pti-126 vacuum tester manual v2-12-03 · 2020. 7. 10. · pti-126 vacuum –v2-12-03 [email protected]...

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Pti-126/2 Vacuum Leak Tester Standard Operating Procedure

Instruction Manual

Version: Pti-126-Vacuum V1/3-03 Packaging Technologies & Inspection 145 Main Street Tuckahoe, New York 10707 Phone: (914) 337-2005

(800) 532-1501 Fax: (914) 337-8519 Web Page: www.ptiusa.com E-mail: [email protected]

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Pti-126 Vacuum –V2-12-03 [email protected]

About PTI ....................................................................................................4 Customer & Technical Support ................................................................5

Pti-126 Vacuum Leak Tester Introduction .................................................. 6

Section 1: Technical Specifications & Feature Highlights ........................8 Overview & Principles of Operation.........................................................9

Section 2 : System Components ...............................................................10 Operator Display .....................................................................................10 PLC ...........................................................................................................11 Venting & Filling Valves ..........................................................................11 Venting Pressure Regulator ...................................................................12 Vacuum Transducers .............................................................................12 Tubing ......................................................................................................12 Main Air.....................................................................................................13 Test Station Heads ..................................................................................13 Container Present Sensors.....................................................................13 Reject Cylinder ........................................................................................14 Reserve Vacuum Tank and Pump ..........................................................14

Section 3: Initial Setup Instructions/Standard Operating Procedures ...15 Installation.......................................................................................... 15-16 Main Air ....................................................................................................16 Power Up ..................................................................................................16 Vacuum Pressure Switch ........................................................................17 Venting Pressure Regulator....................................................................18 Standard Operating Procedures - Startup/Shutdown/Lockout...... 19-23 Startup ......................................................................................................20 Shutdown .................................................................................................22 Lockout.....................................................................................................23

Section 4: Operator Display/Menu Screens........................................ 24-28 Menu Screens Quick Reference Chart ...................................................28

Section 5: Manual Test ......................................................................... 29-31

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Section 6: Settings Menu ..........................................................................32

Section 7: Fill Level/Cycle Time/Self-Teach LEARN .............................. 34 Fill Level ...................................................................................................34 Cycle Time .............................................................................................. 35 Self-Teach LEARN ............................................................................. 35-36

Section 8: Product Testing/Test Results/Reset Counters.......................37 Main Counters and Station Counters.....................................................37 Reset Counters ........................................................................................38 Test Results/Display Messages........................................................ 38-39

Section 9: Sensitivity/Change Learned Data ............................................40 Sensitivity Gauge.....................................................................................40 Change Learned Data ..............................................................................41

Section 10: Mechanical Adjustments .......................................................42 Test Station Height ................................................................................. 42 Distance Between Stations .................................................................... 43 Test Station Frame - Front to Back - Guide Rail Adjustments............ 44

Container Present Sensor.......................................................................45

Section 11: Troubleshooting................................................................ 47-49 Section 12: Safety and Maintenance .................................................. 50-52 Section 13: Spare Parts..............................................................................53 Section 14: Glossary .................................................................................54 Unit Conversion Tables...............................................................................56 Notes:............................................................................................................57 Appendix I: Vacuum Pressure Switch Instructions ........................... 58-60 Appendix II: Electrical Diagrams/Schematics ..........................................61

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Packaging Technologies & Inspection 145 Main Street

Tuckahoe, New York 10707 PTI is dedicated to manufacturing and delivering machinery of the highest quality, providing top performance, efficiency and reliability for your packaging and inspection needs. Our research and development is ongoing to insure that we offer the most efficient, economical solution for your specific requirements. The entire PTI staff is committed to providing the engineering support and service you need. PTI-126 Vacuum Leak Tester offers quick and easy system start-up. We’ve designed both the hardware and software so that you can easily customize operations for optimum productivity and testing accuracy. Please take a moment to review the Introduction that follows and become familiar with the many feature benefits this quality leak tester offers. Tony Stauffer Heinz Wolf President General Manager PTI develops, manufactures & distributes a wide range of high precision leak detection systems for containers, pouches, packages, components, vials, ampoules, medical devices, oil and fuel filters, offering real time quality & process control. PTI integrates machine vision systems, ultrasonic & label inspection systems. PTI is your source for:

• Precision Leak Detection Systems • Package/Container Inspection Systems • Engineering with in-house CAD Systems • Consulting Services for Package Inspection Technologies • Specialized Custom Engineered Systems • Distribution • Package Integrity Testing and Validation Services • Service & Parts (U.S. made)

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CUSTOMER & TECHNICAL SUPPORT Should you have any questions regarding the use of this leak tester, should any problems arise, or to obtain information about other products PTI offers, contact PTI at: Packaging Technologies & Inspection 145 Main Street Tuckahoe, New York 10707 Phone: (914) 337-2005 (Business Hours – 8:00am – 5:00pm (EST) (800) 532-1501 Fax: (914) 337-8519 E-mail: [email protected] ABOUT THIS MANUAL The reproduction, transmission or use of this document or its contents is not permitted without expressed written authority by Packaging, Technologies & Inspection (PTI). If you should have questions, find a discrepancy in this documentation or would like to suggest changes or additions to this manual, please contact us. Your comments are important to us and to future users as well. DISCLAIMER The information in this documentation has been carefully checked and is believed to be accurate and reliable. Furthermore, PTI reserves the right to make changes to any portion of this manual to improve reliability, function or design.

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PTI-126 VACUUM LEAK TESTER INTRODUCTION Highlights and Feature Benefits

• The industry’s first self-teach, self-adjusting vacuum leak detection system. Model Pti-126 Vacuum Leak Tester is designed for standard mounting onto a conveyor.

• Features PTI Self-Teach LEARN adaptive algorithm technology that

automatically sets reject/test criteria using good containers.

• PTI’s innovative software/hardware design enables quick changeover to different size and shape containers in minutes, requiring only two manual adjustments.

• User friendly - minimal skill level required to operate tester. Significantly

reduces operator training requirements by eliminating time consuming decision-making during set-up and operation.

• Increases production throughput while providing consistent and reliable

testing accuracy. Significantly reduces downtime.

• Utilizes high-resolution transducer technology with controlled test pressure to inspect containers precisely and reliably.

• Operator interface panel display for easy operation.

• Test results clearly displayed on operator interface display as each test is

completed.

• Easy Maintenance – color coded hoses and fittings for easy identification and quick, efficient maintenance.

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Please read each section of this instruction manual carefully to fully understand the functionality of this leak test system. Section 1: Technical Specifications, Feature Highlights & Principles of Operation Section 2: System Components – This section outlines the main system components and covers electrical and air connections. Section 3: Initial Setup Procedures & Standard Operating Procedures for Startup, Shutdown, Lock-Out – Covers basic instructions for setup of the tester with conveyor, compressed air and electrical hookup, setting date and time. Factory recommended Standard Operating Procedures for Machine Startup, Shutdown and Lock-Out.

