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HBLT Software Version 2.01

1. NOTE After arrows are pushed it is normal for both values to change on the external gauge and the HBLT screen Allow values to settle before making an additional adjustment The arrows on the left side of screen labeled SET will dim as pressure is being adjusted These buttons will not be used for this method of calibration HBLT User s Manual Page 75 Copyright Crescent Design Inc 2004 4 Press OK when reading between the UP and DOWN arrow buttons on the right side of the screen matches the external pressure gauge Press ESC to abandon calibration without making any changes Touch here once when center screen reading matches external gauge Figure 13 NOTE Pressurizing the outlet to more than 5 of the HBLT s maximum pressure disables the set point arrow buttons When calibration 1s complete new zero and span values are saved in memory The HBLT uses these critical values to correct the output from the pressure transducer to the corrected pressure These values will remain in force until the next calibration 1s performed HBLT User s Manual Page 76 Copyright Crescent Design Inc 2004 Using The HBLT As The Pressure Source for Calibration Crescent Design s HBLT is capable of generating its own pressure in order to pressurize the machine for calibration To use this method attach a calibrated pressure gage to the external pressure outlet of the HBLT NOTE Pressure set points star
2. The HBLT displays this alert message when the password the user enters is incorrect After closing the alert message enter the correct password That test name is already used Please select another one Location PDBASE C gt 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 The Calibration values are not reliable Please recalibrate Location BLTMAIN C gt init hblt The HBLT displays this alert message during initialization when it finds calibration values 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 1s 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 1s leaking contact Crescent Design Inc for service HBLT User s Manual Page 60 Copyright Crescent Design Inc 2004 Alert The import file has
3. 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 Page 40 Copyright Crescent Design Inc 2004 500 PSI Model Parameters Up Ramp Rate minimum per second Up Ramp Rate maximum per second Up Ramp Rate default Down Ramp Rate minimum per second 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 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 defau
4. To test each channel press the touch panel button repeatedly The first press turns on the channel select LED The second press turns off the channel select LED and turns on the channel under test LED The third press turns off the channel under test LED and turn on the channel done LED The fourth press turns off the channel done LED and turns on the valve which makes a click sound The fifth press turns off the valve and leaves all LEDs off To test each output port toggle each input on off The HBLT toggles the corresponding output on off in sync with the input Purging the Smart Manifold Purging the Smart Manifold is very similar to purging the HBLT When starting the purge the HBLT selects the far right channel This allows the most complete purge of the manifold Press the other channel buttons during the exhaust strokes to purge each channel Each internal valve and the outlet plumbing need purging Use a syringe to assist the purge This is more important on the Smart Manifold than the HBLT The manifold and valves increase the surface area and number of crevices that hold onto bubbles with surface tension The syringe vacuum enlarges the bubbles allowing the purge flow to dislodge and sweep the bubbles out of the Smart Manifold Calibration with the Smart Manifold Calibrating the Smart Manifold is similar to calibrating the HBLT When starting the calibration the HBLT select the far left channel Perform the calibration as
5. or NO All 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 enough 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 10 Copyright Crescent Design Inc 2004 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 Ej
6. A ait DESIGN Hydraulic Burst Leak Tester Owner s Manual Software Version 2 01 Released April 12 2004 Crescent Design Inc 9932 Mesa Rim Road Suite B San Diego CA 92121 Voice 858 452 3240 FAX 858 452 3241 rescent abac com www crescentdesign com Revision April 12 2004 Copyright Crescent Design Inc 2004 Table of Contents HBLT User s Manual Page 1 Copyright Crescent Design Inc 2004 HBLT User s Manual Page 2 Copyright Crescent Design Inc 2004 HBLT User s Manual Page 3 Copyright Crescent Design Inc 2004 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 compatible 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 switch
7. 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 1s 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 Maximum Pressure Up Rate The speed at which pressure 1s 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 A 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 S S 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 24 Copyright Crescent Design Inc 2004 Staircase Staircase mzucooc Iz Pressure increases to programmed Target Pressure and remains for the Dwell Time If no burst or leak occurs pressure 1s 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 S S U R E The Fatigue mode repeats a single defined p
8. button when you are finished purging the machine Do not allow air to be pushed or pulled into the machine 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 1 Machine state followed by a colon The states are R Refill state after a burst or leak is resumed U Ramp up u 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 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 Bottom maintain paused by operator cP RP ODPORB Rg oR Se me pe op HBLT User s Manual Page 16 Copyright Crescent Design Inc 2004 u Z Lastrecord of test Sequence number of data followed by a comma This also corresponds to the time frequency count Current Pressure followed by a comma Peak Pressure followed by a comma One of four volume options followed by a comma If this option 1s selected the operator has a choice of encoder counts from start of test encoder counts since last data it
9. respectively test completed no errors This response code is followed immediately by XXX YYY lt cr gt where XXX 1s 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 lt cr gt 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 a leak occurs However during streaming data mode the message 1s displayed after the test completes HBLT User s Manual Page 37 Copyright Crescent Design Inc 2004 DZ 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 the HBLT clears this condition ASCII code 70 decimal waiting for start button This character 1s 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 M
