FasTest FasMate Series User manual

ICON CALIBRATION AND REBUILD INSTRUCTIONS
Roseville, MN
Ph: 1-800-444-2373
Fax: [phone]
www.fastestinc.com
WP158 Rev B, 03/13/2020
WARNING
Use only factory authorized replacement seals and parts. Use
of unauthorized parts/seals can cause failure resulting in
damage or injury.
THREADED
GRIP COLLETS
SQUEEZE HANDLE
(RELEASED
POSITION COLLETS
ENGAGED)
PNEUMATIC
CONNECTOR
MEDIA PORT
MAIN SEAL
O
-
RING
SQUEEZE
HANDLE (INSERT
AND REMOVE
POSITION)
GENERAL INFORMATION:
The FasMate is designed to provide a safe, reliable leak-tight seal and
connection when properly maintained and used. A flat, smooth, sealing
surface perpendicular to the connector axis is required around the female
test port. Verify the connector seal mates well with the sealing surface.
Improper mating with a test piece can result in poor sealing, leakage and risk
of connector failure resulting in damage or injury.
MAINTENANCE:
User must establish a regular interval for maintenance as determined by the
user media and operational environment.
Periodically inspect the FasMate and its seal for wear, damage and proper
operation. Inspect also for lubrication needs or corrosion. Repair or replace as
required to assure proper sealing, function, and safety.
Difficulty of operation indicates a need for inspection, lubrication, repair or
other maintenance.
Parts and instructions available through FasTest or your FasTest
distributor.
NOTE: Any field modification of FasTest connectors voids Factory war-
ranty.
FasTest, Inc. Product Warranty
FasTest, Inc. warrants its products against defects of workmanship and/or material for 12 months from the date of the
sale by FasTest, Inc. This warranty is void if the product is misused, tampered with or used in a manner that is not in
accordance with FasTest, Inc. recommendations and/or instructions. FasTest, Inc. is not liable for conse uential or
other damages including, but not limited to, loss, damage, personal injury, or any other expense directly or indirectly
arising from the use of or inability to use its products either separately or in combination with other products. ALL
OTHER WARRANTIES EXPRESSED OR IMPLIED, WHETHER ORAL OR WRITTEN, INCLUDING BUT NOT
LIMITED TO
WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY
EXCLUDED.
Remedy under this warranty is limited to replacement of the product or an account credit in the amount of the original
selling price, at the option on FasTest, Inc. All allegedly defective products must be returned prepaid transportation to
FasTest, Inc. along with information describing the products performance, unless disposition in the field is authorized
in writing by FasTest, Inc.
FasMate Series
Description: Lever & Pneumatic operated Intelligent
Connectors for Female Threads.
FasMate Connector provides a reliable leak-tight connection that grips and
seals into female threads.
Please thoroughly read and understand these operating instructions prior to
operating connector. The use of pressurized media for sealing and testing
requires a thorough understanding of the FasMate Operating Instructions.
•Operation
•General Information
•Maintenance
•Warranty

ICON CALIBRATION AND REBUILD INSTRUCTIONS
Roseville, MN
Ph: 1-800-444-2373
Fax: [phone]
www.fastestinc.com
WP158 Rev B, 03/13/2020
WIRING DIAGRAM:
SSR MODULE CALIBRATION (LEVER HANDLE TYPE ONLY):
Sure Seal™ enabled connectors need to be calibrated to each application. The FasMate con-
nector retains stored limit(s) even when power is removed. Due to the fine sensor resolution
and variations in seal height, limits may need to be set each time seals are replaced, or the con-
nector is re-built.
1. Rotate the red, back body to the desired location and lock it in place with the set screw. It
can be backed out up to one full turn.
2. Remove the main seal as shown in WP119.
STOP! READ STEPS 3-6 BEFORE STARTING CALIBRATION.
Note: Point A1 is a preset distance from the rest position (A). As the shaft is extended from
rest, it will begin flashing yellow within the good zone. A good connection is only indicated
when the shaft retracts from beyond the upper limit (B). If a good connection is made and
it’s just to the right of Point A1, it could travel through point A1 once test pressure is intro-
duced, and the light will change from green to flashing yellow. Cancel the test, reconnect,
and try again.
The input is asserted by applying 24V. This can be accomplished by pressing the button
on a FasTest Programming tool, or by using a 24V PLC signal or other 24V logic output.
3. Flash input 4 times quickly to enter programming mode. Connector will flash 3 times indi-
cating programming mode. Note: If the first calibration point is not set within about 30
seconds, the connector will return to operational mode.
4. Do not apply pressure to the handle. Hold input line high until indicator begins to flash,
about 2 seconds. The first calibration point will be recorded when the input is released.
Pinout/Standard M8 Cables
Pin Number
Wire Color
Description
1
BROWN
24 DC
2
WHITE
CALIBRATION
3
BLUE
GROUND
4
BLACK
NC
5
GREY
SSR CONTROL A
6
PINK
SSR CONTROL B
Pinout/Standard M8 Cables
Pin Number
Wire Color
Description
1
BROWN
24 DC
2
WHITE
LED GREEN
3
BLUE
GROUND
4
BLACK
ANALOG OUTPUT
5
GREY
LED RED
6
PINK
LED RETURN
STEPS 3-6 MUST BE COMPLETED WITHIN 30 SECONDS
CV04SSR Pinout
CV04SSR
Wiring Diagram
CV04
ANA
Pinout
CV04
ANA Wiring Diagram