Section 4: Operator Display Menu Screens – Covers each of the different menus featured on the operator display and a quick reference flow chart. Section 5: Manual Test - Covers the procedure to perform a manual test on Station 1 and Station 2 test heads. Section 6: Settings Menu – Explains the Settings Menu – this section is designated for supervisory personnel only. Section 7: Fill Level Setting/Cycle-Test Time and Self-Teach LEARN Procedure – Step-by-step procedures for setting Fill Level, Cycle/Test Time and Self-Teach LEARN mode. Section 8: General Product Testing, Test Results/Counters – Explains test results that will display and how to reset counters. Section 9: Sensitivity Adjustment/Change Learned Data – Explains how to modify learned data – pressure reference values. Section 10: Mechanical Adjustments – Covers test station head and frame adjustments. Section 11: Troubleshooting – Provides guidelines and recommendations to assist in troubleshooting. Section 12: Safety & Maintenance Section 13: Spare Parts Section 14: Glossary Appendix I: Vacuum Pressure Switch Instructions Appendix II: Electrical Diagram/Schematics

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SECTION 1: TECHNICAL SPECIFICATIONS & FEATURE HIGHLIGHTS

Tester type: Model Pti-126 Two-Station Vacuum Leak Tester Tester Dimensions: 28”L x 15”W x 68” H (without conveyor) Test Method: Vacuum

High resolution vacuum transducers Controls: PLC based Primary Air: 80-90 PSI Primary Power: 110/220VAC 50/60Hz FEATURE HIGHLIGHTS: • Self-Teach LEARN Technology with Adaptive Algorithm • High-resolution vacuum transducers • Two stations for high output and testing accuracy • User-friendly operator interface • Quick changeover to different size containers • Suitable for both blow molding and filling lines • Adjusts to any conveyor and container type • Manual test feature for system integrity testing • U.S. Made – All components are commercially available

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OVERVIEW AND PRINCIPLES OF OPERATION The Pti-125/6 is a two-station vacuum leak tester. As the containers are fed onto the conveyor through the test station assembly, each test station performs a leak test as explained below:

Each test head features a sealing gasket that tightly seals the container opening during the test cycle. Once a defined vacuum is applied to the container, the transducer monitors and calculates the vacuum decay inside the container, which correlates to the presence and size of leaks in the container. Pass/Fail test criteria are calculated using PTI’s Self-Teach LEARN feature. As a result of the LEARN procedure – testing a pre-set quantity of good packages - the reject, pressure and testing criteria from the test samples are calculated by an algorithm programmed into the leak tester that recommends the test limit settings. Reject values are fine-tuned and adjusted automatically. Test limits can also be manually set if desired. A Reject mechanism, in this configuration a cylinder, will remove the rejected (leaky) containers from the production line. The operator interface display panel is used to monitor all tester activity. Test results are conveniently displayed live on the operator screen as each test cycle is completed.

Containers move on a string-belt conveyor through the test station assembly.

Test Head Sealing Gasket

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SECTION 2: SYSTEM COMPONENTS The following photos and brief descriptions will help you become familiar with the basic components of the PTI-126 Vacuum Leak Tester. Each area will be discussed in more detail throughout the manual. SYSTEM COMPONENTS OPERATOR DISPLAY SCREEN – Each of the Menu screens is covered in detail in Section 4, Pages 24-28.

The Leak, Manual and Auto light indicators will illuminate depending upon the operation mode of the tester.

The five white keys described below on the Operator Panel are used during operation and setup of the tester.

Leak light will illuminate when reject conditions occur during inspection. (For details, see Section 8, Pages 38-39, Test Results.)

In Manual Mode - Tester must be in manual mode when performing a manual test.

Auto Mode is the standard mode for inspection under normal operating conditions. Auto will flash when LEARN is activated

Menu key accesses the menu screens and also changes mode from Manual to Auto and vice versa.

Used to move down within a menu screen. Also used to activate Learn mode.

Used to move up a line within a menu screen.

Minus and plus keys are used to modify a value or setting.

4-Line Backlit LCD Display Panel

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INSIDE MAIN CONTROL CABINET - PLC

Terminal Blocks

PLC Controls - Must be in “TERM” mode for tester to operate. In “RUN” mode, tester operates, but Operator Interface is disabled.

Two Venting Valves for Station 1 and 2.

Two Filling Valves for Station 1 and 2.

Power Supply

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VENTING PRESSURE REGULATOR

TRANSDUCERS

COLOR CODED TUBING ON SIDE OF MAIN CABINET This tubing is installed and connected at the PTI factory prior to shipment. Each connection is numbered and color-coded for easy identification as follows:

TUBE NUMBER COLOR FUNCTION 1 YELLOW STATION 1 CYLINDER UP 2 GREEN STATION 1 CYLINDER DOWN 3 ORANGE STATION 1 FILL LINE 4 BLACK COMPRESSED AIR 5 BLUE REJECT 6 YELLOW STATION 2 CYLINDER UP 7 GREEN STATION 2 CYLINDER DOWN 8 ORANGE STATION 2 FILL LINE 9 OPEN NOT USED

10 BLACK COMPRESSED AIR

Two Transducers located in the lower right side of the control cabinet –

Venting Pressure Regulator - Set to 20 PSI, depending upon the size and volume of the container being tested.

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MAIN AIR CONNECTION AND GAUGE

TEST HEADS

CONTAINER PRESENT SENSORS

Test Station Cylinder controls the up/down motion of the test head during each test cycle.

Container Present Sensors – One for each test station - situated directly behind and to the side of the test head. Sensor detects container for inspection before it reaches test head. This sensor can be tilted or adjusted as needed to enable proper timing and viewing of containers.

Flexible coupling insures smooth operation of test head and enables sealing gasket to make a complete seal over container opening during test cycle.

Test head gasket seals container opening during test cycle.

Main air is connected on side of main cabinet. Recommended setting for this tester and KW container is 80 PSI.

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REJECT MECHANISM– The reject mechanism can be either a nozzle or a cylinder (as shown on the 126 Vacuum) depending upon the type and size of container to be tested. Two Reject Settings (Reject Delay and Reject Blow should be set in the Settings Menu – See Section 6, Page 32).

RESERVE VACUUM TANK AND VACUUM PUMP – located on back of the main cabinet.

Vacuum Pressure Switch

The reject cylinder slides out to eject leakers from the conveyor. The cylinder slides back when the next good container is tested.

Vacuum pump assembly and gauge are located to the left of the vacuum tank. Gauge indicates level of reserve vacuum in tank.

Vacuum tank and Pressure Switch (on top)

Air Supply Line

Vacuum Supply line to Vacuum tank.

See Appendix I for instructions about Vacuum Pressure Switch.