10. XXX YYY lt cr gt where XXX is the current pressure reading in applicable test units and YYY the peak pressure reading again in test units Example 20 200 lt cr gt and 1130 1200 lt cr gt This command is 1gnored when in streaming mode See description of command character D below for details on streaming HBLT User s Manual Page 33 Copyright Crescent Design Inc 2004 ASCII code 33 decimal status query During most test states this command causes the tester to echo back a message formatted like XXX YYY ZZZ Z lt cr gt where XXX is the current pressure reading in applicable test units YYY the peak pressure reading again in test units and ZZZ Z 1s the time 1n 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 when in streaming mode See description of command character D below for details on streaming C ASCII code 67 decimal Streaming mode CANCEL This 1s 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 1s a software function that has no on screen 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
11. 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 When enabling dual passwords the HBLT initially copies the engineering password to the calibration password Then the operator can navigate to the calibration 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 Smart Manifold mode select This option appears if there is a Smart Manifold attached to the HBLT Use this option to change the Smart Manifold mode to single sequential or parallel The default mode is single See Appendix H for fur
12. 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 1s essential select a streaming data rate below 100 that does not cause this alert message HBLT User s Manual Page 61 Copyright Crescent Design Inc 2004 Alert The test record contains an unknown test type Location DOTEST C gt 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 alert appears contact Crescent Design Inc for service Alert There are no more free test memories You must delete one Location PDBASE C gt 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 gt 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 CALI
13. described previously in this manual Purge the Smart Manifold completely before calibration Excessive trapped air can cause failure to calibrate when using the self pressurization method Volume Correction with the Smart Manifold Volume correction with a Smart Manifold attached is similar to the HBLT volume correction method The HBLT turns off all channels while performing the volume correction HBLT User s Manual Page 65 Copyright Crescent Design Inc 2004 Purge the Smart Manifold completely before running the volume correction Trapped air can affect the volume correction results Selecting Smart Manifold Mode The Smart Manifold has three modes of operation The first is single port mode The operator can select any single port to test The second 1s sequential port mode The operator selects one or more ports to test The HBLT conducts the test on each port from left to right The third mode Is parallel port mode The HBLT conducts the test on all selected ports To select the desired mode follow these instructions 1 From the Main menu press the Engineering menu button Then press the System configuration button Then press the Page button twice 2 3 4 Then press the Expander mode select button 5 Press the button that corresponds to the desired mode 6 Finally Press the ESC button repeatedly until back at the Main Menu Smart Manifold Operation To test product with the Smart Manifold follow these
14. in PSI 1s unknown to the software This can also be caused by improper option settings or setup Contact Crescent Design for assistance in solving this problem Invalid exhaust intake limits Error code Zxxx 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 HBLT User s Manual assistance in solving this problem Page 51 Copyright Crescent Design Inc 2004 Appendix G 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 gt 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 Loca
15. instructions 1 Make sure the HBLT is at the Main menu 2 Attach product to the ports 3 Press the button for each channel with product attached 4 Press the Run a test button on the HBLT screen Follow normal test start operations 5 Press the Start button If the Smart Manifold 1s set to single mode the HBLT performs the test and then stops Find the test results on the screen and the printer If the Smart Manifold 1s set to sequential mode the HBLT performs the test on each port from left to right Find the test results on the printer and by pressing the results button on the final test screen If the Smart Manifold is set to parallel mode the HBLT performs the test on all selected ports If there are no errors the test completes If there are errors the HBLT searches for the ports with burst product The test done LED flashes on burst ports The HBLT then finishes the test on the remaining ports Find the test results on the printer and by pressing the results button on the final test screen HBLT User s Manual Page 66 Copyright Crescent Design Inc 2004 Once exiting the last test screen the HBLT clears the results We highly recommend using a printer to save test results Smart Manifold Errors Alert Manifold not on Turn on manifold power Location MULTPORT C gt multi port background The HBLT displays this alert message when the Smart Manifold interface reports that the expander 1s attached but no
16. level operating surface where the height of the touch screen display is convenient for an operator The HBLT operates HBLT User s Manual Page 6 Copyright Crescent Design Inc 2004 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 to expose the unit to temperatures much outside this range Connect power AN The operating voltage on the HBLT is selectable between two voltage ranges It is 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 power cord provided The HBLT consumes a maximum of 400 Watts and operates on any AC frequency between 47 to 63 Hz Connect fluid A quick disconnect fitting with a built in shutoff valve 1s 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 AN IMPORTANT Do not connect the HBLT to any kind of pressurized water source Use a clean distilled water source only Connect the
17. 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 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 1s 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 HBLT User s Manual Page 7 Copyright Crescent Design Inc 2004 Prepare the machine AN The HBLT 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
18. 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 HBLT User s Manual Page 11 Copyright Crescent Design Inc 2004 Enable remote control When this option is set to YES special characters received on the serial channel obeying whatever baud 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 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 D
