Uson Qualiipak-770 User manual

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DocumentNo.770012Rev.2.0
Leak Test System

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Portionsofthesoftwarearecopyright©2012Uson,L.P.and 
copyright©1991FreeSoftwareFoundation,Inc.
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Productortradenamesmentionedinthismanualmaybetrademarksorregisteredtrademarksoftheir
respectivecompanies.
Usonreservestherighttomodifyorotherwisechangespecificationsand/ortesterperformancewithout
notice.Usonhasmadeeveryattempttocompletelydescribetheoperationofthetester.Usonshallnot
beliablefortechnicaloreditorialerrorsoromissions.
Thismanualcopyright©2021UsonL.P.
Allrightsreserved.PrintedintheU.S.A.
PublishedbyUsonL.P.
8640NorthEldridgeParkway
Houston,Texas77041
U.S.A.
(281)671‐2000
(281)671‐2001Fax
Mail:[email protected]
www.uson.com
CustomerSupportHotline:1‐855‐GETUSON/1‐855‐438‐8766
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1
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TableofContents
Section1:Safety......................................................................................................................2
SafetyPrecautions(English).............................................................................................................2
SafetyPrecautions(Español)............................................................................................................3
Section2:Introduction............................................................................................................4
Overview.........................................................................................................................................4
Specifications...................................................................................................................................5
HowitWorks...................................................................................................................................5
GettingStarted................................................................................................................................6
SystemTest/ChamberSealTest...........................................................................................................................9
LidAdjust............................................................................................................................................................10
Section3:Operation..............................................................................................................11
TestingPrinciple.............................................................................................................................11
Testing...........................................................................................................................................12
Pre‐ProgrammedTests......................................................................................................................................13
ProgrammingaNewTest....................................................................................................................................14
ChallengeTest.....................................................................................................................................................17
Section4:Maintenance.........................................................................................................19
RoutineMaintenance.....................................................................................................................19
Daily....................................................................................................................................................................19
Weekly................................................................................................................................................................19
SixMonths..........................................................................................................................................................19
Annually..............................................................................................................................................................19
Cleaning..............................................................................................................................................................20

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Section 1: Safety
Safety Precautions (English)
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WARNING: Areas of the equipment and/or manual that display this
symbol, or variation of, are potentially hazardous. Consult the
appropriate section of the user manual in respect of the specific
hazard.
WARNINGS: The system operates on 24VDC from a power supply
(supplied by Uson or customer), which must be connected to an
earthed (grounded) power supply of 100-240VAC 50/60Hz.
The covers on the equipment should be removed only by personnel
trained to avoid the risk of electric shock. The power supply to the
equipment must be switched off and disconnected before removing
any covers.
Do not substitute the fuse rating. Always use the correctly rated fuse,
failure to do so may be hazardous and can cause damage to the
equipment.
Do not make or break external connectors or connections while the
QMR is switched on.
The component to be tested, and the air supply line to the QMR must
be free from water or liquid residue before testing; otherwise, damage
may be inflicted on the sensitive transducer within the instrument.
Operation of this product outside of the manufacturer's instructions
may impair the protection provided by the equipment.
This instrument is capable of supplying high-pressure air. Before
commencing any component tests, ensure that the system is guarded
to local health and safety standards.
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Safety Precautions (Español)
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WARNING/ADVERTENCIA
Las zonas del equipo que muestran este sRmbolo son potencialmente
peligrosas. Consulte la sección del manual del usuario
correspondiente a ese peligro en particular.
System funciona con 24VDC desde una fuente de alimentación
(suministrado por Usón o cliente), que debe estar conectado a una
fuente de alimentación conectada a tierra (masa) de 100-240VAC
50/60Hz.
No cambie el voltaje del fusible. Utilice siempre el voltaje correcto del
fusible, si no lo hiciera podrRa daZar el QMR .
No realice o rompa conexiones o conectores externos mientras esté
encendido el QMR .
Cuando utilice un acoplamiento neumático con el QMR tenga cuidado
de asegurarse de que tanto el acoplamiento como el componente
estén correctamente empotrados.
Debe comprobar el componente y la línea de suministro de aire al
QMR debe estar libre de agua o cualquier residuo líquido antes de la
comprobación; si no fuera así podría daZar el transconductor,
altamente sensible, que se encuentra en el interior del instrumento.
El falta de cumplimiento de las instrucciones de uso indicadas por el
fabricante para este producto, puede perjudicar la protección provista
en el equipo.
El instrumento es capaz de suministrar aire a alta presión. Antes de
empezar prueba alguna de cualquier componente asegurarse de que el
sistema cumple las normas establecidas por las autoridades locales
en materia de Seguridad e Higiene.
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Section 2: Introduction
Overview
The Qualipak-770 is an easy-to-use leak testing fixture used with Uson’s Qualitek mR
Leak Tester (QMR) to perform seal integrity and leak testing on packages/parts for the
food, medical, and pharmaceutical industries.
The Packaging System instructions are outlined in two manuals:
• Qualipak-770 owner’s guide
• QMR’s owner’s guide (document# 650012)
You will need to reference both manuals for configuring and operating the system.
Figure 1: Qualipak Packaging Tester System