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SECTION 3: INITIAL SETUP - AIR & ELECTRICAL CONNECTIONS

STANDARD OPERATING PROCEDURES: - STARTUP - SHUTDOWN - LOCKOUT This section covers basic setup procedures for tester installation – air, electrical connections and main power up. After Initial Setup and Installation is completed, Important Factory Standard Operation Procedures are also outlined for General Startup, System Shutdown and Lockout Procedures for Maintenance and Service – These procedures should be posted near the machine for all operators and technical personnel. INITIAL SETUP Pti-126 INSTALLATION Step 1 - The Pti-126 Vacuum Leak Tester must be installed in a level area where the following conditions are constant:

Power Supply: 110/220VAC 50/60Hz Compressed Air Supply: Pressure 80 – 90 PSI

! IMPORTANT ! – Use dry and non-lubricated compressed air only! The Pti-126 Vacuum Leak Tester is equipped with a string-belt conveyor. The support legs of the tester must be level. Make sure to tighten the bolts on all four legs securely (5mm Allen key required).

String-Belt Conveyor

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Step 2 – Check for Mechanical Adjustments CONVEYOR GUIDE RAIL ADJUSTMENT/ MECHANICAL ADJUSTMENTS TO TEST STATIONS PTI will check that all mechanical components of the test station assembly are adjusted correctly before shipment (test station height, guide rails, etc.), however at time of installation or if the tester is moved, it is important to again verify the correct positioning. It is important the conveyor guide rails are adjusted properly so that containers feed on the center of the conveyor, under the test station heads. All mechanical adjustments are covered in Section 10, Pages 42-45. See this section for more details. Step 3 - Connect Main Air - Check the compressed air supply and connect the air supply tube to the main air connection, which is located on the upper right side of the tester cabinet. (See photo below). Check the main air regulator gauge and adjust air pressure using the black knob (on top of the gauge) to insure it is set to recommended 80 PSI.

Step 4 - Connect Main Power - Connect tester to the electrical outlet. (Power cord extends from left side of Main Control Cabinet. Turn the main power switch ON (switch is located on the left side of the Main Control Cabinet).

Main Air Connection and Air Regulator Gauge

Power Cord and Power Switch

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The LAMPS on the MAIN CONTROL CABINET (Leak, Manual and Auto) will illuminate and begin flashing, indicating that power is connected and the tester is operating. The initializing screen will display as follows:

The Main Counter Screen will then display.

It is recommended to review Section 4, which outlines each of the Menu screens. Step 5 - Set Vacuum Pressure Switch (located on top of Reserve

Vacuum Tank on back of main cabinet) according to the container size/volume being tested. Refer to Instruction Sheet for Pressure Switch in Appendix I of this manual. Recommended range for KW container is –7.0 to -7.5 PSI.

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Step 6 – Venting Pressure Regulator Gauge - Set Venting Pressure Regulator Gauge (located inside main cabinet) to approximately 20 PSI. (This setting is dependant upon the size and volume of the container being tested – check with a PTI technician if needed for recommended setting.)

Use knob to adjust gauge to recommended setting.

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PTI STANDARD OPERATING PROCEDURES – STARTUP, SHUTDOWN, LOCKOUT The following Standard Operating Procedures are intended to be a guide of recommended routine procedures for all personnel authorized to operate this inspection system. These procedures are designed to insure safety of personnel, as well as the prevention of damage to the machine. ! IMPORTANT ! - Please note these procedures do not include reference to setting any test parameters or system settings – these procedures should be performed by qualified supervisory personnel at the time of installation and checked periodically, but are normally not part of the standard operator startup/shutdown routine. SUPERVISORS SHOULD POST ALL STANDARD OPERATING PROCEDURES NEAR THE PTI-126 LEAK TESTER FOR EASY REFERENCE AS NEEDED. Please contact a PTI technician with any questions regarding these procedures @ 1-800-532-1501 or 914-337-2005.

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START-UP PROCEDURES 1. INITIAL START-UP CONDITIONS – Check and verify the following

conditions before turning on Pti-126 main power.

a. Electrical Power Required: 110 VAC, 60 cycles – Main Power cord extends from the left side of the Main Control Cabinet. Locate cord and plug in to standard 110V/60 cycle outlet.

b. Main Air Supply Required: 80 PSI – must be dry, compressed air. Air

gauge and connector is located on right side of main cabinet.

c. Check that Main Control Cabinet is closed and locked. d. Machine should be clear of containers – check that conveyor, test stations

and all surrounding areas are completely clear before turning on power.

e. Machine should be clear of any tools, cleaning materials or other materials.

2. RECOMMENDED START-UP SEQUENCE ! IMPORTANT ! - The Pti-126 Leak Tester should be turned on at the beginning of the production line startup to allow sufficient warm-up time of approximately 5 – 10 minutes. The customer should designate the recommended start-up sequence according to their particular configuration, however PTI factory recommends starting leak tester at the beginning of line, before starting conveyor and other machinery.

Connect air supply and adjust gauge to 80-90 PSI.

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3. TO TURN ON MAIN POWER ON/OFF SWITCH

a. Before turning on power switch, make sure machine is not locked out/tagged out for maintenance purposes. Check that initial startup conditions (outlined in Point 1 on previous page) are met.

b. Locate Main Power switch located on left side of Main Cabinet and

press switch to ON position.

c. After power up, observe the brief start up of the operator display panel. After initializing, Main Counter screen will display.

d. Allow sufficient warm-up period of approximately 5 – 10 minutes.

e. If needed, check and verify settings for main air, venting pressure

regulator, vacuum pressure switch and reserve vacuum level.

f. Turn on string-belt conveyor and set conveyor speed. Tester operation can then begin.

Press Power Switch to the ON Position.

Power Switch for Pti-126 conveyor.

Speed control of string-belt conveyor.

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SHUTDOWN PROCEDURES There are essentially two different shutdown procedures for the Pti-126 Leak Tester:

1. Half-Shutdown - Turn off leak tester operation so that no testing can take place. This requires turning off string-belt conveyor, however main power will still be on and operator interface display will be on. To perform this shutdown:

a. Make sure no containers are on the conveyor in the test station

area. b. Turn off Pti-126 string-belt conveyor power.

2. Complete-Shutdown – If desired, a complete shutdown of leak tester

can be done requiring main power switch to be turned off. Operator Interface display and all tester operation will turn off.

a. Make sure no containers are on the conveyor in the test station

area. b. Turn off Pti-126 string-belt conveyor power.

c. Turn Main Power Switch on side of Electrical Cabinet to Off

position.

