Kaye Validator 2000 User guide

A

Kaye Validator

User’s Manual

Validation

®

mphenol

Advanced Sensors

M4350E Rev. K

July 2014

A

®

Kaye Validator

Thermal Process Validation System

User’s Manual

M4350E Rev. K
July 2014

mphenol

Advanced Sensors

Copyright © 2014 Amphenol Thermometrics, Inc.

967 Windfall Road

St. Marys, PA 15857-3333, USA

Web: www.amphenol-sensors.com.

[No content intended for this page]

Contents

Chapter 1. The Kaye Validator

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Validator Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1.3 About this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.4 The Kaye Validator System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.4.1 The Validator Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.4.2 Sensor Input Modules (SIMs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.4.3 Plug-In Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.5 The Validator Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.5.1 User Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.5.2 User Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

1.5.3 Electronic Data Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.5.4 The Study Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

1.5.5 Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1.5.6 The Qualification Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1.6 Using the Validator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Chapter 2. The Validator Hardware

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.2 The Validator Instrument. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.2.1 Display Screen and Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.2.2 Connection Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

2.2.3 Symbol Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

2.2.4 Internal Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

2.2.5 Backup Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

2.3 Sensor Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

2.3.1 Wiring SIMs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

2.4 Kaye IRTD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

2.5 Temperature Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

2.5.1 Sensor and IRTD Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

2.6 Connecting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

2.7 Setting the Validator Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

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2.8 Setting the Display Screen Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.9 Viewing Calibration Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.9.1 Return to the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.10 Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.10.1 Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.10.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.10.3 Display Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.11 Transporting and Shipping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Chapter 3. Installing the Software and Creating User Accounts

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.2 PC Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.3 Installing Kaye Validator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.3.1 Installation for a Network Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.3.2 Installation for a Local Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.4 Starting Kaye Validator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3.4.1 Creating Your System Administrator Account . . . . . . . . . . . . . . . . . . . . . . . . . 59

3.5 Creating User Accounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.5.1 Printing the User List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.6 Standalone Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.7 Selecting a Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

3.8 Getting Help. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3.9 Uninstalling the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Chapter 4. Calibrating Sensors

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.1.1 Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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4.2 Performing a Standalone Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

4.2.1 Selecting the Disk Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

4.2.2 Loading a Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

4.2.3 Selecting Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

4.2.4 Calibrating Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

4.2.5 Rewrite Report to Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

4.2.6 Viewing Calibration Offsets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Chapter 5. The Qualification Study

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

5.2 Performing a Standalone Qualification Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

5.2.1 Loading a Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

5.2.2 Starting the Qualification Study. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

5.2.3 Viewing Real-Time Sensor Readings, Calculations, and Events. . . . . . . . . . .107

5.2.4 Viewing Historical Sensor Readings, Calculations, and Events . . . . . . . . . . .118

5.2.5 Reviewing Setup Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

5.2.6 Starting and Stopping the Exposure Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . .122

5.2.7 Ending the Qualification Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

5.2.8 Rewrite Report to Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

5.2.9 Pausing Data Recording During the Qualification Study . . . . . . . . . . . . . . . .131

Chapter 6. Calibration Verification

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

6.2 Performing a Standalone Calibration Verification . . . . . . . . . . . . . . . . . . . . . . . . . . .137

6.2.1 Loading a Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

6.2.2 Selecting Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

6.2.3 Verifying Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

6.2.4 Rewrite Report to Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

Chapter 7. Specifications

7.1 Total System Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

7.2 Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

7.3 Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

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7.4 Thermocouples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

7.5 Voltage Temp Coefficient. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

7.6 Scanning Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

7.7 Input Impedance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

7.8 Compensator Temperature Coefficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

7.9 Common Mode Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

7.10 Input Terminal Temperature Non-Uniformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

7.11 Input Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

7.12 Max. Common Mode Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

7.13 Environmental Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

7.14 Relative Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

7.15 Normal Mode Rejection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

7.16 Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7.16.1 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7.16.2 Fuse Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7.16.3 Voltage Input Resolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7.16.4 Size (H x W x D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7.16.5 Voltage Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7.16.6 Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7.16.7 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

7.16.8 Real Time Clock Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Appendix A. Environmental Compliance

A.1 Waste Electrical and Electronic Equipment (WEEE) Directive . . . . . . . . . . . . . . . . 157

A.2 Battery Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

A.2.1 What do the Markings Mean?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

A.2.2 The Risks and Your Role in Reducing Them . . . . . . . . . . . . . . . . . . . . . . . . . 159

vi Kaye Validator User’s Manual

Chapter 1. The Kaye Validator

Chapter 1. The Kaye Validator

1.1 Introduction

The Kaye Validator® is the latest generation in thermal validation systems. The Validator is a
standalone thermal validation system designed to meet new regulations worldwide for
validation processes. Combining Kaye’s precision thermal measurement hardware and data
storage capability with proprietary Windows-based software, the Validator satisfies your
calibration, qualification, and reporting requirements. When performing sensor calibration and
qualification studies, you can operate the Validator in standalone mode or with a PC attached.

A complete Kaye Validator validation system includes:

• The Validator instrument

• The Validator software for Windows

®

7 and XP

• A notebook or desktop PC (minimum Pentium 300 MHz with at least 256 MB RAM and

Microsoft Office 2007, 2010 (32-bit only) or 2013, and a printer that supports both portrait
and landscape page orientation

• Up to three Kaye Sensor Input Modules (SIMs)

• A Kaye high temperature reference (HTR 400), a Kaye low temperature reference

(L TR-90, LTR -25/140 or L TR -45/140), or a Kaye cold temperature reference (CTR-80 or
CTR-40)

• A Kaye Intelligent RTD probe (IRTD)

• Premium grade thermocouples

• Additional temperature and non-temperature sensors for qualification studies (optional)

• An Epson

calibration and the qualification study.

®

LX-300 printer (optional) attached to the Validator for printing during sensor

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Chapter 1. The Kaye Validator

1.2 Validator Benefits

The Kaye Validator brings important benefits to the validation process:

• Designed to help meet FDA guidelines for protecting electronic data (21 CFR Part 11)

• Fully validated software, hardware, and firmware

• Measures and adjusts internal voltage continuously

• Flexibility to operate as standalone or with a PC during testing

• Built-in floppy disk drive (only in units built before July 2011) for loading setups,

collecting data, and upgrading firmware

• Built-in USB flash drive interface for loading setups, collecting data, and upgrading

firmware

• Over 2 MB internal memory to protect data in case floppy disk or flash disk fills up

• Battery backup for up to 30 minutes if system loses power

• Plug-in Sensor Input Modules minimize sensor handling and save calibration time

• More flexibility to set up your test—assign sensors to groups to perform independent

calculations, perform distribution and penetration tests at the same time, or qualify multiple
chambers

• Test results are stored in secure data files that can only be accessed through the Validator

software

• Generate easy-to-read, spreadsheet formatted reports from a single, protected file: raw data

is never modified

• Export qualification data to an Excel spreadsheet file

• Greater portability over other validation systems—weighs 20 pounds and includes a

carrying case

• Network capabilities allow multiple PCs to store data files to the same location and use one

centralized database for user ID/password maintenance.

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Chapter 1. The Kaye Validator

1.3 About this Manual

This manual is intended to provide overview information on the Validator, instructions on
getting started with the software, and step-by-step instructions on using the Validator in
standalone mode.

The first part of this manual provides an overview of the Validator hardware, instructions for
installing the software and creating user accounts, and an overview on using the Validator
software.The second part of this manual covers using the Validator in standalone mode,
including calibrating sensors, running qualification studies, and verifying sensor calibration.

For complete instructions on PC-controlled operation of the Validator, and instructions on
creating setups and generating reports, see the Validator online Help.

The following is a brief description of each section of this user's guide:

• Chapter 1 provides an overview of the Validator system.

• Chapter 2 explains the Validator hardware and provides instructions for connecting the

system.

• Chapter 3 provides instructions for installing the software and creating user accounts.

• Chapter 4 provides instructions for calibrating sensors in standalone mode.

• Chapter 5 provides instructions for performing a qualification study in standalone mode.

• Chapter 6 provides instructions for performing calibration verification in standalone mode.

• Chapter 7 contains the Validator specifications.

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Chapter 1. The Kaye Validator

1.4 The Kaye Validator System

The Kaye Validator system integrates hardware and software, and gives you the flexibility to
design and run studies in the way you find most productive. This section provides an overview
of the system and its use.

1.4.1 The Validator Hardware

The Validator is a self-contained instrument, incorporating high-accuracy sensor measurement
hardware with secure data recording capability. The Validator provides standalone
functionality when calibrating sensors and running qualification studies.

Figure 1: The Validator Unit

The Validator accepts up to 36 inputs in any combination of thermocouple, voltage or current
inputs. The instrument is equipped with a universal power supply (100-240 VAC) and
connections for two Kaye temperature standards (although only one standard can be used at
any given time), one Kaye temperature reference, a PC, a USB to 9Pin Serial Port Adapter, a
parallel printer for printing raw data during sensor calibration and the qualification study, and
a contact output for signaling a PLC or other device.

The Validator includes a built-in USB flash drive interface and a floppy disk drive for loading
setups, collecting data during the study, and upgrading firmware, a 12 line VGA display for
viewing data during a study , over 2 MB of internal memory to protect data during a study, and
a backup battery that protects data for approximately 30 minutes in case the system loses
power.

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Chapter 1. The Kaye Validator

1.4.2 Sensor Input Modules (SIMs)

The Validator uses Sensor Input Modules (SIMs, shown in Figure 2 ) to provide secure
connection of sensors to the Validator while protecting the electronics from draft, dust,
humidity , electrical noise and mechanical shock. SIMs are designed to be wired once and used
repeatedly. You can wire SIMs yourself, or buy pre-wired SIMs to reduce preparation time.
Once the SIMs are wired, you can calibrate multiple harnesses at the same time and store them
for later use.