19. 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 causes the HBLT to make clicking sounds and can repeat several times before pressure equalizes Compliant products in particular can 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 growing In size to accommodate a 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 HBLT User s Manual
20. than the maximum HBLT User s Manual Page 44 Copyright Crescent Design Inc 2004 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 45 Copyright Crescent Design Inc 2004 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 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
21. the greeting screen with the Crescent Design logo the software versions kernel and application and maximum pressure for your particular machine Press the on screen GO to proceed to the main menu Main Menu This screen allows the user to go to the purging screen perform a test or access the engineering menu screen The 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 1s 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 1s now password protected by its own password This choice was previous protected by use of the engineering password This change HBLT User s Manual Page 8 Copyright Crescent Design Inc 2004 allows both engineers and calibration staff to have protected access to their respective areas while protecting the other area Perform Calibration See Appendix I for calibration procedures Set Calibration Expiration This option opens the Calibration Expiration screen Use
22. 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 1s overheating The motor that generates hydraulic pressure has overheated Turn off the machine and contact Crescent Design for assistance HBLT User s Manual Page 50 Copyright Crescent Design Inc 2004 Motor stalled Five seconds elapsed without any motor motion Check for proper connection of the encoder connector Switch off the HBLT and after a few moments switch on again and retry Contact Crescent Design for assistance 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 Can t configure machine Option switches or internal setup is incorrect Contact Crescent Design for assistance in solving this problem Ver mismatch x xx y yy The Kernel version y yy is incompatible with the Application version x xx Contact Crescent Design for assistance in solving this problem Transducer not installed The pressure transducer 1s disconnected or malfunctioning Contact Crescent Design for assistance in solving this problem Unknown press config xxx The pressure limit xxx
23. to the pressure displayed between the UP and DOWN arrows on the right side of the screen PRESSURE SENSOR CALIBRATION ject the outlet to a gage Compare the pressure on external pressure gauge to this reading Set buttons not used for this method Figure 11 3 Use the UP and DOWN arrows on the right side of the screen to match the pressure source setting Use the large arrows for coarse adjustments and the small arrows for fine adjustments HBLT User s Manual Page 74 Copyright Crescent Design Inc 2004 PRESSURE SENSOR CALIBRATION Finished adjusting pressure Please continue Touch large arrows for coarse adjustments and small arrows for fine adjustments set I50 0 PSI 150 5 PSI E Figure 12 e Ifthe value on external gauge is higher than that shown on the center of the screen press the UP arrows on the right side of the screen to increase the HBLT value until it agrees with the calibrated gauge For example If external gauge reads 1002 PSI and HBLT screen value reads 1000 push UP arrow until both values agree If the external gauge reads 998 PSI and the HBLT screen value reads 1000 push DOWN arrow until both values agree e Calibration is acceptable when the reading on the right side of the HBLT screen agrees with the calibrated gauge within the specified accuracy limits of your specific model See accuracy limits under Specifications
24. try again If the transfer 1s 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 init hblt 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 PURGE C gt StateSystemPurge 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 Alert That number is below a minimum 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 59 Copyright Crescent Design Inc 2004 Alert Alert Alert That password is incorrect Please try again Location PASSWORD C gt get password
25. using the HBLT itself as the pressure source to achieve the pressure needed for calibration It is now possible to protect calibration with its own password It was previously protected by use of the engineering password If selected this change allows both engineers and calibration staff to have protected access to their respective areas while guarding the other area HBLT Front View HYDRAULIC BURST LEAK TESTER MODEL 1000 PRESSURE OUTLET INLET Distilled Water Only Figure 1 Prior to performing calibration please review the following sections of the HBLT user s manual e Set Calibration Expiration e Set Calibration Warning This is necessary because performing the initial calibration calculates the expiration date and the warning date HBLT User s Manual Page 68 Copyright Crescent Design Inc 2004 Pr Initial Calibration Attention Proper initial calibration is important If performing the calibration for the first time calibrate at a pressure 2096 below the HBLT maximum to set an approximate calibration then do the final calibration This prevents the HBLT from detecting an overpressure condition and entering a fatal error condition state Calibration Screen general layout LARGE amp SMALL ARROWS to adjust pressure PRESSURE SENSOR CALIBRATION Finished adjusting press Please contin SET HBLT GENERATED PRESSURE ESCAPE BUTTON Figure 2
26. B C gt 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 gt 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 62 Copyright Crescent Design Inc 2004 Alert You can t select an undefined test Please try another Location PDBASE C gt select process 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 gt 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 gt 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 ente
27. Manual Page 46 Copyright Crescent Design Inc 2004 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 1t 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 for record address This displays hexadecimal numbers that count up as the application data comes into the system At the bottom of the screen
28. Page 21 Copyright Crescent Design Inc 2004 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 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 HBLTs When this 1s 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 1s achieved t