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LOCK-OUT PROCEDURES Lock-out procedures are followed prior to performing any maintenance work on the machine. ! IMPORTANT ! Although the PTI factory can set certain recommendations and procedures for maintenance, the owning company/plant manager in accordance with local procedures and guidelines must establish Lock out/Tag out instructions. General procedures are as follows: Lock and tag leak tester in accordance with local procedures and guidelines. These guidelines must include the following as recommended by the PTI factory:

a. Follow Complete-Shutdown procedures. Turn Main Power Switch to “Off” position on Electrical Cabinet.

b. Disconnect main power cord from electrical outlet. To insure

there is no power to the electrical parts, use a faultless voltmeter.

c. Disconnect all air to tester! Remove air source to the leak

tester by either disconnecting air hose supply; or locate and close the isolation valve that provides the flow of air.

After Maintenance has been performed, before performing Start-up procedures: Prior to any new start of the tester after any repair or maintenance work has been finished, the supervisor should verify that:

- All work has been satisfactorily completed - The machine is in a reliable and safe condition - All mechanical components are secure and safe for operation - No loose parts (rags, tools, etc.) are anywhere inside the tester area,

around the test station cylinders, etc. - All connections – power, air, and pneumatic line connections have been

properly restored.

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SECTION 4: OPERATOR DISPLAY MENU SCREENS This chart illustrates the menus on the Operator Display. It is recommended to take a few moments to become familiar with the different menu screens. The text in the Red boxes explain how to access and move through the different menu screens. The main screens are shown with RED headings, the BLUE headings are secondary screens. Whenever turning power switch on, the three indicator lights (LEAK, MANUAL, AUTO) will flash. After a few seconds, the Main Counter Screen will automatically display. Main Counter Screen (beginning of loop)

Station 1 Counters Station 1 Last Test/Fill Time/mBar

(Manual Test Screen)

Press to exit Main Counter Screen and access Station 1 Counters.

Press Menu to exit Station 1 Counters and access Station 2 Counters.

Press the down arrow key to access the Station 1 Last Test/Fill Time screen shown above right. This screen must be accessed to perform a manual test. Press Menu to return to main Station 1 Counters.

Press down arrow to move to the next line – Current reading in mBar for Station 1 shown below. Press Menu to return to Main Station 1 counters.

Press Menu to return to main Station 1 counters.

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Station 2 Counters Station 2 Last Test/Fill Time/mBar (Manual Test Screen)

Sensitivity Sensitivity Gauge

Press Menu to exit Station 2 Counters and access Sensitivity.

Press the down arrow key to access the Station 2 Last Test/Fill Time screen shown above right. This screen must be accessed to perform a manual test. Press Menu to return to main Station 2 Counters.

Press down arrow to move to the next line – Current reading in mBar for Station 2 shown below. Press Menu to return to main Station 2 counters.

Press Menu to return to Station 2 counters.

Press Menu to exit Sensitivity and access Learn prompt screen.

Press to access the Sensitivity Gauge Use -/+ keys to increase/decrease sensitivity

level as needed. To exit Sensitivity Gauge, press Menu to return to Sensitivity prompt.

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Learn Prompt Station 1 & 2 Learned Data Screen

Fill Level-Test Rate Prompt Fill Level Setting

Press to access the Fill Level and Cycle Time Settings.

Use the -/+ keys to increase or decrease the Fill Level setting. Down arrow advances to Cycle Time setting. Press Menu to return to Fill Level-Test Rate prompt.

Press Menu to exit Fill Level-Test Rate prompt and access Change Learned Data Screen.

Press to activate LEARN mode. The Station 1 Learned Data Screen will display indicating LEARN has been activated. To exit Learn prompt and access Fill Level-Test Rate screen, press Menu.

This screen displays the Learned counter, Vacuum Ref and Fill Time Max values. There is no manual input allowed on this screen. Press down arrow to advance to Fill Time Max shown below.

Press to access Station 2 Learned Data Screens or press Menu to return to Learn Prompt.

In the Learned Data screen, the Vacuum Ref. value automatically defaults to double the Transducer Range (1999.8mBar – shown here as 999.8 due to # of digit limitation). Once LEARN mode is activated, Vacuum Ref. adjusts automatically, but will not exceed max. transducer range.

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Change Learned Data Prompt Change Learned Data Settings

Main Counters (back to beginning of loop)

A brief illustration of the flow of main menu screens is also shown on the following page.

While in “Changed learned data” screen, the down/up arrow keys access the line you want to change (indicated by the ±). Use the +/- keys to adjust the Reference values. The down/up arrows are used to access the line you want to change. Press the down arrow to access the Maximum Fill Time settings shown below.

Press down arrow to access Change Learned Data Screen. Press Menu to exit Change Learned Data screen and return to Main Counters

Use the -/+ keys to increase/decrease Max. Fill Time setting. Press Menu to return to Change Learned Data prompt.

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This quick reference chart illustration shows the flow of the main screens in the LOOP (indicated by red). Once inside the LOOP in the secondary screens, press Up and Down arrow keys to move forward or backward or press Menu to return to a main screen.

Main Counter Screen

Learn

Fill Level-Test Rate Prompt

Change Learned Data

Sensitivity

Station 1 Counter Screen

Station 2 Counter Screen

Press the Menu key to move from each of the main screens in the loop.

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SECTION 5: MANUAL TEST It may be necessary to put the tester in manual mode and perform a manual test on a test station head to check for correct pressure in order to determine if there are any leaks. An unusually high percentage of rejects or false rejects is usually an indication that a leak may be present on the test station. The Manual Test is also used to check for correct position of the test station(s) in order to determine if any mechanical adjustments to height and/or position are required. PROCEDURE FOR DOING A MANUAL TEST Step 1 – Stop tester operation, turn off conveyor and/or infeed. Step 2 – Place tester in Manual Mode as shown below:

BASIC GUIDELINES WHEN DOING A MANUAL TEST To perform a manual test, tester must be in manual mode and Station 1 or Station 2 manual test screen (Current reading in mBar) must be selected as shown below.

A manual test CANNOT be performed if: • The machine is in AUTO mode.

Press and HOLD Menu key to put tester in Manual mode. The Manual light will illuminate.

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Step 3 - Access the Fill Time/Pressure Screen as shown in photo for the test station (1 or 2) you want to conduct a manual test. Refer to Section 3, Operator Display Menus, page 12 if needed.

Step 4 – There are two methods of conducting a manual test.

To quickly check the pressure reading, place a sample container in position at the test head, press and release the + key; the test head will lower for a moment. Check the current mBar level on the display. For system integrity testing, to check for leaks on the test head, position a sample container at the test head, press and HOLD the + key. The test head will stay down. During this period, carefully watch the Current mBar reading on the screen. The mBar value will fluctuate for several seconds, but should eventually stabilize. If the value continuously decreases or rapidly decreases, this indicates there is a leak on the test head. Press the – key to release the manual test.

If a leak is found, the problem is typically due to a defective sealing pad or gasket, or a leak in the tubing or fitting of the test station head. If test head gasket is deeply ridged or indented, it should be replaced. Any leaks found in the tubing should be corrected immediately before any further product testing is done.