Figure 2: Sensor Input Module

The Validator can be configured for up to 3 SIMs. Each SIM has:

• 12 sensor input connections

• A memory chip to store calibration offsets, SIM serial number, slot location, and the serial

number of the Validator measurement board where calibration was performed

• A cold junction reference RTD to maintain measurement accuracy in different

environmental conditions

Using 3 SIMs, you can attach up to 36 inputs in any combination of thermocouples, voltage, or
current inputs. A dedicated 4-20 mA SIM is also available with 12 4-20 mA inputs and one
connection for an external power supply.

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Chapter 1. The Kaye Validator

1.4.3 Plug-In Hardware Connections

The Validator has connectors on the back of the unit for easy plug-in of SIMs, temperature
standards, temperature references, a printer, a memory card, and a USB to 9Pin Serial Port
Adapter, for PC communication. An icon indicating the type of device identifies each
connector.

Figure 3: Validator Connections

For a more complete description of the hardware, see Chapter 2, The Validator Hardware.

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Chapter 1. The Kaye Validator

1.5 The Validator Software

The Validator software provides everything you need to perform validation testing. Using the
Validator software, you:

• Create user accounts and assign user IDs, passwords and permission levels.

• Create validation study setups that can be run standalone on the Validator or from a PC.

When calibrating sensors and running qualification studies from the PC, the Validator
software features expanded tools for graphing study data.

• Generate reports from secure data files that contain original calibration and qualification

data recorded during the study . Use the reporting utility to generate reports containing only
the results you need to document your study. You can also export qualification data to an
Excel spreadsheet file for further analysis.

1.5.1 User Access

You can set user access to the Validator to match the way your company works. The Validator
software is designed for three levels of users. Each user level has specific permissions that
define system access. Permissions can also be customized for each user.

System Administrator - Responsible for the security of the program. The System

Administrator creates and maintains user accounts, sets site options, and backs up and restores

user information.

Supervisor - Creates and modifies setups, calibrates sensors, runs qualification studies, and
generates reports. Supervisors can also change system preferences if the System Administrator
has enabled the Allow Supervisors to change Preferences site option.

Operator - Uses prepared setups to calibrate sensors, run qualification studies and generate
reports. Operators cannot change setups or system preferences.

Kaye Validator User’s Manual 7

Chapter 1. The Kaye Validator

1.5.2 User Identification

Each user is assigned two distinct levels of identification, user ID and password, which are
used to uniquely identify an authorized Validator user. Each user ID is associated with a
unique user name to provide traceability during the validation process.

The Validator requires users to enter their user ID and password whenever they:

• Create, modify, or move a setup

• Change the setup stored in the Validator

• Calibrate sensors or verify sensor calibration

• Manually start or stop a qualification study or exposure cycle

• Change preferences

Whenever an action occurs that requires a user ID and password, the user name associated
with that user ID and a time stamp are written to the file along with a description of the action.

8 Kaye Validator User’s Manual

Chapter 1. The Kaye Validator

1.5.3 Electronic Data Requirements

The Validator is designed to help you meet the guidelines for electronic signatures as specified
in FDA Regulation 21 CFR part 11, Electronic Records; Electronic Signatures.

• Two levels of identification - user ID and password

• Uniqueness of each user ID

• Users create their own passwords

• User ID and password required whenever an action affects the security or integrity of the

data

• Electronic signature identifies the user, and includes the date and time of the action

• If the data is tampered with, the entire data file becomes inaccessible

• Password expiration feature allows you to set a password expiration from 1 to 366 days

• System Administrators can set a minimum-password length requirement

• Option to disable a user account if there are three consecutive login failures for the

user ID

• Secure audit trail files provide a complete listing of events that affect the integrity of the

Validator PC program and the Validator instrument. Audit trail files contain all events and
identify the type of action performed, the date and time the action occurred, the name of the
responsible operator, and any additional information required to understand the action
taken.

• The Validator software detects when files have been added or removed outside of the

program. When a discrepancy is detected, the software informs the user at startup and asks
them to take responsibility for the added or missing file(s). If responsibility is denied, the
software will continue to inform the user of the discrepancy when the software is launched.
If responsibility is accepted, the software will request a user ID and password. Acceptance
and denial of responsibility is logged in the audit trail.

Kaye Validator User’s Manual 9

Chapter 1. The Kaye Validator

1.5.4 The Study Setup

The study setup defines everything required to calibrate sensors and run a qualification study.
When you create a setup, you:

• Define the sensors you are going to use in the study

• Assign sensors to groups and specify group calculations

• Define group events to be monitored during the qualification study

• Enter group comments to be used in report headers

• Specify calibration setpoints, temperature stability, and deviation criteria for sensor

calibration

• Specify start and stop conditions for the qualification cycle and the exposure cycle

• Specify how often to scan sensors

• Specify how often to save and/or print qualification data

• Define the output relay

After you have created and saved your setup, you run the study by loading the setup into the
Validator via USB flash or floppy disk or by direct connection from your PC to the Validator.
See the Validator online Help for instructions on setting up a study.

10 Kaye Validator User’s Manual

Chapter 1. The Kaye Validator

1.5.5 Sensor Calibration

The Validator provides both pre-qualification sensor calibration and post-qualification
calibration verification.

Before you perform a qualification study, you should calibrate the temperature sensors to
correct raw temperature readings to a traceable temperature standard. You can perform a
one-point calibration, a two-point calibration, or a two-point calibration and a one-point check.
Sensors that do not meet the pre-qualification calibration test criteria are marked as failed and
are not calibrated. Sensors that fail calibration cannot be used in a qualification study.

After the qualification study, you can perform a post-qualification verification to verify that

the sensor readings are still within the calibration criteria. You can perform a one-point,
two-point or three-point post-qualification verification. If a sensor fails post-qualification
verification, the sensor is noted as failed but the readings are still reported. Calibration offsets
are not changed during post-qualification verification.

You can calibrate temperature sensors in standalone mode or from the PC using the Validator
software. If your validation system includes a Kaye temperature reference and a Kaye IRTD,
you can perform fully automatic pre-qualification and post-qualification calibrations. If you do
not have a Kaye temperature reference you can manually set your reference. If you do not have
a Kaye IRTD, you can manually enter the reading of your temperature standard.

IMPORTANT: Standalone calibration requires a Kaye temperature reference and a

Kaye IRTD.

For instructions on standalone sensor calibration, see Chapter 4, Calibrating Sensors. For
standalone calibration verification, see Chapter 6, Calibration Verification. For PC-controlled
calibration and calibration verification instructions see the Validator online Help.

Kaye Validator User’s Manual 11

Chapter 1. The Kaye Validator

1.5.6 The Qualification Study

During a qualification study, the Validator performs calculations and compiles data for your
reports. You can run the qualification study in standalone mode or from the PC using the
Validator software.

For instructions on running a standalone qualification study, see Chapter 5, The Qualification
Study. For PC-controlled qualification studies, see the Validator online Help.

1.5.6a Report Generation

The purpose of qualifying equipment is to document its performance, either to satisfy
regulatory requirements or to perform studies of your production processes. The Validator
software includes a comprehensive reporting utility that allows you to access original study
data to generate easy-to-read reports to document the specifics of your validation study. All
reports are generated from secure data files that can only be read by the Validator software.
You can create four different report types:

• Setup Report

• Calibration Report

• Qualification Report

• Calibration Verification Report

Each report is traceable to the original study data. You can export qualification data to an
Excel spreadsheet file for further analysis.

Reports are not saved; you create reports each time from the secure data files. If a secure data
file is tampered with, it is no longer readable by the software and you will not be able to
generate reports.

For a more complete description of report generation, see the Validator online Help.

12 Kaye Validator User’s Manual

Chapter 1. The Kaye Validator

1.6 Using the Validator System

The Validator system allows you the flexibility to design your qualification procedures to fit
your workplace requirements. To perform a typical qualification study, Kaye recommends the
following steps in order:

1. Use the Validator software to create a setup.

A setup defines the type of sensors and the validation parameters specific to your production

process. If you have pre-wired SIMs, assign your sensor locations according to the SIM
configuration.

2. Print the Setup Report.
Use the Setup Report to verify your validation parameters and as a reference for connecting

your sensors.

3. If you do not have pre-wired sensors, wire your thermocouples and auxiliary sensors to the

SIMs as based on the Setup Report.

4. Connect the hardware and confirm connections.
Once the hardware is connected, use the Validator software to display a graphical

representation of your validation equipment to verify hardware and communications
connections.

5. Load the setup into the Validator to calibrate sensors and run your study standalone, or you

can calibrate sensors and run your study directly from your PC.

IMPORTANT: The Validator is designed to run either as a standalone instrument or

PC-controlled. When calibrating sensors and running qualification studies, all
major actions should be consistent. If the PC is connected, you should control
sensor calibration and your qualification study from your PC. During sensor
calibration and the qualification study, you can use the PC and/or the Validator
to view data and track your progress.

6. With your hardware configured for the validation study:

• Calibrate sensors against the temperature standard

• Run the qualification study

• Run post-qualification calibration verification

Kaye Validator User’s Manual 13

Chapter 1. The Kaye Validator

1.6 Using the Validator System (cont.)

The Validator collects all study data and stores it in a secure data file internally, on USB flash
or floppy disk, and in your PC's memory.

7. With the secure data file loaded on your PC, use the Validator software to design and

generate reports to document the specifics of your study. You can choose from two report
utilities:

• Kaye Validator now offers Report Wizard, a reporting utility that enables you to create

setup, calibration, calibration verification and qualification reports, and to export
qualification data to an Excel spreadsheet file. With Report Wizard, you can edit the
groups and sensors that appear in a qualification report, select cycles, change the layout
of columns in the report, and add comments.