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Specifications
Air supply: 6 bar (if using unit’s internal supply)
Vacuum supply (optional): Must meet testing specifications
Mains supply: 100v -240v
Weight: Chamber Packed 40 kg, unpacked 35 kg/QMR Packed 42 kg, unpacked 32 kg
Chamber, lid and internal components Anodised Aluminium.
Adjustment lock nut Black acetyl
Hinges and all Screws Stainless Steel
Latch and Striker plate Hardened Stainless Steel
Pressure plate sheet: Porvair
Sample Infills Polypropylene
Lid seal Silicone
O-rings Nitrile
How it Works
The Qualipak-770 Package Test Fixture is designed to integrate with the QMR Leak
Tester to test the integrity of air tight packages/parts by performing a Vacuum Force Decay
test on the various packages/parts. The test part is loaded into the test fixture. The
operator selects the appropriate program for the part to be tested, then selects the start
button on the QMR; the test automatically starts. During the test, the part under test is
subjected to a vacuum supplied by the Uson Leak Tester. The vacuum level is regulated
by the QMR Leak Tester, and during the test, the Qualipak-770 feeds back a signal from
a load cell to the Uson Leak Tester. The Leak Tester program then differentiates between
a good and bad part, by the varying level of force decay.
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Getting Started
Note: Conduit can be threaded through either side of the test
chamber.
Perform the following steps to get your system ready to use:
1. Unpack the Qualipak-770 Package Test Fixture and the QMR Leak Tester.
2. Turn the Qualipak-770 upside-down and place on a sturdy workbench. Then remove
the fixture’s bracket by unscrewing its 2 screws. See Figures 2 & 3.
3. Connect the vacuum connector to the vacuum connector inlet. See Figures 2 & 3.
4. Load cell plugs left and right. See Figures 2 & 3.
5. Reassemble bracket.
Figure 2: Package Tester Connections
Figure 3:Package Tester Connections Completed
6. Turn the fixture upright, and then remove the two transit screws. See Figure 4.

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Figure 4: Transit Screws
7. Connect power supply to the QMR’s 24vdc input. See Figure 5.
The systems power supply must be connected to an earthed (grounded)
power supply of 90 - 260V, 50 - 60Hz. Only personnel trained to avoid the
risk of electric shock should remove the covers on the equipment. The
power supply to the equipment must be switched off and disconnected
before removing any covers. Do not make or break external connectors
or connections while the system is switched on.
8. Connect the positive pressure to the QMR ’s air inlet port or external vacuum supply
(optional).
9. Connect printer cable (optional).
10. Connect serial communication and power cables to the printer (optional).
See Figure 6.
11. Connect main inlet to power supply unit.
12. Turn the QMR power On. See Figure 5.
13. Connect specified air supply, then turn air or vacuum On to the system. Unit will go
through a boot-up sequence.
Figure 5: QMR Power/Air Connections
Power Receptacle
QMR On/Off Switch
Air Inlet
Serial Communications/Printer

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Figure 6:Serial Communications
14. Switch the program/run key to Run (key in horizontal position). See Figure 7.
Figure 7: QMR Interface Mode Key
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Run Mode: Key in
Horizontal Position