Operator Display MUST be at this screen in order to perform a manual test.

Last Test indicates the actual pressure reading (in mBar pressure units) for the last test competed. Fill time (in seconds) represents the actual filling time during the test cycle.

Press down arrow to access the next line displaying the Current pressure reading (in mBar) for the station.

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Step 5 – To exit Manual Mode and return to Auto Mode, press and hold the

Menu key until the Auto light is illuminated.

Press and hold Menu key to return to Auto mode. Auto light will illuminate.

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SECTION 6: SETTINGS MENU

! IMPORTANT ! – All Settings described in this section have defaults that have been pre-set at the factory and may not require any modification. System settings will be dependent on the customer’s configuration and reject requirements. These settings are critical to the operation of the leak tester and should only be accessed or modified by a supervisor or technical personnel. Operators should not access or modify the Settings menu. Please consult a PTI technician with any questions regarding the Settings menu. To access the Settings screen menu, turn off power switch located on the left side of the control cabinet. Turn power switch back on while pressing and holding Menu and + keys. The Leak light flashes when the Settings screen is activated.

Pti-126 Vacuum Leak Tester Settings Menu

Press and hold Menu and the + keys for a few seconds. The Settings screen will be displayed.

To modify any line of the Settings, the line you wish to change must be the top line. Use the down arrow/up arrow keys to access the setting required. Then use the -/+ keys to change the setting. Each of the Settings is described on the following page in the order in which they appear on the Settings screen.

Use UP/DOWN arrow keys to scroll up or down within the Settings menu.

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Trnsdcr Range (Transducer Range) - This setting correlates to the type of transducer installed in the leak tester. Normally, the Pti-126 Vacuum is equipped with a 999.9 mBar vacuum transducer, as shown on the Settings screen. THIS SETTING SHOULD NOT BE CHANGED! Bottles To Learn - This setting determines how many bottles/containers will be learned when LEARN mode is activated. The default factory setting as shown here is 50 bottles. The maximum setting is 100. Min. Fill Level - The default setting for Minimum Fill Level is .10.0. This level is the absolute minimum fill level allowed by the system configuration.

Reject Delay – This setting is in seconds and determines when the rejected container is removed from the line. The setting depends upon the actual position of the reject cylinder, the number of test stations, container size and conveyor speed. The farther the distance the reject cylinder is from the last test station, the higher the reject delay value.

Reject Blow – This setting in seconds determines the amount of time required for the reject cylinder to physically eject the rejected container. Station 1 On/Off Station 2 On/Off - Each of the test stations can be deactivated if needed. This setting is used to turn off and on each of the test stations. To exit the Settings Menu, press the Menu key to return to the Main Counter screen.

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SECTION 7: FILL LEVEL SETTING/CYCLE TIME/ SELF-TEACH LEARN The yellow box below is a general checklist of the steps required for setup for testing a container. The factory may pre-set Fill Level and Cycle Time prior to shipping tester, however these settings may require adjustment especially if changing to another container type and size.

Pti-126 Checklist For Testing

! IMPORTANT ! – Before testing can begin, check if any mechanical adjustments are required for test station heads, conveyor, etc. – see Section 10, Pages 42-45 for more details. 1. Set Conveyor Speed. 2. Input Fill Level. 3. Set Cycle Time. 4. Put Tester in Auto Mode. 5. LEARN Product. 6. Adjust Sensitivity if needed. 7. You’re ready to inspect!

Step 1 – Set speed of PTI string-belt conveyor.

Step 2 - Fill Level - Access the Fill Level-Test Rate Screen as shown below. If needed, refer to Section 4, Pages 24 - 28.

The Fill Level setting depends on the size, shape and material of the container as well as flexibility. For example, typically a round bottle normally tolerates a higher fill level than rectangular or oval shapes. If uncertain as to the Fill Level setting, as a general rule of thumb, for most containers, the ideal setting is 100.0 mBar. Please be aware this recommendation is not exact, and it may require a higher or lower setting depending on the specifications of the container. Also, it is not possible to set the Fill Level below the Minimum Fill Level (.10 mBar) found in the System Settings menu, explained in Section 6, Pages 32 -33.

To change the Fill Level, with the ± positioned on the Fill Level line, use the -/+ keys to increase or decrease the setting.

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Step 3 – Cycle Time – The Cycle Time – also referred to as Test Time - is the amount of time to complete a test cycle per container and determines the cycle time of the test cylinder. Cycle Time depends mainly on production line speed and the amount of time available to complete the leak test. Generally, the longer the cycle time, the better. (In this example, Cycle Time is set for approximately 1.70 seconds - please note this is an example setting only!) The Cycle Time must be set before LEARN.

To set the cycle time:

Step 4 - Make sure tester is in Auto Mode. Hold Menu key until Auto light is

illuminated. Step 5 - Self-Teach LEARN - The reference points for the test stations are set

automatically by the Self-Teach LEARN Adaptive Algorithm Software. The quantity of bottles to learn is set in the Settings Menu screen covered in Section 6, Pages 32 and 33. The default setting is to LEARN 50 containers. The LEARN mode automatically learns and sets the reject points after a quantity of good containers are processed through the tester. Please note – these do not have to be consecutive good containers. After the good containers are tested, the LEARN mode automatically shuts off. It is recommended to monitor test results on the operator display until LEARN is complete.

To activate Learn, be sure the tester is in Auto Mode, access the Learn

screen shown on the following page. (Refer to Section 4, Pages 24-28 if needed).

Use the down arrow to bring the ± sign to the Cycle Time line. Use the -/+ keys to increase or decrease the setting as needed.

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Station 1 & 2 Learned Data Screens - During the LEARN mode, test parameters can be viewed for each test station. Station 1 is shown below. This data is helpful to the operator in monitoring the learn process; however no parameters can be modified in this screen – only in the Change Learned Data screen.

Step 6 - After the LEARN mode is complete, the screen will automatically display

the Main Counters. It is recommended to take a minimum of one (or more) known bad containers and run through the tester to be sure it produces a bad test result and is rejected. This is an important step to be sure the tester recognizes the leaky container. If the bad container is not rejected, it may be necessary to adjust the sensitivity as explained in Section 8, Page 40.

Press the down arrow key to activate the LEARN mode. The Auto light will flash while in LEARN mode. To view Station 1 and Station 2 learned data screens, press the down arrow key to view these screens shown on the following page.

Test Result is displayed on the top line. Bottles Learned – displays a counter indicating the number of bottles learned. Vacuum Ref – displays the vacuum reference value, which determines the reject level/test criteria, as it is set during the LEARN MODE. Press Down arrow to display Fill Time Max data.

Fill Time Max – This parameter as set during the LEARN mode indicates the maximum time allowed to reach the fill level. Fill Time Max. typically defaults to 75% of Cycle/Test Time. Press the down arrow key to display Station 2 learned data.