• As an alternative, you can apply the basic reporting utility to generate the setup,

calibration, calibration verification and qualification reports. For qualification reports,
enhanced graphing capabilities allow selecting and removing sensors, constants and
calculations. You can also control graph colors, line styles and gridlines, and insert
relevant text and illustrations.

• In both utilities, you can access and print out the Audit Trail; you can apply filters based

on users, dates, Validators or serial numbers, and specific events.

14 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

Chapter 2. The Validator Hardware

2.1 Introduction

The Kaye Validator comes equipped with a universal power supply, a power cord for 115
VAC (or 230 VAC as necessary), over 2 MB of internal memory, a 1.44 MB 3.5-inch floppy
disk drive (only for units built before July 2011), a USB flash drive interface, a backup battery,
and a soft carrying case. This chapter describes the Validator hardware and provides
instructions for connecting the system. Included are sections describing:

• The front of the Validator instrument, which has a display screen, controls for standalone

operation, and a floppy disk drive

• The back of the Validator instrument, which has a USB flash drive interface and

connection ports for all system devices

• Internal memory

• Backup battery

• Sensor Input Modules (SIMs), which are used to connect sensors to the Validator

• The Kaye temperature reference, which provides the stable temperature required for

sensor calibration

• The Kaye IRTD, a self-contained temperature standard

• Connecting the system

• Setting the Validator time and date

• Setting the display screen contrast

• Viewing calibration information

• Preventive maintenance

• Transporting and shipping

Kaye Validator User’s Manual 15

Chapter 2. The Validator Hardware

2.2 The Validator Instrument

The Validator instrument is equipped with a display screen, control keys for standalone
operation, a USB flash drive interface and a floppy disk drive, connection ports for all system
devices, over 2 MB of internal memory, and a backup battery in case the system loses AC
power.

2.2.1 Display Screen and Control Keys

The front of the Validator (shown in Figure 4 below) has a display screen, control keys
(security, menu, and navigational) for standalone operation, and a floppy disk drive. Each of
these is discussed below.

Display Screen

Menu Keys

Navigation Keys

Security Key

Figure 4: The Kaye Validator

2.2.1a Display Screen

The 12 line, monochrome VGA displays data in text only mode. If there is more data than can
be displayed on the screen, you will see an up and/or down arrow at the bottom of the screen.
Use the up and down navigational keys on the Validator keypad to scroll through the next or
previous page of data.

You can increase or decrease the contrast of the display screen as necessary. See Adjusting the
Display Screen Contrast later in this chapter for more information.

IMPORTANT: To clean the display screen, Kaye recommends that you use only a soft, dry

cloth. Do not spray liquid cleaner on the screen.

16 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.2.1b Security Key

The security key (the key with the lock icon) prevents unauthorized access to the system. You
must press this key whenever you are going to take an action that affects the Validator, such
as:

• Loading a setup

• Calibrating sensors

• Starting and stopping qualification

• Starting and stopping exposure

When you press the security key , you are prompted for your user identification and password.
Once you have identified yourself to the Validator, you can perform the desired action. All
user logins are recorded in the audit trail and extracted to the PC program when the program
establishes communication with the Validator.

2.2.1c Menu Keys

There are six menu keys (the blue keys). The functionality of each menu key is determined by
the active display screen. Press a menu key to perform the action indicated by the label
corresponding to that key.

2.2.1d Navigation Keys

There are four navigation keys (the arrow keys). These keys correspond to up, down, left and
right. Use the up and down arrow keys to navigate within a screen when there is more data
than fits on the display. Use the left and right arrow keys to move from screen to screen.

Kaye Validator User’s Manual 17

Chapter 2. The Validator Hardware

2.2.1e USB Flash Drive Interface

The Validator is equipped with a standard USB flash drive interface and a standard 1.44 MB

3.5-inch floppy disk drive for loading setups, collecting data, and upgrading firmware. You
can collect data over multiple flash or floppy disks during a qualification run, allowing you
unlimited data storage capability . The flash drive or floppy disk drive is monitored at all times
for faults and status.

The Validator is designed to write data to the USB flash drive interface or floppy disk drive.
To provide data security, data is stored in secure data files that can only be read by the
Validator software. Files that have been tampered with are no longer readable by the software.

IMPORTANT: Data will not be written to a disk drive for PC-controlled studies if the System

Administrator has selected the Disable Validator disk recording site option. See
Setting Site Options in Chapter 3.

2.2.2 Connection Ports

The back of the Validator (shown in Figure 5 below) has ports for electrical and
communication connections. Each connection port is labeled with an icon representing its
function. The connection ports are defined on page 18.

RJ11 for IRTD

PC Serial Comm.

RJ11 for IRTD

RJ11 for Temp. Ref.

Parallel Printer

USB Flash Drive Interface

Relay NC/NO

USB Port (some versions)

Figure 5: Connection Ports

18 Kaye Validator User’s Manual

2.2.2 Connection Ports (cont.)

Table 1: Connection Port Explanations

Icon Connection Port

RJ11 Connector

There are three 6-pin RJ11 connectors, labeled with a temperature
reference icon, for connecting IRTDs and one Kaye temperature
reference. (
any given time.)

USB Flash Drive Interface

For USB flash disk insertion.

Output Relay

There is one NO/NC relay output, labeled with a contact switch icon,
for signaling a PLC or other device.

Relay Rating:

110 VAC ½ amp resistive load
24 VDC 2 amps resistive load
110 VAC ¼ amp inductive load
24 VDC 1 amp inductive load

Note: The Validator can accept data from only one IRTD at

Chapter 2. The Validator Hardware

PC Connector

There is one 9 pin D shell subminiature serial communications cable
connector, labeled with a PC icon, for connecting a PC or notebook.

USB PC Port (some versions)

One USB PC connector, labeled with a USB icon, is available for
connecting a PC.

Parallel Printer Connector

There is one 25 pin sub D connector, labeled with a printer icon, for
connecting an Epson® LX-300 printer to the Validator for printing
during sensor calibration and the qualification study. Use a standard
Centronics printer cable to connect the printer to the Validator.

Kaye Validator User’s Manual 19

Chapter 2. The Validator Hardware

2.2.3 Symbol Identification

Protective Earth Terminal

Caution (Refer to accompanying documentation.)

20 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.2.4 Internal Memory

The Validator is designed to write data to internal memory, USB flash disk, floppy disk, and
your PC hard drive (if connected) during sensor calibration and qualification studies.
Qualification data resides in internal memory until you power down the system or load a new
setup.

The Validator provides over 2 MB of internal memory to maintain qualification data during a
study. When running a qualification study, internal memory can fill up quickly depending on
the length of your study and your file rate (the rate at which data is written to internal memory ,
USB flash or floppy disk and the PC hard drive during a qualification run). File rates are
limited to valid rates for the number of assigned sensors and the scan rate.

The Validator allows you to scan data at one of two rates during the qualification study: 8
inputs per second or 12 inputs per second. Each rate has a maximum file rate that is
automatically determined based on the number of sensors being sampled, as shown below.
(For further information, refer to the Validator Online Help topic, “Data Storage Rate.”)

The maximum file rate for an 8 inputs/second scan rate is determined as follows:

Number of Sensors Maximum File Rate

1 - 8 1.0 seconds

9 - 16 2.0 seconds

17 - 36 5.0 seconds

The maximum file rate for a 12 inputs/second scan rate is determined as follows:

Number of Sensors Maximum File Rate

1 - 12 1.0 seconds
13 - 24 2.0 seconds
25 - 36 3.0 seconds

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Chapter 2. The Validator Hardware

2.2.4 Internal Memory (cont.)

IMPORTANT: If 8 inputs/second is selected, the file rate for 17 - 36 sensors is 5 seconds due to

overhead processing.

When you create a setup, you select the file rate from a list of valid rates. If you choose to
write data to internal memory at the maximum file rate, the internal memory can fill up
quickly.

When data is deleted from internal memory, data already stored to disk or printed is not
affected, however the amount of data that can be downloaded to disk at the PC after a
standalone qualification study has ended may be affected.

2.2.5 Backup Battery

The Validator is equipped with a NiCad backup battery to provide short-term power in case of
AC power loss. The intent of the battery is to provide sufficient time (approximately 30
minutes) so that you can perform an orderly shutdown of the system. When the Validator
detects that the AC power has failed and the system is running from battery, it issues a
message and then disables the Validator display backlight. You can momentarily re-enable the
backlight by pressing any key on the unit.

IMPORTANT: In the event of power glitches or short-term drops in supply voltage

(“brownouts”), there is a remote chance that the Validator will fail to fall back
to its backup battery. In this case the Validator will reset and potentially lose
any study data stored in internal memory. To prevent this from occurring, Kaye
recommends connecting the Validator to an Uninterruptible Power Supply
(UPS) in areas likely to experience brownouts.

CAUTION! Power is still supplied to the unit via the backup battery after the AC

power cord is unplugged. Disconnect the W2005 cable from the battery
pack before servicing the instrument.

The Validator monitors its own battery voltage. When the battery has approximately one
minute of power remaining, the Validator stops collecting data and closes its data files. To
ensure long service life and minimize the “memory” effect inherent in NiCad batteries, it is a
good practice to completely discharge and recharge the NiCad battery on a periodic basis.

22 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.2.5 Backup Battery (cont.)

To discharge the battery:

1. Turn the power switch on.

2. Disconnect the AC power cord.

3. Let the unit operate on battery power until the battery is completely discharged (the fan

will shut off when the battery is completely discharged).

4. Turn the power switch off.

To recharge the battery:

1. Connect the AC power cord.

2. Turn the power switch on.

3. Let the unit run for 3 hours to fully charge the battery.

A replacement battery pack, part number W2005, is available from Kaye.