29. _ PRESSURE READING TOUCH OK WHEN CALBRATON IS COMPLETE Perform Calibration This choice comes up automatically when the HBLT is powered on for the first time and also may be accessed by completing the following steps Tf performing initial calibration see above section entitled Initial Calibration HBLT User s Manual Page 69 Copyright Crescent Design Inc 2004 1 Turn On Power push the toggle switch located on the back of the machine exterior right to the Up position Figure 3 2 Touch the GO button on the Crescent Design screen Touch here once Figure 4 3 Touch the Engineering menu button on the MAIN MENU screen HYDRAULIC BURST LERK TES Touch here once Figure 5 HBLT User s Manual Page 70 Copyright Crescent Design Inc 2004 4 Touch the Perform calibration button on the ENGINEERING MENU screen Touch here once Figure 6 5 Touch the Perform calibration button on the CALIBRATION Screen Touch here once Figure 7 HBLT User s Manual Page 71 Copyright Crescent Design Inc 2004 To perform calibration complete the following steps 6 Choose the appropriate pressure units PSI Atmospheres KiloPascals or Bars Figure 8 7 As the next screen prompts open the pressure outlet to the atmosphere by removing any attachments The pressure outlet is lo
30. aintain pressure time setting 1s zero this character 1s 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 ASCII code 93 decimal ends a quoted text string when transmitting redirected parallel port output out the serial port ASCII code 126 decimal quotes a single character when transmitting redirected parallel port output out the serial port HBLT User s Manual Page 38 Copyright Crescent Design Inc 2004 Appendix B Model Parameters 100 PSI Model Parameters PSI Up Ramp Rate minimum per second Up Ramp Rate maximum per second Up Ramp Rate default Down Ramp Rate minimum per second 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 Increment Pressure minimum step Increment Pressure maximum step Increment Pressure default Maximum Test Pressure minimum Maximum Test Pressure max
31. allel port output back to original port Z 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 HBLT User s Manual Page 35 Copyright Crescent Design Inc 2004 DA ASCII code 61 decimal status report responding to remote query This response code is followed immediately by XXX YYY lt cr gt where XXX 1s 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 YYY ZZ Z lt 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
32. and ZZZ 1s the time elapsed since the pressure started ramping up in the current cycle Example DB360 500 4 2 cr 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 1s followed immediately by XXX YYY ZZZ lt cr gt where XXX is the burst pressure in test units YYY the peak pressure in test units and ZZZ 1s the time elapsed since the pressure started ramping down in the current cycle Example DC360 500 4 2 cr 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 1s displayed after the test completes ASCII codes 68 and 68 decimal respectively test aborted leak dip condition This response code is followed immediately by XXX YYY ZZZ lt cr gt where XXX is the leak pressure in test units YYY the peak pressure in test units and ZZZ 1s the time elapsed since the pressure started ramping up in the current cycle Example DD360 500 4 2 cr 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
33. are the same version If the transfer 1s between an HBLT and Pressure Manager insure that the HBLT version 1s 1 81 or later If the transfer 1s 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 Invalid Calibration Please Recalibrate Location BLTMAIN C gt init hblt The HBLT displays this alert message at initialization Calibrate the HBLT before running tests Alert Invalid Calibration Please Recalibrate Aborting the test Location DOTEST C gt 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 Alert HBLT Invalid test type aborting to main menu Location DOTEST C gt 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 User s Manual Page 58 Copyright Crescent Design Inc 2004 Alert No pressure unit was present so the test will not be saved Location PDBASE C 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
34. 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 Incremental 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 1s 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 ATM 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
35. 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 1f 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 1s ignored l 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 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 HBLT User s Manual Page 34 Copyright Crescent Design Inc 2004 r lower case ASCII code 114 decimal execute process command The lower case r 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
36. cated on the exterior of the machine in the front lower left corner alt N Remove attachment here Figure 9 HBLT User s Manual Page 72 Copyright Crescent Design Inc 2004 8 Press OK to continue To abandon calibration without making any changes press ESC PRESSURE SENSOR CALIBRATIOH Open the outlet to the atmosphere then press UK Touch here after removing attachment NOTE There are two methods of applying pressure to the HBLT The first method of calibration is the conventional method of attaching a pressure source and calibrated gauge to the external pressure outlet and applying pressure The second method utilizes the HBLT as its own source of pressure for calibration For detailed directions refer to the following sections e Using An External Pressure Source and Calibrated Gauge e Using the HBLT as the Pressure Source for Calibration Using An External Pressure Source And Calibrated Gauge HBLT User s Manual Page 73 Copyright Crescent Design Inc 2004 To use this method attach a pressure source and calibrated gauge to the external pressure outlet of the HBLT The source should be capable of generating pressures near to the top of the HBLT s range Then complete the following steps 1 Apply pressure using the external pressure source and calibrated gauge Apply pressure here 2 Compare the pressure registered on the external pressure gauge
37. 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 1s to either press the on screen STOP button or to open the safety door assuming that a safety door switch 1s enabled After the test 1s 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 a
38. e 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 and 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 e 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 1s achieved when a product stretches under pressure differs from when a product does n
39. ears 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 Calibration warning days not defined Set days first Location CALIB C gt StateCalibWarning 0 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 gt 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 HBLT 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 User s Manual Page 54 Copyright Crescent Design Inc 2004 Alert 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 Clear the calibratio
