerate to zero speed at the target pressure As a result the time to achieve a given pressure will not be the pressure change divided by the ramp rate It will always be a longer time The smaller the pressure jump the greater the exaggeration will be HBLT User s Manual page 44 Appendix D Option jumpers On the main circuit board containing the HBLT electronics and logic are six option jumpers that define what model pressure and

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