CAUTION! Batteries must be disposed of in accordance with local, state

and federal regulations.

Kaye Validator User’s Manual 23

Chapter 2. The Validator Hardware

2.3 Sensor Input Modules

The Validator plug-in Sensor Input Modules (SIMs) help reduce the time it takes to perform
validation studies. Each SIM has:

• 12 sensor input connections

• A memory chip to store calibration offsets, SIM serial number, slot location, and the serial

number of the Validator measurement board where calibration was performed

• A cold junction reference RTD to help maintain measurement accuracy through changing

environmental conditions

Each SIM accepts T, J, and K type thermocouples as well as current and voltage inputs up to
10 VDC. Using 3 SIMs, you can attach up to 36 inputs in any combination of thermocouples,
voltage, or current inputs.

SIMs are designed to be wired once and used repeatedly. You can wire SIMs yourself, or buy
pre-wired SIMs to further reduce preparation time. Once the SIMs are wired, you can calibrate
multiple harnesses at the same time and store them for later use, saving you valuable
preparation time. Since calibration of thermocouples requires compensation for errors
measured in fractions of microvolts, making these offsets specific to this instrument and SIM
location, Kaye recommends that you use the supplied erasable labels to record:

• SIM serial number

• SIM slot number

• Serial number of the Validator where the sensors were calibrated and the date they were

calibrated

When you want to use these SIMs, just pull them off the shelf and plug them in. The
calibration offsets are stored in the SIM's internal memory. To prevent you from using the
wrong instrument or SIM slot, the system will alert you during the qualification run that the
SIM is plugged into the wrong instrument or the wrong SIM slot.The SIMs are made of high
impact materials that will withstand 5000 insertions, and are designed with a tilt and a drain
hole to minimize the effects of condensation.

IMPORTANT: SIMs are recognized by the system when you power up the Validator. Make sure

all SIMs are connected prior to powering up the Validator, or you will have to
power down, insert your SIMs, and power up again. If a SIM is disconnected
after power up, that SIM's sensors will be read as Open and no data will be
recorded for that SIM. To rectify this, power down, reconnect the SIM, and
power back up.

24 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.3.1 Wiring SIMs

There are two methods for wiring SIMs. You can assign sensor locations in your setup file,
and then wire the sensors according to the Setup Report, or you can buy pre-wired SIMs or
wire the SIMs yourself and then create a setup that reflects the sensor locations. This section
shows you how to wire SIMs yourself.

IMPORTANT: The SIM contains a static sensitive component that stores calibration

information. Use caution when connecting sensors. Kaye recommends that you
wear an anti-static ground strap when connecting sensors and routing wires.

To connect sensors to SIM locations:

1. Loosen the two screws in the top of the module to open a SIM. Figure 6 below shows the

inside of a SIM.

1
1

2

3

4
5

Figure 6: SIM Wiring

Legend:

1 = Tie wrap mounts
2 = Connector (locations 1 - 6)
3 = Sensing RTD
4 = Connector (locations 7 - 12)
5 = Sensor location number. There are 12 connection locations, labeled 1 - 12, with a

positive and negative connector for each input.

2. Loosen the two retaining screws where the sensor is to be inserted.

Kaye Validator User’s Manual 25

Chapter 2. The Validator Hardware

2.3.1 Wiring SIMs (cont.)

3. Connect your inputs. Valid inputs are:

• Thermocouples J, K, T and premium T (see Connecting a Thermocouple later in this

chapter)

• Contacts (see Connecting a Contact later in this chapter)

• Voltage (see Connecting a Voltage Input later in this chapter)

• Current (see Connecting a Current Transmitter With a Precision Shunt Resistor later in

this chapter)

4. Tighten the retaining screws.

5. Repeat Steps 2 through 4 for remaining sensors.

6. Once all sensors are connected, route the wire harness around the connectors and out the

drain hole. Secure the harness with the tie wraps provided. Follow Figure 7 below to
maintain the thermal accuracy of the module.

1
1

2
2

2
3

Figure 7: SIM Wiring

Legend:

1 = Tie wraps provided by Kaye
2 = Tie wraps (optional - user-supplied)
3 = Drain hole

7. Tighten the two screws in the top of the module to close the SIM.

8. Label the SIM with SIM slot number, SIM serial number , the Validator serial number, and

the calibration date.

Note: To wire the dedicated 4-20 mA SIM, see document Z2036, “4 to 20 mA Sensor Input

Module.”

26 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.3.1a Connecting a Thermocouple

Connect types J, K and T thermocouples to the connectors as shown in Figure 8 below. Cut
through the outer insulation to separate the red and blue wires, and then strip back each wire
approximately ½ inch in order to make the connection with the connector.

Figure 8: Thermocouple Connections

Always connect the positive (+) lead to the positive (+) connector and the negative (-) lead to

the negative (-) connector. The negative thermocouple lead is normally red, in conformance
with ANSI standards.

Moist Heat Environments

When validating moist heat processes, a sealed PTFE tip thermocouple should be used with a
drip cut (shown in Figure 9 below) on the outer insulation close to the SIM module to reduce
the possibility of drawing moisture into the SIM. To add a drip cut, remove 4 inches (10 cm)
of the outer insulation from each thermocouple at a point where natural drainage can take
place without water reaching the terminal screws (see Figure 9 below).

Figure 9: Drip Cut

Kaye Validator User’s Manual 27

Chapter 2. The Validator Hardware

2.3.1a Connecting a Thermocouple (cont.)

Also, Kaye recommends shaving open about 1/4 inch from each of the red and blue inner wire
jackets at opposite ends of the outer insulation drip cut to allow condensate drainage from
within the individual wires, as shown in Figure 10 below.

Figure 10: Shaving from Inner Wire Jackets

If moisture does collect in the SIM, remove the SIM from the instrument, open, and allow to
air dry before storage.

28 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.3.1b Connecting a Contact

You can connect dry contact inputs directly to the SIM, as shown in Figure 11 below. Dry
contact inputs can be used to make a time notation in the data file (to mark start exposure, stop
exposure, start of qualification, end of qualification) and to mark any events that occur during
the qualification study. You can also wire a dry contact to your vessel's PLC to detect status
output, and use it to automatically mark the start and end of the exposure cycle during the
qualification study.

–

+

+

1

23456

–

–

+

+

–

–

+

–

+

Figure 11: Connecting Dry Contact Inputs

2.3.1c Connecting a Voltage Input

Connect a voltage input (up to 10 VDC) to the connectors, as shown in Figure 12 below.

Always connect the positive (+) lead to the positive (+) connector and the negative (-) lead to

the negative (-) connector.

–

+

1

–

–

+

+

23456

–

–

+

–

+

+

Voltage

Transducer

+
–

Figure 12: Voltage Input Connection

Kaye Validator User’s Manual 29

Chapter 2. The Validator Hardware

2.3.1d Connecting a Current Transmitter With a Precision Shunt Resistor

A dedicated 4-20 mA SIM (discussed on the next page) is available that provides 12 current
inputs and a connection for an external power supply. However, a current transmitter can also
be connected to the standard SIM. Connect a precision shunt resistor to the connectors to
convert the current to a measurable voltage, as shown in Figure 13 below. Make sure the
resistor you are connecting here and the value of the shunt resistor in your setup file agree.
Kaye offers two resistors, 250  and 62.5 . The 250  resistor converts a 4-20 mA signal to
1-5V. The 62.5  resistor converts a 4-20 mA signal to 0.25-1.25V . Kaye recommends the 250
 resistor.

Current

Transmitter

–
+

Power

Supply

–

–

+

+

1

+

–

–

+

+

2345 6

–

–

–

+

+

Figure 13: Current Transmitter Connection

2.4 Kaye IRTD

The Kaye IRTD temperature measurement standard is a self-contained measurement system
providing temperature data directly to the Validator software. The measurement accuracy is
NIST-traceable to 0.025ºC, with a range of 183ºC to 420ºC.

The IRTD provides a traceable standard that is used to correct the temperature readings of
your thermocouples. During the calibration process, the Validator automatically reads and
monitors the value of the temperature reference and the IRTD probe.

The IR TD probe is shipped from the factory with its baud rate set to 9600 and its address set to

01. The Validator communicates with IRTD probes with addresses 01 or 02. However, if both
IRTD probes are set to 01, the system displays a communications error. The Validator also
reports a communications error if an IRTD is disconnected from the unit during sensor
calibration or a qualification study.

30 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.5 Temperature Reference

Temperature references provide the stable temperature required for sensor calibration. Kaye
has six temperature reference models available. They are designed to provide different
temperature ranges and are compatible with the Validator.

LTR-90 (setpoint range -95°C to 140°C at 23°C ambient)
Recommended for calibration of sensors used in freeze dryers, freezers, cryogenic units,
incubators and steam autoclaves. The LTR-90 accepts up to 12 thermocouples

LTR -25/140 (setpoint range -25°C to 140°C at 25°C ambient)
Recommended for calibration of sensors used in freezers, cold rooms, incubators and steam
autoclaves. The LTR -25/140 accepts up to 18 thermocouples.

LTR -40/140 (setpoint range -40°C to 140°C at 25°C ambient)
Recommended for calibration of sensors used in freezers, cold rooms, incubators and steam
autoclaves. The LTR -40/140 accepts up to 18 thermocouples.

HTR 400 (setpoint range 25°C above ambient to 400°C)
Recommended for calibration of sensors used in steam autoclaves, dry heat ovens and tunnel
sterilizers. The HTR 400 accepts up to 24 thermocouples.

CTR -80 (setpoint range -80°C to 30°C)
Recommended for calibration of sensors used in freeze dryers, freezers, and cryogenic units.
The CTR -80 accepts up to 36 thermocouples.

