Uson sprint iq User manual

Owner’s
Guide

Product or trade names mentioned in
this manual may be trademarks or
registered trademarks of their
respective companies. Microsoft
Windows is either registered
trademark or trademark of Microsoft
Corporation in the United States and/
or other countries.
Due to a program of continual
improvement, 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.
Copyright©2007 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.
[phone]
[phone] Fax
Mail: [email protected]
www.uson.com
First Edition, Jun 2007, Revision 003

1
Table of Contents
Chapter 1: Safety ............................................. 3
1.1: Safety Considerations ........................................................3
1.1.1: Pneumatic Hazards ...................................................3
Fixture Considerations ..................................................3
1.1.2: Electrical Hazards .....................................................4
1.1.3: General Safety Issues ................................................4
Chapter 2: Quick Start .................................... 5
2.1: Fast-Track Setup ................................................................5
2.1.1: Sprint iQ Requires Clean Dry Air ............................6
2.2: Front Panel Features ..........................................................7
2.2.1: Pass/Fail Lights .........................................................9
2.2.2: Back Panel Components .........................................10
2.2.3: Connecting Power ...................................................11
2.2.4: Switch-On the Tester ..............................................12
2.2.5: Run Mode Display Overview .................................12
2.2.6: Mode Box Messages ...............................................14
2.2.7: Status Box Messages ..............................................15
2.2.8: Test Parameters .......................................................16
Fine Tuning .................................................................18
2.2.9: Put Sprint iQ to Work .............................................18
2.2.10: In Case of Trouble ................................................19
2.2.11: Start Options .........................................................20
Local Start Option .......................................................20
Remote Start Option ...................................................20
Chapter 3: Menus ............................................ 23
3.0.1: Test Starting While in Menu System ......................23
3.0.2: Navigation ...............................................................23

2
Run Mode Options Menu ...........................................24
Program Mode Menu ..................................................32
Chapter 4: Programming................................. 49
4.1: Introduction ......................................................................49
4.1.1: Decay Testing .........................................................50
Decay Test Parameters ................................................53
Test Pressure ...............................................................53
Pressure Error .............................................................54
Timers in Decay Tests ................................................55
Delta Pressure .............................................................57
Pressure Change Calc. (Leak Rate) ............................59
Pneumatic Signal/Noise Ratio ....................................60
4.1.2: Back-Pressure Flow Test ........................................61
4.1.3: Occlusion (Blockage) Test .....................................64
4.1.4: Flow Test ................................................................69
Flow Test Parameters ..................................................69
Leak Test Using Flow .................................................71
Flow Sensor Over Pressure Limits .............................73
4.1.5: Burst Test ................................................................73
4.1.6: Creep Test ...............................................................76
4.1.7: Crack Test ...............................................................76
4.1.8: Pass/Reject Jumps ...................................................79
4.1.9: Timers .....................................................................80
Chapter 5: Reference ..................................... 81
5.0.1: General Specifications ............................................81
5.0.2: Standard Features ....................................................83
5.0.3: Optional Features ....................................................84
5.0.4: Digital I/O Pin Assignments ...................................85
5.0.5: Converting Pressure to Flow Rate ..........................86
5.0.6: Concepts Applicable to Testing ..............................87
5.0.7: Terminology Reference ..........................................95
5.0.8: Electronic Programmable Regulator .....................111

Safety 3
Chapter 1 Safety
1.1 Safety Considerations
Electrical and pneumatic (or air pressure) hazards are the two
primary areas of concern when operating leak-testing equipment.
1.1.1 Pneumatic Hazards
1.1.1.1 Fixture Considerations
Fixture safety considerations vary depending on the fixture being
leak tested.1However, the following hazards of working with
pressurized systems should be given serious consideration before
operating the Sprint iQ:
• High-pressure pneumatic air systems are exponentially
more hazardous as the pressure increases, or as the
volume of a system increases. Testing equipment
subjected to consistently high-pressure ranges has an
If the equipment is used in a manner not specified in this manual,
the protection provided by the equipment may be impaired.
Always wear eye protection when working with pressurized air.
Disconnect all pressure sources when working with internal
components of Uson equipment.
1.Jackson, Charles N., Jr., Sherlock, Charles N., technical editors, and Moore,
Patrick O., editor. “Safety Aspects of Leak Testing.” Nondestructive Testing Hand-
book, third edition: Vol. 1, Leak Testing. Columbus, OH: American Society for
Nondestructive Testing (1998): p 136.