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SECTION 8: GENERAL PRODUCT TESTING AND TEST RESULTS/RESET COUNTERS

IMPORTANT NOTE: The Self-Teach Learn procedure should be followed

before proceeding with product testing. The Main Counter Screen shown below indicates the total number of units tested and the number of units rejected. The Reject counter value is shown as a percentage.

Station 1 and Station 2 Counters

Counters – can reach a maximum of 8 digits.

Press Menu key to view individual Station 1 and Station 2 counters.

Station 1 and Station 2 counters display total number Tested and the percentage of rejects for each station. While in the Station counter screen, press the down arrow to display the vacuum reference/fill time values.

The values shown for each test station are as follows: Last Test indicates pressure reading for last test complete. Fill Time value. Current mBar reading for the test head.

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To Reset Counters – Counters can only be reset at the Main Counter Screen. One procedure clears the main counters as well as Station 1 and Station 2 counters. If you wish to reset the counters to zero, (e.g. at the end of a shift or at the start of a specific production run), at the Main Counter Screen, press and HOLD the – and + keys. This will reset all counters to zero.

Test Results – Test results appear on the top line of the operator display as

they occur. Test results for Station 1 and Station 2 will alternate on the top line of the display. Some additional information is provided in Troubleshooting explaining the messages that can be displayed.

Fill Ok, Vacuum Ok – Indicates GOOD CONTAINER– Fill level was achieved before the maximum time and vacuum was above Vacuum Reference.

Fill Ok, Vacuum BAD – Indicates CONTAINER WITH LEAK – Leak light will illuminate and container will be rejected. Vacuum is below the Vacuum Reference. If this message occurs repeatedly during LEARN or with every test and the containers are good, try setting a lower fill level and re-LEARN.

To reset main counters to zero, press and HOLD the – and + keys. All counters will be reset.

Counters – Tested indicates total containers tested (will count up to 8 digits). Rejected indicates percentage of rejects, based on number of containers tested.

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Transducer Unplugged! – Leak light will blink; containers will be rejected. Usually indicates transducer became unplugged from PLC. It is recommended to check all electrical connections inside control cabinet.

Transducer plug to PLC.

Fill BAD indicates CONTAINER WITH LEAK – leak light will illuminate. Fill BAD usually means a large leak – fill level was not reached before maximum fill time.

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SECTION 9: SENSITIVITY ADJUSTMENT/CHANGE LEARNED DATA

Adjusting the test sensitivity changes the Vacuum Reference values for both Station 1 and Station 2 as set during LEARN mode. These reference values can be changed by using the easy Sensitivity Gauge or a specific Vacuum Reference Value can be set in the Change Learned Data Screen. Sensitivity Gauge – To change sensitivity, access the Sensitivity Gauge shown below (Refer to Section 4 Pages 24-28 if needed).

Guidelines for Sensitivity Adjustment – Increasing vs. Decreasing: As a general rule of thumb:

Increase the sensitivity if the tester is not detecting a container with a known “unacceptable” leak.

Decrease the sensitivity if the tester is rejecting bottles that are known good “acceptable” bottles.

Since this is a “live” adjustment, the changes in sensitivity are effective immediately. It is recommended to continue testing containers until the desired sensitivity is achieved.

Use the -/+ keys to increase or decrease the sensitivity as needed, using the indicator gauge as a guide. Sensitivity is adjusted for both Station 1 and Station 2.

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Change Learned Data – Another method of changing test sensitivity is to access the “Change Learned Data” screen and manually input or change the “learned” values, specifically the Vacuum Ref values. During testing of bottles, if vacuum is below the Vacuum Reference value, the container is rejected (Leak); if vacuum is above the Vacuum Reference value, the container is good. To change the Vacuum Reference settings, access the “Change Learned Data” screen shown below.

Note: The Ref Values shown in the Change Learned Data screen will default

to 999.8 mBar at power up, however when LEARN is activated, these values will not go beyond 999.9 mBar, which is the maximum transducer range.

Ref Value #1 represents Station 1. Ref Value #2 represents Station 2. Press the down arrow to bring the +/- sign on the Ref line for the station you wish to adjust. Then use the -/+ keys to increase or decrease the value until the desired mBar value is achieved. The Maximum Fill Time is the maximum time allowed to reach the designated fill level and typically defaults automatically to 75% of the Cycle/Test time. Adjusting this Max. Fill Time setting applies to both Station 1 and 2. When finished, press Menu to exit the Change Learned Data screen and return to the Main Counter screen.

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SECTION 10: MECHANICAL ADJUSTMENTS For the Pti-126 Vacuum Leak Tester, there are a few easy mechanical adjustments that may be required for the initial setup of the tester and may require readjustment when changing container size. It may be necessary to adjust the horizontal position and the height of the test station(s) according to the containers that will be tested. Refer to each section as needed Height of Test Station Achieving the correct test station height is critical to the smooth operation of the tester. To accommodate different container heights, it may be necessary to adjust the height of the test station heads. The test station frame can be raised or lowered as needed. A manual test can also be used to check for proper test station height – see Section 5, Pages 29-31.

There are 4 brackets – on each leg of the test frame that can be loosened, allowing the height of the test head assembly to be raised or lowered as needed. Press in center of bracket and turn to loosen. After adjustments, be sure to re-tighten to secure.

Place a container under the test head to check for proper height. Perform a manual test if needed – see Section 5, Pages 29-31. Sealing gasket should be snug against rim of container, but not crushing.

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Pti-126 Vacuum-V2-12-03 914-337-2005

Distance Between Stations It may be necessary to adjust the distance between the test stations and move them to the left or right depending upon the size and variation of the containers that will be tested. Step 1 - If you will be testing different containers that vary in width – some

narrow, some wide, have samples readily available for the initial setup and take the two widest containers and position them under each test station. The distance between the test stations should be that of the widest container plus one inch, as measured from the respective centers of the two container necks. (see photo below)

Distance between containers should be approximately one-inch when they are correctly positioned under the test station – aligned with the center of the container opening.

Align center of bottle or container neck opening under each test head.

When adjusting test head height, use a measuring tape to check each side of the frame make sure frame is level and adjusted evenly on all sides.

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Step 2 - To move the test station, using a 5mm Allen key, loosen the bolts of back of each cylinder. Turn the key counterclockwise to loosen the bolt, allowing the test station cylinder to move freely from side to side.

Step 3 - Once you have determined the proper distance, tighten the bolts

turning the Allen key clockwise to secure the cylinder. Test Station Position (Front to Back) and Conveyor Guide Rail Adjustments To insure proper alignment of the containers with the test stations and container present electronic-eye sensors, the stations can move from front to back or vice versa depending on the size of the container. The test stations should be aligned to the center of the conveyor. Step 1 - Position the container on the conveyor belt under the test head to

determine if this position needs to be adjusted. Access the bolts located under the test station frame and loosen using a #5 Allen key. (see photo that follows).