ICON CALIBRATION AND REBUILD INSTRUCTIONS
Roseville, MN
Ph: 1-800-444-2373
Fax: [phone]
www.fastestinc.com
WP158 Rev B, 03/13/2020
AT REST
EXTENDED WITH PILOT PRESSURE
TOO FAR
AT REST
PNEUMATIC
CONNECTOR
LEVER
CONNECTOR
5. Squeeze lever handle until the back of the main seal groove on the collet’s lines up with
the flat face of the front body. (See next section for pneumatic connectors)
Note: this location will change depending on thread size and fitting type.
6. Apply 24V signal to the input line until the indicator begins to flash, about 2 seconds. This
will set point B on the graph above. Release the input line to record the second calibration
point.
7. Release the handle.
8. Slowly squeeze the handle through its entire movement. Confirm that the proper output is
achieved. Refer to the graph above to see the LED output.
9. Re-install main seal.
ANALOG CALIBRATION (LEVER HANDLE AND PNEUMATIC):
A FasMate will not make a good connection if cross-threaded or short-connected. If short-con-
nected, the piston will sit near or at rest position, and the voltage will be smaller than the voltage
for a good connection. If cross-threaded, the piston will be over-extended, and the voltage will be
larger than for a good connection. To detect a good connection on an analog Sure Seal
TM
Fas-
Mate, the voltage must be above the short-connect threshold voltage (V
SC
) and below the cross-
thread detection voltage (V
CT
). This calibration procedure is a guideline for determining these two
voltages, but exact values depend on the user application.
The pneumatic FasMate cannot be slowly moved into position like the lever handle. It is either at
rest or fully extended when pilot pressure in introduced.
1. Rotate the red, back body to the desired location and lock it in place with the set screw. It
can be backed out up to one full turn.
2. Record the connector’s voltage at rest. The short-connect voltage (V
SC
) will be approxi-
mately 0.8V larger than the voltage at rest but may vary depending on your application.
3. Activate connector by introducing pilot pressure. Note the voltage output at max travel.
4. Insert into test port and firmly hold it in place.
5. Remove pilot pressure to de-energize connector and verify that a good connection has been
made. Record the output voltage.
6. Repeat steps 3-5 several times and record the connector’s voltage. Use the distribution of
values to determine a cross-thread detection voltage (V
CT
) that is suitable for your pro-
cess, e.g. 2 standard deviations above the mean., or the largest voltage observed for
a good connection minus some safety margin.
7. A good connection is indicated by the output voltage settling in the range between V
SC
and
V
CT
8. Once the range is determined, a 24VDC signal may be applied to pins 2 and 5 to provide
red/yellow/green LED indication of connection quality.
* When using Analog, please note that the shielded cable improves noise (single termination); 0-
10VDC is used over operational range of the sensor.
Each time the connector is actuated, the threads can grip in a slightly different position. Therefore,
a range needs to be set during the calibration stage. It is suggested to try and short connect it
several times after the range has been set to ensure the range rejects bad connections. If the
connection falls outside of this range, the system can be setup to alert operators.
REBUILD:
1. Loosen set screw.
2. Unthread back actuator from front body.
3. Lever version:
a. Remove two screws securing PCA module.
b. Remove/replace PCA module, spring, and actuator.
CALIBRATION POINT
LINE UP GROOVE
ON COLLETS WITH
THIS FACE
PCA
MODULE
SCREWS
SPRING
ACTUATOR

ICON CALIBRATION AND REBUILD INSTRUCTIONS
Roseville, MN
Ph: 1-800-444-2373
Fax: [phone]
www.fastestinc.com
WP158 Rev B, 03/13/2020
4. Pneumatic version:
a. Remove two screws and PCA module.
b. If needed, use a short blast of air at low pressure to remove the pressure piston. The
spring and actuator are located behind that.
5. Reverse the above steps to reassemble the connector.
a. Use a petroleum-based lubricant on the pressure piston o-ring for the pneu-
matic version.
6. Apply Loctite 242 to the screws that hold down the PCA module and tighten them to 5
in-lbs.
OTHER RESOURCES:
1. WP101: Operating Instructions
2. WP118: Rebuild Instructions
3. WP119: Main Seal Replacement Instructions
PCA
MODULE
SCREWS
SPRING
ACTUATOR
PRESSURE PISTON
O-RING