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System Test/Chamber Seal Test
To perform a system test/chamber seal test:
1. Select Program Mode, then select Program 125 Chamber Seal Leak Test.
2. Select Test Setup.
3. Select the Regulator tab (see Figure 8), then adjust external pressure regulator (see
Figure 9) until QMR displays ~-827mbar. Once pressure is achieved, select
deactivate. (Note the system could be tested at any pressure.)
4. Return to Run Mode, then select Start to run the Chamber Seal Test program. The
test will continue through the vent phase. The result of this test should be less than
0.3 mbar. The QMR will give a pass (green diamond) if within tolerance. If not
within tolerance, the QMR will display a fail/abort (red diamond). If the test fails,
check vacuum connections.
5. Once the chamber and part seal are determined to be leak tight, proceed to the
intended production test.
Figure 9: QMR Controls/External Pressure Regulato
r
External Pressure
Regulator
Figure 8:Regulator Screen

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Lid Adjust
Lid adjustment is only required when either infills have changed, new infills have been
fitted, or when a new test pressure has been set.
To Adjust the Lid:
1. While in Run Mode, touch the program name at the top of the QMR’s screen. This
will take you to the program selection screen.
2. Select Lid adjust program (126).
3. Select the Details Icon to view the test. See Figure 10.
4. Undo large clamping nut on top of chamber (see Figure 11), then turn the center
screw counter-clockwise about 20 turns or until the stop on the screw is reached.
5. Press Start on QMR, and allow chamber to evacuate to its normal test pressure.
6. Turn the center screw clockwise until displayed force starts to increase. Stop turning
when the force sensor has increased to approximately 50 grams +/- 10grams.
7. Retighten clamping nut. Lid adjust is complete.
Figure 11: Large Clamping Nut
Figure 10: Run Mode –Testing

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Section 3: Operation
Testing Principle
The Qualipak-770 is based on the same test principle as the early Q700 range for flexible
package testing. However, the parameters are now unrestricted, and can be programmed
to suit your specific application.
The test principle is a vacuum is applied to the chamber, which encourages the pack to
inflate. The package inflates until the control pressure is achieved; this creates a force
onto the load cells. Once the control vacuum has been reached, the chamber is isolated
and a period of time is allowed for the package to stabilise. Then the force is monitored
for a decay. If a package decays at a rate greater than expected, it’s assumed to have a
leak, failure (red light). If the force does not decay, then the package is assumed to be
good /pass (green light).
Results can either be logged to USB, network, or printer using the pre-written format, or
can be edited to meet individual needs (see Options in QMR manual).

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Testing
1. Select correct program for package to be tested. (See “Pre-programmed Tests” later in
this section.)
2. Insert package into package tester’s cavity, ensuring the pack is central; that it doesn’t
overhang the cavity; and that it’s not folded. See Figure 12.
3. Close package tester lid firmly and latch. Then press the Green Start button on
QMR. See Figure 12. The test will continue through to the vent phase.
4. If the packs are within the specified limits, the green light/pass displays on the QMR
tester screen. If pack is not within specified limits, the red light /fail displays on the
tester screen. Test results will be outputted to the selected external destination.
Results will also be logged internally. To view results, select the Audit log
icon.
5. Remove packs and resume to next test.
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Figure 12: Package Tester Lid Open Correctly inserted package
Green start button

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Pre- Programmed Tests
The QMR Package system contains several pre-programed tests:
 Program 1: Master vacuum program (This can be cloned to another position for
editing into a new position or for a different product.)
 Program 2: Master force program (This can be cloned to another position for
editing into a new position or for a different product.)
 Program 3 -119: These are free for customer designed programs unless requested
for pre-programmed tests.
 Program 122: Challenge test. (See “Challenge Test” later in this document.)
 Program 123: Set Regulator.
 Programs 125: Chamber Leak. (See “System Test/Chamber Seal Test” earlier in
this document.)
 Program 126: Lid adjust. (See “Lid Adjustment” earlier in this document.)