Loosen bolts (2 on back of each test head cylinder to enable the cylinders to move from side to side to achieve the proper distance. Be sure to retighten bolts to secure cylinders in place.

Loosen bolts under the test station frame to allow movement forward and backward as needed. Tighten bolts to secure position.

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Step 2 - Check the guide rails of the string belt conveyor. These guide rails can be easily adjusted to insure correct positioning of the container and clearance as it moves through the test station assembly.

Container Present Sensor Position The Container Present photo-eye sensor should be positioned approximately one-inch in front of the test head. See photo below for correct positioning. It is recommended to follow this procedure for initial positioning, however, for more fine adjustments of this sensor, sensor can be moved or tilted slightly by hand while tester is running.

Measure distance between center of test head to center of container present sensor. Ideal distance should be approximately one-inch. Check container sensor for each test station.

Guide rails on each side of the conveyor can be adjusted if needed to make sure containers are moving on the center of the conveyor, under the center of the test heads.

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The sensor can be moved in two ways. For small adjustments, the sensor can be tilted or moved as needed to achieve the correct position (used mostly in Auto Mode). To slide the sensor, loosen the bolt located on the back of the sensor using a #5 Allen key and slide the sensor to the proper position. Tighten the bolt to secure the sensor in place.

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SECTION 11: TROUBLESHOOTING The list on the following page describes some common problems and possible solutions. For many of the conditions, there are several possible causes that require investigation. In the majority of situations, if the tester worked fine and now suddenly is not working properly, SOMETHING CHANGED! The quickest way to solve the problem is to determine what changed… is it the product, the settings on the tester? This is the most effective way to troubleshoot. If you require more information or further assistance, please call the PTI Service Department, Monday through Friday 8am – 5pm (EST) at (914) 337-2005 or 800-532-1501 or E-mail: [email protected].

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Condition

Procedure

Display shows “Fill Ok, Vacuum BAD”

1. Indicates container with leak – Leak light will illuminate and container will be rejected. Indicates Vacuum in container is below Vacuum Ref.

2. If this message occurs repeatedly during LEARN mode or occurs with every test, check the following areas:

- Check sealing pad and gasket of test heads for wear and tear. - Are containers centered under test heads?

3. Lower fill level and Re-LEARN. Display shows “Fill BAD” 1. Indicates container with leak – Leak light will illuminate and container will

be rejected. 2. Indicates fill level was not reached before maximum fill time. 3. If this message occurs repeatedly during LEARN or frequently while

testing, check: - Cycle Time (test time) setting. - Verify fill level is correct for container being tested.

4. After settings are checked, Re-LEARN. Display shows “Vacuum too high!” – Leak light illuminates and containers are rejected.

1. This message indicates that Vacuum exceeds range of transducer. First try to reduce fill level and re-LEARN.

2. Check Settings Menu and Transducer Range – must be set for 9.999mBar. 3. If problem continues, contact a PTI service technician.

All lights on Operator Interface Display are flashing.

1. Check Main Electrical Cabinet - OP Interface has been disconnected from the PLC.

2. Open main control cabinet door and check switch on back of operator display. If switch is in “RUN” position, operator interface is disabled. If switch is in “TERM” position, operator interface is enabled – all buttons are operating. If switch is in the “STOP” position, the tester will not operate.

Operator Interface does not work, but tester is running.

Check the back of the operator display on the inside door of the Main Electrical Cabinet – the PLC/CPU switch must be in TERM mode. Operator Interface will not work if in RUN mode. (see photo above)

Product with known leak is not detected.

1. Increase sensitivity. 2. Check that the seal between the container and the test head is good. 3. Are the containers centered on the sealing pad? 4. Perform a manual test to check for leaks on the sealing pad, gasket

and/or fittings of the test cylinder. 5. Check if any mechanical adjustments are required to test head (height,

distance, etc.) 6. Is the sealing pad or gasket of the test station worn out, causing a leak?

Leak light illuminates frequently – too many rejects - False rejects.

1. Did line speed change? 2. Check Cycle Time (test time) setting. 3. Check that the seal between the container and the test cylinder is good. 4. Are the bottles centered on the sealing pad? 5. Perform a manual test to check for leaks on the sealing pad and/or fittings

of test cylinder. 6. Is the sealing pad of the test head worn out, causing a leak? 7. Check if any mechanical adjustments are required to test head (height,

distance, etc.) 8. Decrease sensitivity.

Switch must be in TERM mode for operator display to function.

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Condition

Procedure

Auto Light is Flashing Indicates Learn mode is activated. Rejected containers are not ejecting off conveyor

1. Check Reject cylinder for proper functioning. 2. Check Reject cylinder position and adjust Reject Delay/Reject Blow

settings in Settings menu. Transducer Unplugged Message appears and Leak light blinks.

1. Check that transducer is plugged into the PLC as it may have become

disconnected. 2. If transducer is connected to PLC, check all electrical connections.

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SECTION 12: SAFETY FEATURES/MAINTENANCE

!IMPORTANT! – PLEASE READ CAREFULLY The responsibility of a safe working environment must be carried out by the employer and, in addition, by the appointed personnel who operate, maintain, repair or perform any duties on or around this machine. The employer is responsible to understand the functionality and safety features of this inspection system, which insure optimum performance. The employer is responsible that: - PTI’s Standard Operating Procedures for STARTUP,

SHUTDOWN AND LOCKOUT are posted near machine and reviewed by all authorized operators of this leak tester.

- The safety regulations are observed – including each of the

safety features described in detail below. - The safety regulations are posted and available for all

employees to read - All employees and operators are instructed as to their

specific responsibilities regarding this tester. Safety Features The Pti-126 Vacuum Leak Tester is equipped with several features specifically designed to insure safety of personnel, as well as the prevention of damage to the machine. Please review and become familiar with the essential safety elements of the machine. • Pti-126 tester is designed to be used following the “Learn Mode – Self

Teach Procedure”. It is not recommended to test products without following this procedure.

• Do not attempt any mechanical adjustments of tester components using

tools of any kind or hands while tester is operating. Place tester in Manual mode or turn power off completely.

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• Check for correct test station height and guide rail position. Incorrect adjustments can cause damage to test heads, false test results and damage to other mechanical components of leak tester.

• When making any mechanical adjustments, take special care to insure

bolts and screws are securely tightened, and check that all components are securely in place.

• Periodically check air pressure and pneumatic lines to insure

connections are secure and leak free. • Periodically perform a manual test on each test station to check for

leaks in the sealing pad, gasket, tubing or fittings. • Periodically check the sealing pad and gasket of the test cylinder to

determine if replacement is necessary. If sealing pad has ridges or indents, test results will be affected and most likely good bottles will be rejected in error – causing false rejects.