40. ects 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 outlet port 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 speed 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 drawn 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
41. een allows you to test all the buttons on the HBLT s touch sensitive front panel The screen 1s 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 1s 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 Smart Manifold tests This option appears only if there is a Smart Manifold attached See Appendix H for instructions on using this diagnostic 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 any software updates See Appendix E for more on downloading HBLT User s Manual Page 14 Copyright Crescent Design Inc 2004 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 sett
42. em volume in milliliters since beginning of test or volume in milliliters since last data item The HBLT removes the last comma on the string 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 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 1 2 3 Touch the Engineering menu button on the main menu Touch System configuration button on engineering menu Touch PAGE button to get second page of system configuration menu Touch Select remote output 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
43. ent Design Inc 2004 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 Specifications Operating Temperature Range 59 104 F 15 40 C Humidity Range 35 85 RH Non Condensing Dimensions H x W x D 6 34 x 20 7 8 x 17 24 17cm x 53cm x 45cm Weight 65 Ib 29 5 kg Power 105 130V 2A 50 60HZ 210 260V 1A 50 60HZ Environmental Conditions Installation Category Overvoltage Category II Pollution Degree 2 Maximum Operating Altitude 6560 feet 2000 meters Maximum Deliverable Pressure Model Maximum Pressure Volume Accuracy Resolution 25 PSI 1 7 ATM 1 7 BARS 172 KPA 0 5 PSI 0 01 PSI 100 PSI 6 8 ATM 9 BARS 689 KPA 0 5 PSI 0 1 PSI 500 PSI 34 ATM 34 BARS 3447 KPA 2 PSI 0 5 PSI 1000 1000 PSI 68 ATM 69 BARS 6895 KPA 4 PSI 1 PSI 2000 2000 PSI 136 ATM 138 BARS 13790 KPA 8 PSI 1 PSI 250 PSI 17 ATM 17 BARS 1724 KPA 1 PSI 0 1 PSI Machine setup AN Perform the following steps before using the HBLT Read all steps before starting The HBLT is a heavy instrument so keep in mind that wherever it 1s set up should be a permanent location Remove from carton AN Carefully remove the HBLT from its packing carton It contains electronic and mechanical components that can break if dropped Set it on a
44. heir 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 received 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 Test MYPROC where MYPROC 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
45. hen 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 Tester 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 HBLT User s Manual Page 22 Copyright Crescent Design Inc 2004 or small leaks will be compensated for by further pressurization Maintain Time begins concurrently with Dwell Time Bursts may
46. imum 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 Page 39 Copyright Crescent Design Inc 2004 250 PSI Model Parameters Up Ramp Rate minimum per second Up Ramp Rate maximum per second Up Ramp Rate default Down Ramp Rate minimum per second 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 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
47. ing 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 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 requires removal of any covers can expose parts that involve the risk of electric shock or personal injury Make HBLT User s Manual Page 4 Copyright Crescent Design Inc 2004 sure that the power
48. ings Browse Tests This function allows the operator to select and view a test s 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 1s 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 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 fo
49. llow 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 HBLT User s Manual Page 15 Copyright Crescent Design Inc 2004 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 leaves 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
50. 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 rMY TEST lt cr gt The r command resets the operator id string and lot number string to null Use the 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 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 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 Y ASCII code 89 decimal redirect parallel port output to serial port Used by Pressure Manager to redirect reports to the Windows application y ASCII code 121 decimal restores par
51. lt See the notes at the end of this appendix HBLT User s Manual Page 41 Copyright Crescent Design Inc 2004 1000 PSI Model Parameters Up Ramp Rate minimum per second Up Ramp Rate maximum per second Up Ramp Rate default Down Ramp Rate minimum per second 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 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 See the notes at the end of this appendix HBLT User s Manual Page 42 Copyright Crescent Design Inc 2004 2000 PSI Model Parameters Up Ramp Rate minimum per second Up Ramp Rate maxim
52. 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 HBLT User s Manual Page 17 Copyright Crescent Design Inc 2004 6 Touch PAGE to view the second page of the Output Format menu Here you may select the data rate or optional column headings 7 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 8 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 screen 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 Mai
53. n 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 password 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 HBLT Enable the dual password option first Location CALIB C gt 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 User s Manual Page 55 Copyright Crescent Design Inc 2004 Alert Import data had errors and therefor cannot be saved Location PDBASE C gt 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 a
54. n HBLT and Pressure Manager insure that the HBLT version 1s 1 81 or later If the transfer 1s 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 IMPORT ERROR PRESSUNIT lt val gt PSI ATM KPA BAR Location PDBASE C gt valid The HBLT displays 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 val 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 HBLT User s Manual Page 56 Copyright Crescent Design Inc 2004 Alert IMPORT ERROR var 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 tw
55. n Menu The next prompt asks for Operator Name This 1s 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 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 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 HBLT User s Manual Page 18 Copyright Crescent Design Inc 2004 the atmosphere Compliant products 1n particular can