4 Safety
increased probability of becoming unable to permanently
resist the effects of such pressure.
• Observe caution when working with nonreactive gases or
liquids above their boiling points (even at lower
pressures), especially when larger volumes of gases are
involved. It is essential that relief valves, rupture disks,
and pressure regulators are employed to ensure safety.
• Even at moderate pressures, pressurized systems can
present a hazard in the form of pressurized air escaping
from a leak or a failure. The hazard of flying particles is
added when a sight glass or glass flow meter is introduced
to the system. The sudden burst of a part could generate
sufficient sound concussion to cause hearing damage.
1.1.2 Electrical Hazards
Always use a replacement fuse of the same type and rating as the
original. Failure to do so may be hazardous and can cause damage
to the equipment.
1.1.3 General Safety Issues
Perform operations, maintenance, or troubleshooting procedures
only after reading and comprehending all manuals and materials
supplied with the Sprint iQ.
Always exercise caution when working with electricity.

Quick Start 5
Chapter 2 Quick Start
2.1 Fast-Track Setup
Connect clean, dry supply air.
Connect peripheral devices, if any.
Connect the power supply and turn on Sprint iQ. Turn the
connector’s collar until it is finger-tight to ensure a good
connection.
Use the back panel switch to turn on the Sprint iQ.
Turn the Lockout Keyswitch to the program position (horizontal).
Set the units of measure to use for pressure, flow volume, and
flow time.
Enter test parameters for the first program to run.
Enter test parameters for additional programs if you are using
more than one program.
Set communication values for the connected peripherals, if used.
Turn the Lockout Keyswitch to run position (vertical). Sprint iQ
is now ready to use.
Do not allow the power supply’s ventilation slots to be blocked.
The power supply has an automatic fan that runs as necessary to
prevent overheating.

6 Quick Start
2.1.1 Sprint iQ Requires Clean Dry Air
Before connecting air (or other gas) to Sprint iQ, make certain the
supply air is clean and dry and pressure doesn’t exceed the
maximum input listed on the rear panel.
Supply air is connected to the 1/8-inch female NPT bulkhead on
the back of Sprint iQ.
Compressor
Step-down regulator
Mist and Particulate Filter
Sprint iQ
Water vapor, particulates, and excessive pressure can damage
Sprint iQ’s internal components and affect product testing
2
3
4

Quick Start 7
2.2 Front Panel Features
The front panel has an LCD display, keypad, Lockout keyswitch,
USB port, and Stop and Start buttons.
Display. The Sprint iQ has a 5.7" diagonal 320 x 240 color
graphic liquid crystal display (LCD) with backlight.
Keypad. The keypad has 6 keys:
• Exit. Use the Exit key to exit the Run
Mode Options Menu mode and return
to the Run display. It is also an
“escape” key, allowing parameter entry
to be aborted without saving changes.
2

8 Quick Start
• Enter. Use the Enter key to select the
chosen item. This key is also used to
save a value that has been entered.
This may be a highlighted item or an
entry. If it is not desired to save an entry, use the Exit
key instead.
• Increment and Decrement (Up
and Down). These keys are used
to move up and down. They are
most often used when moving
through the Test Parameters
screen. These keys will also
change digits and characters in the Parameter Editor of
certain menus.
• Next and Previous (Left and
Right). These keys are used to
set parameters. They are most
often used to move along in
menu selections to the desired
entry.
Lockout Keyswitch. Sprint iQ is in Run mode when the
keyswitch is vertical. Turn the keyswitch counter-clockwise to
the horizontal position to enter Program mode. The keyswitch
in illustration below is in the vertical position.
3
RunMode
Program Mode

Quick Start 9
USB 2.0 Port. The port can communicate with USB devices.
A memory stick can be inserted and recognized as Drive C:.
There is also a similar USB port on the back panel. Only one
port may be used at a time.
Start and Stop Switches. The front panel has a green Start
switch and a red Stop switch. The green switch is used to start
the test. The red switch is used to abort a test in progress.
2.2.1 Pass/Fail Lights
The most convenient test result indicators to observe are the pass
and fail lights. A green and red light is assigned for each installed
channel.
A green pass light signals that
the test cycle was completed
and all test values were within
tolerances stored in the
program that ran on that
channel.
A red fail light indicates that at least one test parameter went out
of tolerance at some time during a test cycle. The fail light turns
on if a gross leak occurred, a pressure error value is exceeded, or
the product exceeded an established pressure or flow tolerance.
Repeated failures can indicate Sprint iQ or external fixtures have
set-up problems.
If a fail light turns on during a test, the operator can read the
status box on the run display to see why the test was unsuccessful.
4
5