CTR -40 (setpoint range -40°C to 150°C)
Recommended for calibration of sensors used in freezers, cold rooms, incubators and steam
autoclaves. The CTR -40 accepts up to 36 thermocouples.

Kaye Validator User’s Manual 31

Chapter 2. The Validator Hardware

2.5.1 Sensor and IRTD Installation

The Kaye LTR-90, LTR -25/140, LTR -40/140, and the HTR 400 temperature references have
inserts for thermocouples and two Kaye IRTDs. Failure to use these inserts to achieve proper
thermocouple placement in the temperature reference will result in reduced accuracy during
calibration.

The Kaye CTR -80 temperature reference has three thermocouple wells and two 12-inch nylon
spacers to allow you to properly position your thermocouples and Kaye IRTDs.

LTR-90, LTR -25/140, LTR -40/140, and HTR 400
To insert thermocouple sensors into the LTR-90, LTR -25/140, LTR -40/140, and HTR

400:

• For LTR-90, insert the thermocouple sensors through the rubber insulator first.

IMPORTANT: The LTR-90 comes with a rubber insulator. This rubber insulator must be used

at all times. If it is not used, Kaye does not guarantee specifications. Also, at
cold temperatures, there will be significant ice buildup, that will affect
accuracy and uniformity.

• Insert the thermocouple sensors into the inserts and push all the way down into the well.

For 22 gauge wire, three Type T PTFE or Kapton thermocouples fit into each well.

For 28 gauge wire, six Type T PTFE thermocouples fit into each well.

To install the IRTD into the LTR-90, LTR -25/140, LTR -40/140, and HTR 400:

• For LTR-90, insert the IRTD through the rubber insulator first.

• Insert the IRTD very slowly into one of the two reference wells (the two small wells) in

the LTR-90, LTR -25/140, LTR -40/140, or HTR 400. Do not drop it from the top of the
well. To prevent mechanical shock to the IRTD when immersing it in a new temperature
environment, ensure that the immersion process takes place over a 30-second interval. The
IRTD should fit snugly, but still be easily removed.

32 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

CTR -80
To insert thermocouple sensors into the CTR -80:

• Loosen the sliding clamp mechanism on a thermocouple well, insert the thermocouple

sensors 7.5 inches into the well, slide the clamp into place, and tighten the clamp to hold
the sensors in place. When properly installed, the sensors will protrude approximately 0.5
inches beyond the end of the thermocouple wells. For 22 gauge wire, 12 PTFE
thermocouples fit into each well.

Note: The access cover, which is 7.5 inches wide, can be used as a measuring device in

positioning the sensors.

To install the IRTD into the CTR -80:

• Insert the IRTD into one of the two 12-inch nylon spacers. An IRTD with the standard

18-inch stem fits properly. If you have an older model IRTD with a 15-inch stem, shorten
the length of the nylon spacers accordingly.

Kaye Validator User’s Manual 33

Chapter 2. The Validator Hardware

2.6 Connecting the System

All system connections are on the back of the Validator. Make sure the unit is powered off
before connecting the IRTD, temperature reference (LTR-90, LTR -25/140, LTR -40/140,
HTR 400, CTR -80, or CTR -40), and SIMs

To connect your Validator, complete the following steps:

1. Connect the IRTD to one of the RJ11 sockets, using the M2810 cable supplied with the

IRTD.

2. Connect the temperature reference to one of the RJ11 sockets, using the W1885-1 cable

supplied with the temperature reference.

3. Insert the wired SIMs into their associated slot positions.

4. Insert the thermocouple sensors into the temperature reference. See the previous section,

Sensor and IRTD Installation, for installation instructions.

5. Connect your PC to the 9Pin Serial Port with the USB to 9Pin Serial Adapter provided.

6. (Optional) Connect a parallel printer to the 25-pin port. The Validator supports the

®

Epson
the Validator.

LX-300 printer. Use a standard Centronics printer cable to connect the printer to

7. Connect the temperature reference power cable and the Validator power cable to a

grounded power source.

8. Turn the temperature reference power switch to the ON position.

9. Turn the Validator power switch to the ON position.

IMPORTANT: SIMs are only recognized by the system when you power up the Validator. If a

SIM is disconnected after power up, that SIM's sensors will be read as Open
and no data will be recorded for that SIM. To rectify this, power down and
power back up.

34 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.7 Setting the Validator Time and Date

When the PC first establishes communication with the Validator, the current time and date are
automatically transferred to the attached Validator. No action on your part is required. Refer to
your Windows documentation for instructions for changing the date and time.

Note: If you change the time of day of the PC via the control panel on a Windows NT

operating system, restart the Validator PC program to update the time in the
Validator.

2.8 Setting the Display Screen Contrast

Once your system is connected and powered on, you may have to adjust the contrast of the
Validator display screen.

IMPORTANT: When the Validator is powered up, the last display screen contrast settings are

in effect. If the contrast settings make the display screen unreadable, press the
left and right arrow keys simultaneously to restore the default settings.

The first screen that displays when you power on the instrument is the Validator screen, shown
in Figure 14 below.

Validator
Setup:
Default Setup
Date: 28-Jan-2005

G1: Distribution
G2: Penetration
G3: Pressure
G4: Contact

Copyright© 1998-2006

Kaye

Main Menu

Figure 14: Validator Screen

Kaye Validator User’s Manual 35

Chapter 2. The Validator Hardware

36 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.8 Setting the Display Screen Contrast (cont.)

To adjust the screen contrast:

1. Press Main Menu from the Validator screen. The Main Menu displays, as shown in

Figure 15 below

Main Menu

Real-time Data

Historical Data

Setup Review

Hardware Controls

Home

Figure 15: Validator Main Menu

2. Press

Kaye Validator User’s Manual 37

Hardware Controls. The screen in Figure 16 on the next page displays.

Chapter 2. The Validator Hardware

2.8 Setting the Display Screen Contrast (cont.)

Hardware Controls

Increase Contrast

Decrease Contrast

Pause Disk

Pause Printer

Engineering Log

Figure 16: Hardware Controls Screen

Home

3. Press Increase Contrast/Decrease Contrast as necessary to adjust the screen display.

4. Press Main Menu. The Main Menu screen redisplays.

38 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.9 Viewing Calibration Information

Once your validation system is connected and powered on, you can view calibration
information for your Validator and your SIMs. If you are using a Kaye IRTD and temperature
reference, you can also view calibration information for your IR TD and temperature reference.

To view calibration information:

1. From the

below) displays.

Main Menu, press Setup Review. The Setup Review screen (shown in Figure 17

Setup Review

Sensor Definitions

Calculations and Events

Calibration Information

Summary

Main Menu

Figure 17: Setup Review Screen

Kaye Validator User’s Manual 39

Chapter 2. The Validator Hardware

2.9 Viewing Calibration Information (cont.)

2. Press Calibration Information. The Calibration Information screen (shown in Figure 18

below) displays.

Calibration Information

System Calibration

Sensor Calibration

IRTD/Temp Ref

Review Menu

Figure 18: Calibration Information Screen

3. Press

40 Kaye Validator User’s Manual

System Calibration. The screen in Figure 19 on the next page displays.

2.9 Viewing Calibration Information (cont.)

System Calibration
S/N: 00010007 MB S/N: 0499029
Calibrated: 07-Oct-2002
FW Version: 3.10
Setup:
Default Setup
Sensor Input Modules:

S/N Calibrated
#1 12345678 01-Jan-05
#2 98765432 02-Jan-05
#3 34567876 03-Jan-05

Figure 19: System Calibration Screen

Chapter 2. The Validator Hardware

Cal Menu

The System Calibration screen identifies the Validator serial number, the measurement board
serial number, the date this unit was calibrated, the installed firmware version, the name of the
setup that currently resides in the Validator, and the serial numbers and calibration dates of the
attached SIMs.

4. Press

Kaye Validator User’s Manual 41

Cal Menu. The Calibration Information screen (Figure 20 on the next page) displays.

Chapter 2. The Validator Hardware

2.9 Viewing Calibration Information (cont.)

Calibration Information

System Calibration

Sensor Calibration

IRTD/Temp Ref

Review Menu

Figure 20: Calibration Information Screen

5. Press IRTD/Temp Ref. The IRTD/Temp Ref screen (Figure 21 below) displays.

IRTD/Temp Ref
Time: Mon 11:06:08
Real-time Reading IRTD 1
IRTD 1: 90.0C
IRTD 2: OFFLINE IRTD 2
Temp Ref: 90.3C

Temp Ref

Cal Menu

Figure 21: IRTD/Temp Ref Screen

42 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.9 Viewing Calibration Information (cont.)

The IRTD/Temp Ref screen displays the current time and the real-time temperature readings for
up to two IRTDs and your temperature reference. You can display more information about
your IRTDs and your temperature reference from this screen.)

6. Press IRTD 1 or 2 to display more information about your IRTD. The IRTD Parameters

screen (Figure 22 below) displays.

IRTD Parameters

IRTD - 1

Address: 1
Probe ID: X2001V4.B
Label: KL25/60-70125
Calibrated: 19-Oct-2006
User Label: (Displays User Label)
Temp Scale: IPTS-68

IRTD/Temp Ref Menu

Figure 22: IRTD Parameters Screen

IRTD Parameters screen identifies the IRTD number (1 or 2) and the IRTD address (1 or

The

2), the probe ID and firmware version (Probe ID), the model number and serial number
(Label), the date the IR TD was calibrated, and the temperature scale. User-defined information
entered through the IRTD probe software displays in the User Label field.