56. n 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 r 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 lf stands for an ASCII linefeed code 10 decimal Examples in quotes 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 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 ASCII code 63 decimal status query During most test states this command causes the tester to echo back a message formatted like
57. nd 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 HBLT Version 2 01 Kernel 1 40 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 If a burst or leak occurs time elapsed burst cycle number burst pressure and maximum pressure attained If the engineering option Print the test settings is set to Yes the HBLT prints the test settings between the version line and test name line 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 tests with or without a printer connected HBLT User s Manual Page 19 Copyright Crescent Design Inc 2004 If there is a Smart Manifold attached the following line appears below each set of results gt gt gt gt The above results are for port lt lt lt lt There may be multiple lines for a set of results See Appendix H for more information about Smart Manifold operation HBLT User s Manual Page 20 Copyright Crescent Design Inc 2004 Test Definition and Management Definition of Terms Maintain pressure time Dwell time Pressure increment P R E S S U R E Initial
58. nect the HBLT outlet to the Smart Manifold inlet using the provided tubing set 4 Connect the communications cable between the HBLT and the Smart Manifold The DB15 end connects to the HBLT expander connector found on the HBLT back panel The RJ45 connect plugs into a receptacle on the Smart Manifold rear panel 5 Connect the power cord to the HBLT 6 Connect the power supply to the Smart Manifold The power plugs into J1 You should see the green LED on the back panel light indicating power connected You should also see the orange LED light on the upper right corner of the front panel 7 Turn on the HBLT On the first screen verify that the version is 2 00 or greater and that the kernel version is 1 40 or greater Verify that the blue LED indicating correct communications is lighted 8 Press GO Then press Engineering menu Then press System configuration Then press the page button twice Make sure that one of the options is Expander mode select If not there is a communications problem HBLT User s Manual Page 64 Copyright Crescent Design Inc 2004 9 Attach a printer to the HBLT The HBLT prints the test results on the printer Diagnostics The Smart Manifold diagnostics allows the operator to check for correct expander operation Form the Main Menu press Engineering menu Then press System configuration Then press the Page button once Then press the Diagnostics button Finally press the Expander tests button
59. 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 1s between a PC and HBLT verify that the text file on the HBLT contains the TESTTYPE record and that the record 1s 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 gt import process The HBLT displays this 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 1s 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 CheckCPS0 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
60. nt 1s 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 1s 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 gt init hblt BLTMAIN C gt CheckCalibExpiration The HBLT 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 53 Copyright Crescent Design Inc 2004 Alert Alert Calibration expires in 99 days Schedule recalibration now Locations BLTMAIN C init hblt BLTMAIN C gt CheckCalibExpiration The HBLT displays this alert message when the warning period defined by the calibration occurs This 1s only a warning The HBLT will function after closing the alert panel Contact your metrology group vendor to schedule calibration This message app
61. o HBLT s insure that both HBLT s have the same application version If the transfer is 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 problem persists contact Crescent Design Inc for service 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 HBLT IMPORT ERROR lt var gt lt value gt lt var gt min lt val gt max Location PDBASE C gt import process gt withinLimits The HBLT 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 User s Manual Page 57 Copyright Crescent Design Inc 2004 Alert 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 1s between two HBLT s insure both HBLT s
62. 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 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 1s 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 Men
63. 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 Units 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 HBLT User s Manual Page 23 Copyright Crescent Design Inc 2004 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 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
64. ot 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 HBLT User s Manual Page 27 Copyright Crescent Design Inc 2004 Highly compliant products those best fit for settings 4 through 10 consume large volumes of water before showing 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 1t since the actual weight of water inflating the product can apply much more than eight PSI to its sides seams etc 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 Fast 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
65. ownramp 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 correct 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 HBLT User s Manual Page 12 Copyright Crescent Design Inc 2004 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
66. pplication 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 HBLT User s Manual Page 48 Copyright Crescent Design Inc 2004 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 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 program and verify properly The system will automatically progress to another sta
67. r a new unique test name Alert You must define expiration days before warning days Location CALIB C gt StateCalibWarning 0 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 63 Copyright Crescent Design Inc 2004 Appendix H Smart Manifold Introduction The Smart Manifold 1s an expander that allows testing of up to ten products at a time The HBLT communicates with the Smart Manifold and conducts tests singly sequentially or in parallel The Smart Manifold has ten channels available on the front panel Each channel consists of a touch panel button a channel select LED a channel under test LED a channel results LED an outlet fitting and a valve located inside the expander The Smart Manifold also has eight digital inputs and eight digital outputs The Pressure Manager Protocol version 1 23 has commands to read and write to these outputs Installation The Smart Manifold design allows the HBLT to stack on top the Smart Manifold This saves space on the work area To install the Smart Manifold follow these instructions 1 Place the smart manifold on the work surface 2 Place the HBLT on top of the Smart Manifold aligning the HBLT feet with the pads on top of the Smart Manifold 3 Con