10 Quick Start
2.2.2 Back Panel Components
Pressure Regulator 1
(if ordered)
Pressure Regulator 2
(if ordered)
Coupling Ports
(number varies with
tester configuration)
Fuse
Power Switch
Needle Valve
(depends on
configuration)
Power Supply
Connector
Air Supply
Connection Ethernet Port (Optional)
Digital I/O #2
(Optional)
USB 2.0 Ports:
One Type A and One Type B
Digital I/O
(Optional) Serial Com Port
3
4
5
67
8
9
10
11
12
13
2
2
3
4
5
6
7
811
912
10 13

Quick Start 11
2.2.3 Connecting Power
1. Check that the power switch on the back panel of the
tester is OFF.
2. Referring to the figure below, connect the AC power
cord to the power supply. (The type of power cord
supplied with Sprint iQ will vary, depending on the
country.)
3. Attach the DC output power cord to the rear panel of
the tester at location shown on page 10 at location .
Lock it in position by turning the connector collar so that
it firmly grips the receptacle.
4. Finally, connect the AC power cord to the facility power
receptacle. The green light on the power supply should
now be illuminated indicating that the power supply is
receiving AC power.
Before switching the tester ON, be sure that the power supply is
located in a position where it will be open to air flow and stable.
2
3
7

12 Quick Start
2.2.4 Switch-On the Tester
Turn the lockout keyswitch to the vertical position.
When the power supply is connected correctly as previously
explained, press the power switch on the rear panel to turn on the
tester.
The tester will begin its initialization process and display a
“splash screen” showing the firmware version number.
Initialization will continue as the splash screen remains until the
tester finishes and shows the Run Mode display.
2.2.5 Run Mode Display Overview
Sprint iQ shows the Run Mode display during all test cycles in
every test mode. If multiple programs are linked, Sprint iQ shows
the run display for the program currently running.
Program Header. Ninety-nine programs may be stored in
Sprint iQ’s memory. The header shows the program number
that is currently selected for running.
Test Pressure Column. This column displays real-time
pressure measurements. At the end of a Vent step it shows the
Run Mode - Program #1
Test Pressure
Mode StatusStep Countdown
Tested Rejects
10.000 Psi
Ch 1
Ch 2
Ch 3
Ch 4
0
P Decay
0
4
5
876
2 3
2

Quick Start 13
pressure that was measured at the beginning of the step.
Shows preset pressure before a test is started.
Tested Box. Shows number of tests. Counts total times pass
and fail lights turn on. Counts up to a maximum of 65,535.
Rejects Box. The number of rejected (failed) tests is shown
here. This number reflects the number of times the fail light
has turned on. The maximum count is 65,535.
Channel Number/Bar Graph/ Status readout. The left column
shows the Channel Number and pressure at that channel. The
middle column displays a color bar graph to help monitor
progress on that channel. The bar graph shows an analog trend
of what the current test program is measuring. This helps to
show whether values are going up or down, and how rapidly
values change. The right column shows the pass/fail status
information for the last test completed on that channel.
Mode Box. The testing mode is shown in this box. Sprint iQ
can operate in many modes such as pressure decay (P Decay),
flow, burst, etc. This box shows an abbreviated display of
what test type Sprint iQ is set to run.
Step Countdown Box. The time of each phase counts down
during a test. The phases vary depending on the type of test
being run.
Status Box. Shows what phase a test is in and possible
reasons for an unsuccessful test.
3
4
5
6
7
8