Kaye Validator User’s Manual 43

Chapter 2. The Validator Hardware

2.9 Viewing Calibration Information (cont.)

7. Press IRTD/Temp Ref Menu. The IRTD/Temp Ref screen (Figure 23 below) displays.

IRTD/Temp Ref
Time: Tues 09:00:06
Real-time Reading IRTD 1
IRTD 1: 90.30C
IRTD 2: OFFLINE IRTD 2
Temp Ref: 90.30C

Temp Ref

Cal Menu

Figure 23: IRTD Temp/Ref Screen

8. Press Temp Ref. The screen shown in Figure 24 below displays.

Temperature Reference Parameters
Temp Ref - 1
Address: 1
Version: 3.51
Model: HTR-400
Cutot Temp.: 208
Setpoint: 90.00

IRTD/Temp Ref Menu

Figure 24: Temperature Reference Parameters Screen

44 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.9 Viewing Calibration Information (cont.)

The Temperature Reference Parameters screen identifies the address of the temperature
reference, the firmware version number, the temperature reference model number, the cutout
temperature (the upper temperature limit the reference can reach), and the current setpoint.

2.9.1 Return to the Main Menu

Now that you have reviewed the calibration information, you can return to the Main Menu.

To return to the Main Menu:

1. Press IRTD/Temp Ref Menu.

2. From the IRTD/Temp Ref screen, press Cal Menu.

3. From the Calibration Information screen, press Review Menu.

4. From the Setup Review screen, press Main Menu.

Kaye Validator User’s Manual 45

Chapter 2. The Validator Hardware

2.10 Preventive Maintenance

2.10.1 Fuse Replacement

The Validator is equipped with a 250V T 2A fuse. The fuse is located in the line filter along
with the power cord.To replace the fuse:

1. Turn the power off.

2. Disconnect the power cord from the line filter.

3. Using a small, slotted screwdriver (provided with the SIMs), pry open the fuse holder

from the bottom tab.

4. Slide the fuse holder out and replace the fuse with a 250V T 2A replacement fuse.

2.10.2 Calibration

Kaye fully calibrates each Validator before shipment. The equipment normally requires no
further adjustment or calibration during installation.

Under normal operating conditions, Kaye recommends you calibrate the Validator once a year
to maintain peak system accuracy. If you use a Validator for high accuracy measurements, or
if you replace or add circuit boards, you may need to certify the calibration more often.

2.10.3 Display Cleaning

To clean the Validator display screen, Kaye recommends that you use only a soft, dry cloth.
Do not spray liquid cleaner on the screen.

46 Kaye Validator User’s Manual

Chapter 2. The Validator Hardware

2.11 Transporting and Shipping

The Validator is designed to be easily transportable from one place to another within a plant.
The unit weighs approximately 20 pounds, and comes with a soft case with a padded handle
and shoulder strap. A zippered compartment accommodates small items such as a manual or
power cord. You can order additional cases to carry your wire harnesses and accessories.

For shipping the Validator, you'll need a safe and durable container . Kaye can supply a rugged,
foam-fitted case equipped with wheels and a collapsible handle to transport your Validator.
Two compartments include a secure space for the instrument and accessories such as SIMs
and cables. Contact the Sales Department at Kaye for pricing.

If you use another type of container, make sure the Validator is padded on all sides with four
inches of cushioning filler.

If you need to return the Validator to Kaye for service, contact the Customer Service
Department for a Return Materials Authorization Number before you ship. Include the number
with the instrument.

Kaye Validator User’s Manual 47

Chapter 2. The Validator Hardware

48 Kaye Validator User’s Manual

Chapter 3. Installing the Software and Creating User Accounts

Chapter 3. Installing the Software and Creating

User Accounts

3.1 Introduction

Before using the Validator system, you have to install the Validator software on your PC and
perform some basic system administration tasks.

The Validator software includes a Password Maintenance utility that allows a user with
System Administrator permission to create and maintain user accounts and set site options.

A default System Administrator account is included with the software. You use this account to

initially log in to the Password Maintenance utility and create your own System Administrator
account. The default account is deleted once your own System Administrator account is
created. You can then use your own account to perform all your system administration tasks.

In this chapter you:

• Install the Validator software configured for network or local applications

• Start the program and log in to the Password Maintenance utility using the default System

Administrator account

• Set site options

• Create your System Administrator account

• Create Supervisor and Operator accounts

• Print the active user list

• Select the Communications Port

• Access the Validator online Help

Kaye Validator User’s Manual 49

Chapter 3. Installing the Software and Creating User Accounts

3.2 PC Requirements

To run the Validator Windows-based software, your PC should meet the following minimum
requirements:

• Pentium microprocessor with 300 MHz processor speed and at least 256 MB RAM

• Microsoft® Windows 7 Professional (32 bit and 64 bit), or XP

• Microsoft Office Professional 2007, 2010 (32-bit only) or 2013

• One unused serial port or USB port for communicating with the Validator hardware (do not

configure any other programs, e.g., PDAs, to use the same serial communications port you
have selected to communicate with the Validator)

• Windows printer with graphical printer capability

• Color monitor with a minimum of 256 colors and resolution at least 800 x 600

3.3 Installing Kaye Validator

Kaye Validator offers the option of configuring the software for network capabilities. The
Validator data files can thus be saved to and reported on from a central network location,
rather than stored on each individual PC's hard drive. In addition, by enabling network
capabilities, the Validator software will utilize one central password database for managing
user names and passwords. You can then manage passwords for all your users in one place,
rather than having a different password database on each PC running the Kaye Validator
software.

Follow these steps to install the Kaye Validator software. Before installing the software, you
should close any applications that may be running.

• If you are installing Kaye Validator to a network drive (from which you will install it to

individual PCs), proceed to “Installation for a Network Application” on the next page.

• If you are installing Kaye Validator to an individual PC, proceed to “Installation for a

Local Application” on page 57.

50 Kaye Validator User’s Manual

Chapter 3. Installing the Software and Creating User Accounts

3.3.1 Installation for a Network Application

1. Be sure the network drive is mapped on your PC. On the drive, identify or create a network

location (folder) to hold the Validator installation and data files. This location will also
provide a central database for managing user names and passwords. The folder should be
protected against data deletion.

2. Insert the Validator CD into your CD-ROM drive.

3. If the installation does not automatically begin, complete the following steps:

• Click Start on the Windows task bar, and then click Run.

• Click Browse. From the Browse dialog box, select your CD-ROM drive, click Setup.exe,

and then click

4. Follow the on-screen instructions to perform the installation.

5. Click on the appropriate installation path to install Kaye Validator to the network drive.

6. Once installation has completed, the Kaye Validator Initialization program will run

automatically. The Kaye Validator splash screen will appear, followed by the System
Administrator Site Options screen, as shown in Figure 3-1 on the next page.

Open.

When you start up the program for the first time, you will first set up the System Administrator
Site Options. Afterwards, you will log in using the default System Administrator account and
then create your own System Administrator account.

Kaye Validator User’s Manual 51

Chapter 3. Installing the Software and Creating User Accounts

3.3.1 Installation for a Network Application (cont.)

Figure 25: System Administrator Site Options

3.3.1a Setting up Site Options

The Site Options screen lists nine options that give users more flexibility while running the
Validator software. These options are not mutually exclusive. You can enable any
combination that your site supports. As the System Administrator, you can enable options that
will:

• Set a login timer for user identification. The login timer allows users, after initial

identification, to enter only their password if user identification is within the preset time
limit. When this option is enabled, the login timer can be set from 1 to 15 minutes.

• Require minimum-length passwords for all user accounts, from 6 to 16 characters.

• Set passwords to expire after a number of days, up to 366. The user will be prompted to

change their password once their current password has expired. By default, passwords are
set to expire after 90 days. The software will display the password expiration date to the
user at login when there are five days or less until their password expires.

52 Kaye Validator User’s Manual

Chapter 3. Installing the Software and Creating User Accounts

3.3.1a Setting up Site Options (cont.)

• Disable user accounts after 3 unsuccessful login attempts. This option will disable a user

account if there are three consecutive PC login failures for the same user ID. If a user's
account is disabled, the System Administrator must enable the account and assign a new
temporary password. This option does not affect logins from the Validator instrument
panel.

• Display a warning to calibrate the Kaye Validator (in months).

• Allow users to specify the D value for lethality equations.

• Disable Validator disk recording. When this option is enabled, the Validator will not write

data to a USB flash disk or floppy disk for PC-controlled studies. This option does not
affect the loading of setups to the Validator via the disk drive.

• This option applies to PC-controlled studies only. A disk is always required for studies

run in standalone mode.

When the option to disable disk recording is selected, any setups loaded to the Validator

or saved to disk from the PC program will be set to not record to disk. This means that
any setups currently saved on a disk will need to be moved to the PC program and
loaded to the Validator or re-saved to disk in order for the disable Validator disk
recording option to take effect.

• Disabling disk recording also disables the “rewrite report to disk” function.

• When a loaded setup is set to not record to disk, the disk recording disabled icon

displays on the Validator instrument's display screen.

• Disable the password system. User IDs and passwords will not be required to use the

software.

Note: If you select this option, the Kaye Validator system will not enable compliance with

21CFR Part 11 requirements for electronic records.To restor e this option, return to the
Windows Start menu and click on Programs>Kaye Validator>Site Defaults.

• Display User ID during entry. By default the user ID is shown to the user when logging in.

Clearing this option will replace the user ID characters with asterisks (*****).

Kaye Validator User’s Manual 53

Chapter 3. Installing the Software and Creating User Accounts

3.3.1a Setting up Site Options (cont.)

7. Click the check box next to any option that you want to enable. An X appears in the check

box when the option is enabled. Click the check box again if you want to disable it. The
check box will be blank.

• If you enabled the Allow timer for User ID entry option, the Time Interval readout

displays to the right of that option, and the timer is initially set to 5 minutes. You can set
the timer from 1 to 15 minutes using the spin buttons.