68. ressurization 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 25 Copyright Crescent Design Inc 2004 Incremental Incremental mzucooiIagu Pressure increases to programmed Target Pressure and stays there for the specified Dwell 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 1s achieved Custom Custom P R E S S U R E This 1s a custom pressurization profile It works like Incremental mode except that each successive Target Pressure 1s 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 26 Copyright Crescent Design Inc 2004 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 ar
69. s 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 2 Remove the eight screws that hold the cover on 3 Carefully remove the cover of the instrument 4 Locate the water filter Clamps in the center of the hydraulic subassembly hold it down 5 Release the hose clamps HBLT User s Manual Page 31 Copyright Crescent Design Inc 2004 6 Remove the hose from the filter and replace the filter with a new one 7 Replace the hose clamps 8 Replace the cover 9 Attach the power cord 10 Turn on the instrument and purge it thoroughly Fault conditions Internal fans 1n 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 electronics get too hot In order to clear an over temperature error you must turn off the HBLT and turn it back on again Motor Stalled The HBLT automatically adjus
70. ser s Manual Page 78 Copyright Crescent Design Inc 2004 e Calibration is acceptable when the reading on the HBLT screen agrees with the calibrated gauge within the specified accuracy limits of your specific model See accuracy limits under specifications 3 Press OK when pressure has been finely adjusted to match the set pressure reading on the calibrated gauge indicating that calibration is complete OR press ESC to abandon calibration without making any changes Touch once here when satisfied with calibration Figure 17 NOTE After arrows are pushed it is normal for both values to change on the external gauge and the HBLT screen Allow values to settle before making an additional adjustment When calibration 1s complete new zero and span values are saved in memory The HBLT uses these critical values to correct the output from the pressure transducer to the corrected pressure These values will remain in force until the next calibration 1s performed HBLT User s Manual Page 79
71. sually an OK button appears on screen After pressing OK the download will start over from the beginning Download succeeded The application has been received initialized and 1s 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 1s 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 1n 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 1t 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 functioning smoothly the new application will be ready to run in a matter of minutes Receiving last block The a
72. switch 1s turned off and the instrument 1s 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 1s properly wired and earth grounded 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 1s associated with a safety alert symbol These symbols are found in the manual and inside the instrument The definition of these symbols 1s described below General Warning Caution Refer to the instruction for details on specific danger Caution Electrical Shock Hazard Caution The HBLT should be used for the purpose and in the manner described in this manual N Caution Hot Surface If you use the HBLT in a manner other than that for which it was intended unpredictable behavior could ensue with possibly hazardous consequences HBLT User s Manual Page 5 Copyright Cresc
73. t at 3096 of the maximum pressure and increase or decrease in increments of 1096 of maximum pressure of your HBLT for each touch of an Up or Down arrow button For example Calibrating HBLT Model 1000 The first press of the UP set arrow button raises the pressure to 300 PSI The second press raises it to 400 PSI 1 Press the UP arrow on the left side of screen and wait as the machine generates its own pressure to match the set point Do this repeatedly until the pressure reaches the desired calibration set point Touch UP PRESSURE SENSOR CALIBRATIOH or DOWN Connect the outlet to a gage arrows r calibrated pressure source until 3 desired set pressure is displayed 0 0 PS we 7 Figure 14 HBLT User s Manual Page 77 Copyright Crescent Design Inc 2004 Please wait the arrows will dim while the HBLT adjusts pressure Arrows dim while HBLT adjusts Figure 15 2 Use the UP and DOWN arrows on the right side of the screen to adjust the setting Use the large arrows for coarse adjustments and the small arrows for fine adjustments Touch large arrows for coarse adjustments and small arrows for fine adjustments to match set point displayed at left Figure 16 e Ifthe value on external gauge is higher than that shown on the right side of the screen press the UP arrows to increase the HBLT value until it agrees with the calibrated gauge For example HBLT U
74. t powered Check the interface cable and power and then restart the HBLT Alert Bad manifold status Check the cable Check the power Location MULTPORT C gt multi port background The HBLT displays this alert message when the Smart Manifold interface reports that the expander is present but not attached to the expander or not powered Check the interface cable and power and then restart the HBLT Alert manifold error Check the cable Check the power Location MULTPORT C gt multi port background The HBLT displays this alert message when the Smart Manifold interface reports that the expander status changed during operation Check the interface cable and power and then restart the HBLT Alert There are no ports selected Locations DOTEST C get test name DOTEST C perform test DOTEST C wait to start ENGR C gt edit_menu The HBLT displays this alert message when an operation such as running a test requires the operator to first select ports and there are no ports selected Select at least one port and then close the alert message HBLT User s Manual Page 67 Copyright Crescent Design Inc 2004 Appendix I Calibration Procedure Calibration The HBLT requires a simple two point calibration which can be completed without opening the machine The user is guided through this cover on calibration process by following a series of onscreen prompts using an external pressure source or
75. t 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 1s calibrated If the current calibration HBLT User s Manual Page 9 Copyright Crescent Design Inc 2004 is valid the HBLT leaves the setting as they were If the current calibration 1s 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 1s 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 on screen buttons that read YES