IF REPAIR OR MAINTENANCE IS REQUIRED: • Power must be turned off prior to doing any repair or maintenance on

tester. To insure there is no power to the electrical parts, use a faultless voltmeter.

• Air Supply must be disconnected prior to doing repair or maintenance. • Become familiar with the color-coded tube connections on the side of

the tester. These tubes are numbered and color-coded for easy identification and maintenance.

• While working on the tester for repair, maintenance or other reasons, a

warning sign should be posted alerting employees. • Repair work must be performed only by trained and qualified personnel

and should be supervised by one responsible person. • All necessary precautions have to be met so as not to endanger anyone

and prevent damage to machine parts. • Prior to any new start of the tester after any repair or maintenance work

has been finished, the supervisor should verify that:

- all work has been satisfactorily completed

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- the machine is in a reliable and safe condition - all mechanical components are secure and safe for operation - no loose parts (rags, tools, etc.) are anywhere inside the tester

area, around the test station head, feedscrew, etc. • PTI will discontinue any guarantee or warranty for the safety of the

machine if these safety regulations are not properly followed. GENERAL SAFETY REGULATIONS • Persons under the influence of alcohol, drugs, medicine or similar are

not allowed to operate, maintain or repair the machine. • The operator must inform the supervisor and/or responsible personnel

of all defects or problems – especially those concerning safety. • Technical modifications which could influence the functionality and/or

the safety of the machine can only be performed by PTI technicians or with special written authorization from PTI. Any failure on the customer’s part of observing this point would cause PTI to discontinue any guarantee or warranty of the machine both for the performed modifications and for any damage caused thereby in the future.

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SECTION 13: SPARE PARTS LIST Description

Part Number

906-1067

06 PLC (D0-06DD1)

906-1036

Analog Input Card (F0-04AD-1)

906-1020

Operator Interface (OP-640)

908-1129

Main Air Regulator incl. Gauge (NAW2000-N02BG-C)

908-1133

Reserve Regulator incl. Gauge (NIR200-N02BG)

908-1025

Cylinder and Reject Valve (VQZ1121-5L-M5)

908-1074

Fill Valve (VDW21-5G-3-01N-F)

908-1293

Vacuum Switch (ZSE4-T1-65L)

956-1002

PIAB Vacuum Pump (H120B6-ENA)

915-1073

Sealing Disk 60mm OD

915-1028

Sealing Disk 80 mm OD

915-1029 Sealing Disk 100mm OD

996-1001 Transducer 1.805 psi (8367656)

Sealing Pad

Call PTI for size and diameter

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SECTION 14: GLOSSARY Absolute pressure (psia): Pressure measured relative to absolute vacuum. Accuracy: Referred to as combined error of non-linearity, hysteresis, thermal error and non-repeatability. Burst Pressure: The maximum pressure that may be applied without physically damaging the pressure transducer. Calibrated leak: A precision orifice calibrated to a defined leak rate. Differential pressure: The difference between two absolute pressure points, also the difference measured across physical resistor. Stabilizing: The time between the filling and testing cycle – usually required to stabilize a test conditions in the container and eliminate turbulences. Filling: The cycle referred to for applying pressure or vacuum to the container for testing purposes. Gage pressure (psig): Measured relative to ambient atmospheric pressure. Used for pressure leak testing. Hysteresis: The difference in output when the same value is approached by increasing and decreasing pressure. Laminar flow: Is a steady non-turbulent flow of a medium (air, gas liquid), inside a tube, fitting, nozzle, hole or any solid boundary. Leak rate: Referred to as an air mass flow rate in sccm (standard cubic centimeters per minute, at standard pressure and temperature condition). Leak size: Referred to as a diameter of the round hole in the container wall. Linearity error: The deviation of an output voltage at the specified straight line that represents calibrated pressure to voltage response. Pressure switch: Provides a discrete voltage output when pressure approaches the preset level. Pressure transducer: Measure the pressure difference across a device, and provides a linear dc voltage output proportional to that pressure. Repeatability: The ability to reproduce test results when the tests are repeated.

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Reserve vacuum hysteresis: this is an allowance in mBar that defines how much the reserve vacuum level can fluctuate – either plus or minus. Response time: The time interval required for the output to change state as a result of the step change in pressure. Thermal error: Output change due to air temperature change. It does not include effect of changing container flexibility that depends on container material. Turbulent flow: An airflow in which the velocity at a given point varies erratically in magnitude and direction. The turbulent flow could introduce a significant error in the pressure reading.

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UNIT CONVERSION TABLE Pressure Unit Conversion From 1 To

Psi bar in.Hg in.H2O mm Hg (Torr)

mm H2O Pascal atm

psi 1 14.504 .49116 3.6127 *10-2

1.93368*10-2

1.4223 *10-3

1.4504 *10-4

14.696

Bar 6.8947 *10-2

1 3.3865 *10-2

2.4908 *10-3

1.3332 *10-3

9.8068 *10-5

1*10-5

1.0132

in.Hg 2.0360 29.529 1 7.3552 *10-2

3.9368 *10-2

2.8959 *10-3

2.9529 *10-4

29.920

in.H2O 27.680 401.47 13.596 1 .53525 3.9372 *10-2

4.0147 *10-3

406.78

mm Hg (Torr)

51.715 750.06 25.401 1.8683 1 7.3558 *10-2

7.5006 *10-3

760.00

mm H2O 703.08 10.197 *103

345.32 25.399 13.595 1 1019.7 10.332 *103

Pascal 6894.8 1*105 3386.5 249.08 133.32 9.8068 1 1.0332 *105

Atm 6.8046 *10-2

.98692 3.3422 *10-2

2.4583 *10-3

1.3158 *10-3

9.6788 *10-5

9.8692 *10-6

1

Volume unit conversion From 1 To

ounce gill pint quart gallon inch3 liter cm3

Ounce 1 4 16 32 128 0.55411 33.812 3.3812 *10-2

Gill 0.25 1 4 8 64 0.13853 8.4531 8.4531 *10-3

pint 6.25 *10-2

0.25 1 2 8 3.4632 *10-2

2.1133 2.1133 *10-3

quart 3.125 *10-2

0.125 0.5 1 4 1.7316 *10-2

1.0566 1.0566 *10-3

gallon 7.8125 *10-3

3.125 *10-2

6.25 *10-2

0.25 1 4.329 *10-3

0.26417 2.64173*10-4

inch3 1.8048 7.219 28.875 57.75 231 1 61.0239 6.1024 *10-2

liter 2.9575*10-2

0.1183 0.4732 0.9464 3.7854 1.6387 *10-2

1 10-3

cm3 29.575 118.3 473.2 946.4 3785.4 16.387 1000 1

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NOTES

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APPENDIX I: VACUUM PRESSURE SWITCH INSTRUCTIONS Please refer to the following two pages for operating instructions for the Vacuum Pressure Switch.