• If you select the Require minimum-length password option, use the spin buttons to set

the requirement from 6 to 16 characters.

• The password expiration requirement can be set from 1 to 366 days with the spin

buttons. Click the spin buttons once to move in 1-day increments, or click and hold to
move in 10-day increments.

8. Once your site options have been set, click on the

appears, as shown in Figure 26 below.

Figure 26: The Preferences Tab in the Site Options

Preferences tab.The Preferences screen

54 Kaye Validator User’s Manual

Chapter 3. Installing the Software and Creating User Accounts

3.3.1b Establishing Site Preferences

The Preferences tab has the following settings that can be initially set for all users who install
Kaye Validator software from the network:

• Select temperature units (Celsius or Fahrenheit) for all temperature calculations

• Select the line frequency (60 Hertz or 50 Hertz)

• Select the absolute pressure units for saturated steam calculations. If you selected Other,

enter the value of 1 Standard Atmosphere in the absolute pressure units you are using.

• Allow users to specify the lethality criteria for calculation in reports

• Select the COM port from the COM Port list box

• Enter the Company Name

• Specify the data directory, which will be the default location for storing and retrieving data

files and storing the password database. Navigate to the location on the network you
identified to store the data files. This folder should be protected against file deletion.

9. Select the desired options, and click

Kaye Validator User’s Manual 55

OK.

Chapter 3. Installing the Software and Creating User Accounts

3.3.1c Completing Installation

10. Click Finish to complete the initialization program.

11. Return to the Windows task bar. Click Programs, then Kaye Validator, and then Client

Setup, shown in Figure 27 below.

Figure 27: Client Setup Program

in Kaye Validator Menu

12. Follow the on-screen instructions to complete the installation to the first PC.

Note: Once you have installed Kaye Validator to the first PC, and set up user accounts as

shown on page 61, you can return to the network initialization folder. Y ou can then run
Client Setup to install Kaye Validator from the network to other PCs.

56 Kaye Validator User’s Manual

Chapter 3. Installing the Software and Creating User Accounts

3.3.2 Installation for a Local Application

1. Insert the Validator CD into your CD-ROM drive.

2. If the installation does not automatically begin, complete the following steps:

• Click Start on the Windows task bar, and then click Run.

• Click Browse. From the Browse dialog box, select your CD-ROM drive, click Setup.exe,

and then click

3. Click on the appropriate installation path to install Kaye Validator to your PC.

4. Follow the on-screen instructions to perform the installation.

5. Once installation has completed, the Kaye Validator Initialization program will run

automatically. The Kaye Validator splash screen will appear, followed by the System
Administrator Site Options screen, as shown in Figure 25 on page 52.

6. Select the desired System Administrator Site Options and Preferences as described on

page 52, and click OK.

7. Click Finish to complete the initialization program.

Open.

8. Return to the Windows task bar. Click Programs>Kaye Validator> Client Setup.

9. Follow the on-screen instructions to complete the installation.

Kaye Validator User’s Manual 57

Chapter 3. Installing the Software and Creating User Accounts

3.4 Starting Kaye Validator

1. To open Kaye Validator for the first time, click Start >Programs>Kaye Validator>Kaye

Validator.

A control box opens similar to Figure 28 below.

Figure 28: Default Kaye Account Box

2. Click

Yes. The Identification Required dialog box (shown in Figure 29 below) appears.

Figure 29: Identification Required Box

3. Enter Kaye in the User ID text box.
Kaye is the default System Administrator user ID. The User ID text box is case sensitive, so

make sure you enter the default user ID exactly as it appears here.

4. Enter 411 in the Current Password text box. 411 is the default System Administrator

password.

5. Click OK.

The Password Maintenance user screen appears (shown in Figure 30 on the next page). You
can now create your own System Administrator account.

58 Kaye Validator User’s Manual

Chapter 3. Installing the Software and Creating User Accounts

3.4.1 Creating Your System Administrator Account

Figure 30: Password Maintenance User Screen

Once your System Administrator account is created, the default account you used to log on to
the system (Kaye/411) will be deleted. You will then be logged in under the user name you
create.

Note: At this point, the only options available are those for a System Administrator;

therefore, the user option buttons in the lower left are grayed out.

1. Enter your name in the

Name text box.

The name you enter here displays in the active user list. User names must be unique. Once you
have added your name to the active user list, you can never use the same name again. Your
name is associated with the user ID that you enter in step 2. You use your user ID and your
password to log in to the Password Maintenance utility.

2. Enter your new System Administrator identification in the

User ID text box. Your user ID

can be any combination of numbers and characters, up to a maximum of 16. A user ID may
not be used by more than one active account.

3. Enter your new System Administrator password in the

Password text box. Your password

can be any combination of numbers and characters, up to a maximum of 16. For security
reasons, it is preferable to use more than six characters or numbers.

4. Enter your password again in the

Kaye Validator User’s Manual 59

Confirm password field.

Chapter 3. Installing the Software and Creating User Accounts

3.4.1 Creating Your System Administrator Account (cont.)

At this point you should maintain a copy of your user ID and password in a manner acceptable
to your local security procedures. You need both to log in to the Password Maintenance utility,
to access reporting and to move or delete files. If you do not enter the correct user ID and
password, you will be denied access.

5. Click OK. The Main Menu appears, as shown in Figure 31 below.

Figure 31: Validator Main Menu

60 Kaye Validator User’s Manual

Chapter 3. Installing the Software and Creating User Accounts

3.5 Creating User Accounts

The Validator is designed for three levels of users:

System Administrator - Responsible for the security of the program. The System

Administrator creates and maintains user accounts, sets site options, and backs up and restores

user information.

Supervisor - Creates and modifies setups, calibrates sensors, runs qualification studies, and
generates reports. Supervisors can also change system preferences if the System Administrator
has enabled the Allow Supervisors to change Preferences site option.

Operator - Uses prepared setups to calibrate sensors, run qualification studies and generate
reports. Operators cannot change setups or system preferences.

In the previous section you created a System Administrator account. In this section you create
Supervisor and Operator accounts.

IMPORTANT: A good practice is to establish more than one individual as a System

Administrator. This way the Password Maintenance utility functions can still be
accessed even if one of the System Administrators is unavailable.

When you create user accounts, each user's name is added to the active user list. You assign a
unique user ID for each user and a temporary password. The user will change the password
when they first log in.

To create user accounts:

1. From the Main Menu screen, click Password Maintenance, and log in as a System

Administrator. The Password Maintenance screen appears similar to Figure 32 below. Note
that the System Administrator account is the only user listed.

Figure 32: Password Maintenance Screen

Kaye Validator User’s Manual 61

Chapter 3. Installing the Software and Creating User Accounts

3.5 Creating User Accounts (cont.)

2. From the Password Maintenance menu, select Users>New User.
The Password Maintenance dialog box, shown in Figure 33 below, displays.

Figure 33: Password Maintenance User Screen

3. Enter the new user name in the

Name text box.

The user name is associated with the user ID that you enter in step 3. The user ID is used to
identify the user to the Validator software. The name you enter here appears in the active user
list.

IMPORTANT: User IDs must be unique. Once an ID has been used, it cannot be used again.

4. Enter the new user identification in the User ID text box. The user ID can be any

combination of numbers and characters, up to a maximum of 16. The user ID and password
are case sensitive. A user ID may not be used by more than one active account.

62 Kaye Validator User’s Manual

Chapter 3. Installing the Software and Creating User Accounts

3.5 Creating User Accounts (cont.)

5. Enter a temporary password for the user in the Password text box. The password can be any

combination of numbers and characters, up to a maximum of 16. The user will change this
password when they first log in to the program.

6. Enter the temporary password again in the Confirm password text box.

IMPORTANT: If this user plans to use the Validator hardware in standalone mode, use the

numbers 1-5 only for the user ID, and inform the user to enter numbers from
1-5 when they create their permanent password. Standalone mode accepts the
numbers 1-5 only.

At this point you should record the new user ID and temporary password. You will need to

supply this information to all new users. A user ID and password is required any time a user:

• Changes preferences (if the System Administrator has enabled the user to modify

preferences, then other users can change preferences, otherwise the System Administrator
is responsible for changing preferences)

• Creates or modifies a setup

• Changes the setup stored in the Validator

• Calibrates sensors or verifies sensor calibration

• Manually stops sensor calibration or calibration verification

• Manually starts or stops a qualification study or exposure cycle

IMPORTANT: A user account is not active until users change their temporary password when

they log in to the PC program for the first time. Users will be unable to run the
Validator in standalone mode if they have not changed their temporary
password.

7. Set default user permission for this new account to Supervisor or Operator by clicking the

associated button.

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Chapter 3. Installing the Software and Creating User Accounts

3.5 Creating User Accounts (cont.)

8. The Disable User Account option allows you to deny access to the system for this user . For

example, if you are creating an account for a user who will not need access to the system
for several months, you may want to select this option to deny access to the user. You can
de-select this feature once the user is ready to use the system (see the Validator online
Help for instructions on editing user accounts).

9. Click any specific Permissions you wish to grant the user. While Operators or Supervisors

have certain standard permissions, you can modify a specific account so that the user can:

• Create setups

• Execute qualifications

• Execute or verify sensor calibration

• Create reports

• Move or delete studies

• View and print the Audit Trail

• Modify preferences

• Calibrate the Validator

• Modify site options

• Maintain passwords

10. Click

The Password Maintenance screen now appears similar to Figure 34 on the next page, with the
new account listed.

Note: Use the scroll bar at the bottom of the screen to view additional information for user

64 Kaye Validator User’s Manual

OK.

accounts.