14 Quick Start
2.2.6 Mode Box Messages
Mode Box Display
The test mode is shown in the Mode Box . If Sprint is set to
run linked tests, the Mode Box shows the first test type in a series.
Selected TestMode Box Display
Back P Back Pressure
Back P Rate Back Pressure Rate
Crack Crack
Creep Creep
Flow Flow
Flow FF Flow Fast Flush
Gauge Gauge
P Burst Pressure Burst
P Decay Pressure Decay
P Occ Pressure Occlusion
P Occ Rate Pressure Occlusion Rate
P Rise Pressure Rise
P Rise Rate Pressure Rise Rate
P SC Pressure Sealed Component
PD Rate Pressure Decay Rate
V Burst Vacuum Burst
V Decay Vacuum Decay
V Occ Vacuum Occlusion
V Occ Rate Vacuum Occlusion Rate
V Rise Vacuum Rise
V Rise Rate Vacuum Rise Rate
V SC Vacuum Sealed Component
VD Rate Vacuum Decay Rate
6

Quick Start 15
2.2.7 Status Box Messages
The status box on Sprint iQ’s run display shows information
before, during, and after a test. Three kinds of facts are displayed
in the status box-test type set to run, test phase, and results of the
completed test.
Status Box Messages
These are some of the messages which may display while the
Sprint iQ operates.
Couple X One or more coupling valves have
opened, or a test is in a wait period to
allow an external fixture to activate.
EOC End of cycle.
Fill Product is being filled with air.
Isolate A test is in isolate stage to ensure a valve
is in the correct state before another is
activated.
Pre-Fill Product is being pre-filled with air.
Stabilize The programmed stabilize time is count-
ing down.
Test The test phase is in progress.
Uncouple X One or more coupling valves have
opened, or a test is in a wait period to
allow an external fixture to activate
Vent The test part is open to atmospheric pres-
sure.

16 Quick Start
Channel Pass/Fail Messages
These are some of the messages that may appear in the right
column of the channel display.
2.2.8 Test Parameters
Test parameters are setpoints and tolerances that tell Sprint iQ
how to conduct a test and decide whether a product is accepted or
rejected. Test parameters are set in Sprint iQ’s Test Parameters
menu.
When Test Parameters are Available
If existing test values are at hand, begin by simply entering those
values into the Sprint iQ. Once all values are set correctly, the
Sprint iQ is ready for fine tuning.
When Test Parameters are not Available
If there are no established test values, some experimenting is
needed to arrive at values for pressures, flow rates, and times best
suited to the product. Little effort is required to program Sprint iQ
after test parameters are established. Yet, coming up with test
values takes consideration when starting from scratch.
Gross Pressure fell below minimum
during stabilization phase.
HiBurst Burst above max setpoint
HiCrack Crack above max setpoint
LoBurst Burst below min setpoint
LoCrack Crack below min setpoint
NoBurst Burst not detected
NoCrack Crack not detected
Pass The last test on this channel passed.
UserAB Abort: Stop switch was pressed.

Quick Start 17
Setting Test Time
As test times are developed,
keep in mind the size and
material of parts to be
tested. Parts that are both
small and rigid typically
require short test times.
Parts that are both large and
flexible generally require
longer test times.
Avoid the Tendency to
“Over-Test”
Optimum setup values are typically established after trial and
error when working with known good and bad product samples.
One point to keep in mind is not to over-test product. Avoid
setting leak tolerances too tight with the idea that absolutely no
leak is acceptable. Through experimentation you’ll probably find
that a small pressure drop occurs simply due to how your product
behaves during pressurization. Many products create conditions
that merely appear to be small leaks when pressurized.

18 Quick Start
2.2.8.1 Fine Tuning
After you’ve entered the basic parameters into a program, you’re
ready to fine-tune your setup. A few tips:
• If not using external fixtures, set coupling time to zero.
• If product blows out of external fixtures, make sure you
have a long enough coupling time.
• If you get gross failures when testing a flexible product, try
increasing fill time or evacuate (for vacuum tests) time.
• Add fill and stabilize time to slow the decay rate and make
it more consistent.
• If your test doesn’t need a dump valve to vent product
pressure after testing, set the vent parameter to off.
• In a flow test, set test time long enough for the product
under test to fill and produce a stable flow rate.
• If repeated parts failures of good parts occur, try widening
the pressure error tolerance or adding more fill or evacuate
(for vacuum tests) time.
2.2.9 Put Sprint iQ to Work
When everything is programmed and checked out, you’re ready to
put Sprint iQ to work and start testing products. A few tips:
• Explain controls and run display messages to operators.
• Keep external connections to the product under test as
straight, rigid, and direct as possible. Flexible connections
can cause inconsistent readings.
• Put Sprint iQ in a place where the pressure regulator and
other controls on the back won’t get moved around or
damaged.