76. ther information about the Smart Manifold Vacuum position select This option allows setting the piston position when a return pressure is less than zero psi When selected this option displays a screen that allows the operator to select the piston position from 1096 2096 3096 4096 5096 6096 70 80 90 or Legacy The percentages are a percentage of the full piston stroke The Legacy option sets the piston to 15 for return pressures ranging from less than Opsi to 5psi to 3096 for return pressures ranging from less than 5psi to 10psi to 45 for return pressures ranging from less than HBLT User s Manual Page 13 Copyright Crescent Design Inc 2004 10psi to 12psi This option affects fatigue tests incremental tests custom tests and scripts with pressure targets below zero The default vacuum selection is Legacy Use this option when a test errors with an Intake limit alarm This 1s more likely to occur when there is a Smart Manifold attached and the Smart Manifold mode is parallel Print the test settings This option directs the HBLT to print the test settings before the test results on the test results printed report The default value for this option is No Do not use this option when using Pressure Manager Pressure Manager already includes the test settings in its report Diagnostic Menu This menu allows you to perform diagnostics on the HBLT and analyze its performance Touch Screen Test This scr
77. 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 expiration 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 warning 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 prin
78. tion FILL C gt FillStateError The HBLT displays this alert message when the fill 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 1s a faulty component Alert A purge timeout has occurred Please call for service Location PURGE C 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 52 Copyright Crescent Design Inc 2004 Alert An intake timeout has occurred Please call for service Location DO TEST C gt 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 complia
79. ts 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 1s 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 overpressure is incorrect calibration Always insure the HBLT is correctly calibrated HBLT User s Manual Page 32 Copyright Crescent Design Inc 2004 Appendix A Serial Remote Control Serial Remote Control 1s 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 1s 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 Ru
80. tus message if subsequent retries fail HBLT User s Manual Page 49 Copyright Crescent Design Inc 2004 Appendix F Troubleshooting If the HBLT will not operate when the power switch 1s 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 AN 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 Message Explanation Pressure limit exceeded The hydraulic pressure exceeded operational limits Remove pressure from the system manually by venting
81. type of engineering units specified for the test Example data responses would be without quotes 50 5 cr and 5 100 lt crs ASCII code 63 decimal remote test name rejected This character 1s followed by the test name up to 10 characters long and a lt lf gt lt cr gt sequence This is always in response to a remote command r 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 the r command or in sending a 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 ASCII 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 HBLT User s Manual Page 36 Copyright Crescent Design Inc 2004 DB DC DD DK DL ASCII codes 68 and 66 decimal respectively test aborted up ramp burst condition This response code 1s followed immediately by XXX YYY ZZZ lt cr gt where XXX is the burst pressure in test units YYY the peak pressure in test units
82. u Select the type of test see definitions above HBLT User s Manual Page 28 Copyright Crescent Design Inc 2004 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 1s easy to go back and change values by Editing a test see below The test will be saved automatically when all 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 Test MYPROC where MYPROC is the name of the test recently created 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 an
83. um per second Up Ramp Rate default Down Ramp Rate minimum per second 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 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 See the notes at the end of this appendix HBLT User s Manual Page 43 Copyright Crescent Design Inc 2004 Notes This value is upper bounded by 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 QV ium Decet Items with gray backgrounds bounded the limit of their data types These values are lower
84. will be brought to your attention as well as related error messages should an imported test have problems HBLT User s Manual Page 30 Copyright Crescent Design Inc 2004 Changing the engineering password Tests and other Engineering Menu items may be protected with a password When a password is applied access 1s 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 password 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 To disable the 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 1s needed use a damp cloth to clean the exterior surfaces Touch Screen It i
85. 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 HBLT User s Manual Page 47 Copyright Crescent Design Inc 2004 Data CRC err The application data was received with improper formatting or checksum The system will automatically progress to another status message 1f correct data does not come in within a certain amount of time Download aborted The download process had too many problems in receiving data including the lack of data Several attempts have been made to recover and retry without success U
86. y settings change the HBLT will ask what to do with these changes You may choose to save the changes into the original test updating 1t 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 Test MYPROC where MYPROC is the name of the test recently edited Deleting a Test Select Edit test information from the Engineering menu Select Delete on the Test Editing Menu 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 delete Touch YES to confirm deletion of the test HBLT User s Manual Page 29 Copyright Crescent Design Inc 2004 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 Importing a Test This feature allows you to send information that defines a given test from one similar HBLT instrument to another Similar means identical pressure model and identical application Using a Crescent Design customized serial cable connect two HBLT instruments together via their serial ports located on t

HBLT Software Version 2.01

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