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Programming a New Test
The QMR includes pre-configured tests. The pre-configured test in Position 1 (also called
the “Master Program”) can be used as the basis for creating new tests. When setting up a
new test, configure parameters under the Specifications, Steps, and Setup tabs, as
outlined below (reference the QMR’s Owner’s guide for additional information on setting
up a new test):
It is recommended to clone program 1 into a new position before editing.
To Clone a Program:
1. Turn the key on the QMR to the program position (vertical position).
2. Open the Test Setup screen .
3. Select the first tab “Specifications”. Use arrow keys to Select Program 1, then
select Clone. Follow the prompts for cloning. Once cloned, select the cloned
program from the menu. See Figure 13.
4. Under the Specifications tab (Figure 14), begin configuring your program. For each
test, the following parameters are recommended for programming a new test:
 Test type: Used to select pressure decay, vacuum mode, or force mode.
Pressure decay: Monitors pressure during the test and makes a pass/fail decision
on whether the pressure decay is less than a pre-set limit.
Vacuum mode. Runs the test as described using the vacuum reading as its control
point; vacuums the chamber to the control vacuum in the fill/evac stage before
moving onto the stabilization step.
 Force mode: This runs the test using the force reading as its control point. The
vacuum set by the regulator and the system, vacuums the chamber for the part to
inflate, and once the control force is reached, the test moves on. If the force is
Figure 13: Test Setup/Specifications Tab

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insufficient at the end of the fill/evac stage, the test is aborted as a gross failure.
Fine leaks are determined with the force decay in the measure step.
 Measure type: Defaults to force change.
 Test Pressure: The pressure the test is set at. Used as a guide for defaults and can
be changed later in the programming.
5. Configure the Steps for the new program by first selecting the Specifications tab,
then selecting/configuring the desired Program number, Test type, Test pressure,
and Test tolerances.
6. Press Apply Defaults. The QMR will auto-populate the required steps and default
times into the steps screen. See Figure 14.
7. After “Applying Defaults” to the selected program, select the Step tab (Figure 15) to
finish configuring step parameters, as described below:
Figure 15: Steps Tab
Figure 14: Test Setup/Specifications Tab
Apply Defaults
Note: Test Volume should be the size
of the chamber to ensure correct fill
time.

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 Auto zero: Zeros sensor before testing to remove ambient pressure/ force changes
that may affect the test.
 Fill/Evac 1: Evacuates the chamber of air to a controlled pre-set limit; which
allows the positive pressure inside the pack to inflate the pack, creating the force
onto the load cell, and a pressure differential between the inside of the pack and
its outside. The lower the pre-set pressure, the greater pressure differential is
inside and outside the pack. Depending on the pack’s construction, a large
pressure difference can cause the pack to burst/split/open.
 Fill/Evac 2: A second Fill/Evac step. (Normally not used in this configuration.)
 Isolate: A half second step to allow time for valves to operate before proceeding.
 Stabilize: Allows the pack to stabilize. After the pack inflates, it takes a period of
time to settle into its inflated position; packs don’t inflate uniformly. While the
pack is stabilizing, the force on the load cell varies as it settles into its inflated
shape. If the stabilization step is too short, it could lead to false failures of good
packs.
 Measure: Measures the different in force between the start of the measure step
and the end of the measure step. If the force decay is larger than the limit, the
pack will be rejected. If the force decay is less than the limit, the pack will pass.
The limit should be the maximum limit the pack is allowed to decay over the test
time. This is normally worked out by testing packs with known leaks and setting
the limits around the results.
 Exhaust: Vents the chamber back to atmospheric pressure. Note the lid cannot be
opened until the exhaust step is completed.

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Challenge Test
The Challenge test is a pre-programed test (Program 122) used for checking the unit’s
performance against a known calibrated standard.
You will need the Uson challenge unit and a calibrated micron leak.
Standard programs with the standard results use a force of 10,000 grams. The program
can be modified so the parameters more closely match the production setup, but the limits
would also need adjusting after trials.
To Perform a Challenge Test:
1. Select Program 122.
2. Adjust Regulator to approximately 0.5 bar (see Figure 16).
3. Insert micron leak cartridge into challenge unit, resting the infill on its side, holding
the bellows still with one hand and inserting the leak with the other. The leak must be
released between tests so any remaining vacuum in the bellows is released. See
Figure 17.
Figure 17: Inserting Micron Leak Cartridge
Figure 16: QMR Regulator Location
Regulator

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4. Place the infill into the Qualipak-770 cavity. See Figure 18.
5. Close lid, then press Start on the QMR. After testing is complete, check that results
match those in Table 1.
Table 1: Challenge Test Performance Table
Part No LEAK ATTRIBUTED
READING*
TOLERANCE
172908 BLANK 0 + / -10
171265 12.5um 85 + / - 15
171264 25um 380 + / - 80
171263 50um 1300 + / - 200
171262 100um 3300 + / - 500
*WhereappropriatesubtractBlankreadingfromresult
Figure 18" Challenge Test- Insert Infill