Chapter 3. Installing the Software and Creating User Accounts

3.5 Creating User Accounts (cont.)

Figure 34: Updated Password Maintenance Screen

11. Repeat steps 1-10 to add more users to the system.

3.5.1 Printing the User List

When displayed on your PC monitor, the user list displays the active user accounts. The printed
user list contains active and deleted user accounts, disabled user accounts, user accounts
waiting for initial login, the name of the System Administrator that printed the list, the date and
time the list was printed, the timestamp of the user list, and the machine ID.

Note: You can view deleted user accounts on your PC monitor by deselecting the Hide

deleted entries option from the File menu.

To print the user list:

• From the Password Maintenance screen, select File>Print Users. The user list prints to your

default printer. It includes a date and time stamp, machine ID, the user table, permissions,
disabled and deleted users.

To change your default printer:

• From the Password Maintenance screen, select File>Print Setup. Select a new printer from

the list and click

The Password Maintenance screen displays. Select File>Exit to exit the Password Maintenance
utility.

Kaye Validator User’s Manual 65

OK.

Chapter 3. Installing the Software and Creating User Accounts

3.6 Standalone Passwords

Once user accounts are created by the System Administrator with the Validator software, users
running the Validator instrument in standalone mode can enter their user ID and password at
the Validator instrument panel to run qualification studies, verify sensor calibration, and
calibrate sensors, (provided that the user ID and password consist of numbers from 1-5, and
the user has activated their account by creating a password through the PC program).

If users are running the Validator in standalone mode with the password expiration site option
enabled, steps should be taken to ensure that users have the ability to change their passwords
before they expire. The Validator firmware will reject expired passwords— users will need
access to the Validator software in order to update them. A setup will need to be copied again
to USB flash or floppy disk and transferred to the Validator instrument, or re-loaded directly to
the Validator from the PC in order for the firmware to read the new user table with the updated
password information.

Kaye recommends informing standalone users when their passwords are nearing the
expiration date, allowing them time to use the software to change their password. For users
who routinely access the Validator software, they will receive a prompt at login when there are
five days or less until their password is set to expire.

It is possible that a user running a study in standalone mode could login with their user ID and
password to start a qualification study, but be unable to stop the study because by that time
their password has expired. In this circumstance, follow the steps below to safely stop the
study without losing data:

1. On the Sensor Inputs - Real Time screen at the Validator instrument, press the Main Menu

soft key.

2. On the Main Menu, press Hardware Controls. Press Pause Disk on the Hardware Controls

screen.

3. Once the USB flash or floppy drive indicator light goes out, disk recording is paused. Eject

the flash or floppy disk from the drive. Insert a new disk in your PC's flash or floppy drive
and start the Validator software.

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Chapter 3. Installing the Software and Creating User Accounts

3.6 Standalone Passwords (cont.)

4. From the Main Menu, click the Preferences tab. At the Identification Required login screen,

enter the expired user ID and password and click OK. Change the password when prompted
and return to the Main Menu.

5. Use the Validator software to copy a setup (it does not matter which one — the purpose is

to save a new user table only) to the disk.

6. Transfer the new disk to the Validator instrument's USB flash or floppy drive. The

Validator should be displaying a message confirming disk recording has been paused.
Press Continue.

7. On the Hardware Controls screen, press Resume Disk.

8. Press the blue security key. The System Login screen appears.

9. Enter the updated user ID and password. At the Password Operations screen, press Stop

Qualification. Your qualification study data is now saved on two flash or floppy disks.

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Chapter 3. Installing the Software and Creating User Accounts

3.7 Selecting a Communications Port

Note: If you have installed Kaye Validator from a network, the communications port may

have been already selected. You must have appropriate permissions to modify
preferences.

You must select a communications port in order for the Validator to communicate with your
PC. To select a communications port:

1. Click Start >Programs>Kaye Validator>Kaye Validator.

2. Click the Preferences tab at the top of the screen.

The Identification Required dialog box displays, shown in Figure 35 below.

Figure 35: Identification Required Dialog Box

3. Enter your user ID and the password supplied by your System Administrator and click OK.

If you are entering the program for the first time, you will need to change the password
before you can exit the password entry box.

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Chapter 3. Installing the Software and Creating User Accounts

3.7 Selecting a Communications Port (cont.)

The Preferences screen displays, as shown in Figure 36 below.

Figure 36: The Preferences Screen

Click the down arrow in the

COM Port list box to display the available communications ports

and select a port from the list.

IMPORTANT: Do not configure any other programs, e.g., PDAs, to use the same

communications port you have selected to communicate with the Validator.

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Chapter 3. Installing the Software and Creating User Accounts

3.7 Selecting a Communications Port (cont.)

The selected COM port displays on the Preferences screen, as shown in Figure 37 below.

Figure 37: Preferences Screen with Selected Port

You can also select on the Preferences tab:

• Temperature units (Celsius or Fahrenheit) for all temperature calculations

• The line frequency (60 Hertz or 50 Hertz)

• The absolute pressure units for saturated steam calculations. If you selected Other, enter the

value of 1 Standard Atmosphere in the absolute pressure units you are using.

• The Company Name

• The IRTD Stability Threshold

• Whether you will use Report Wizard to generate qualification reports, and whether you can

merge ValProbe studies. Report Wizard is a reporting utility that enables you to create
setup, calibration, calibration verification and qualification reports, and to export
qualification data to an Excel spreadsheet file. With Report Wizard, you can edit the groups
and sensors that appear in a qualification report, select cycles, change the layout of columns
in the report, and add comments. (Please note that if you do not select Report Wizard, you
will not be able to merge ValProbe studies.)

Select the desired options, and click

70 Kaye Validator User’s Manual

OK.

Chapter 3. Installing the Software and Creating User Accounts

3.8 Getting Help

There are four ways to get help while using the Validator software:

Help Screen—Click the Help tab to access the Help screen. From the Help screen you can
access the online help Contents and Index.

Help Button—Click the help button on any screen to display online help for the
currently active screen.

F1 Function Key—Position the cursor on the field or control that you want help on, or tab to
that field or control, and press the F1 function key to display context sensitive help for that
field or control. If that field or control does not have its own help topic, the help topic for the
active screen displays.

Status Messages—When you move your cursor over a control or item on the screen, a brief
status message appears at the bottom of the screen.

3.9 Uninstalling the Software

If for any reason you need to uninstall the Validator software, access the Validator uninstall
program through Windows.

To uninstall the software:

1. Click Start>Settings>Control Panel.

2. Double-click Add/Remove Programs.

3. Select Kaye Validator from the list of programs, and click Change/Remove.

4. Follow the on-screen instructions to uninstall the software.

5. Select Kaye Validator Initialization from the list of programs, and click

Change/Remove.

6. Follow the on-screen instructions to uninstall the software.

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Chapter 3. Installing the Software and Creating User Accounts

72 Kaye Validator User’s Manual

Chapter 4. Calibrating Sensors

Chapter 4. Calibrating Sensors

4.1 Introduction

Before you perform a qualification study, you should calibrate your temperature sensors to
correct raw temperature readings to a traceable temperature measurement standard.

The Kaye Validator can perform standalone or PC-controlled calibration:

• You can perform standalone calibration only if your validation system includes a Kaye

temperature reference and IRTD.

• You can perform PC-controlled calibration automatically if your validation system includes

a Kaye temperature reference and IRTD, or manually if your validation system does not
include a Kaye temperature reference and/or IRTD.

IMPORTANT: The Validator is designed to run either as a standalone instrument or

PC-controlled. When calibrating sensors, all major actions should be
consistent. If the PC is connected, you should control sensor calibration from
your PC. During sensor calibration you can use the PC and/or the Validator to
view data and track your progress.

The Validator uses the calibration parameters defined in your setup to perform sensor
calibration. Calibration parameters specify the temperature reference setpoints at which
calibration is performed, and the stability and deviation criteria for the temperature sensors
and the temperature standard. See Specifying Calibration Parameters in the Validator online
Help.

The Validator allows you to calibrate sensors at a low setpoint, a high setpoint, or both. When
you start calibration, the Validator computes the stability of the temperature sensors and the
temperature standard at the specified setpoint, according to the parameters defined in your
setup. When the temperature standard and all sensors pass the stability criteria, the Validator
logs the stability readings to the calibration report file. The Validator then computes and logs
deviation on the uncalibrated sensors, and calibrates all sensors that passed the deviation
criteria. Finally, the Validator computes and logs deviation on the calibrated sensors for a
specified time period. If you are performing a two-point calibration (low and high setpoints),
the Validator repeats this process.

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Chapter 4. Calibrating Sensors

4.1 Introduction (cont.)

You can also specify a check setpoint in your setup. During check setpoint, the Validator
calculates and logs deviation on the calibrated sensors. Calibration offsets are not altered
unless a sensor fails at the check setpoint.

During the calibration process, the Validator writes calibration data to the USB flash or floppy
disk drive, the PC hard drive (if calibration is PC-controlled), and to the Validator printer (if
attached).

Note: Data will not be written to the disk drive for PC-controlled calibrations if the System

Administrator has enabled the Disable Validator disk recording site option. See Setting
Site Options in Chapter 3.

When calibration is complete, the Validator writes the calibration offsets, the serial number of
the Validator measurement board where calibration was performed, and the SIM slot number
to the SIMs. If a sensor fails at the low, high, or check setpoint, it is marked as failed in the
SIM and in the calibration report file.

4.1.1 Preliminary Steps

Before you begin the calibration process:

• Place the Validator in a location with stable and even temperature, not exposed to any local

heat sources (i.e., close to a sterilizer, an open door causing a draft, etc.). Temperature
variations and/or exposure to external heat sources during calibration may cause temporary
temperature measurement errors.

• To provide maximum accuracy during the calibration process, power up the Validator and

let it run for approximately 30 minutes in the operating environment where calibration is to
be performed in order for the Validator to acclimate to the ambient temperature.

• Place the temperature sensors and the IRTD into the temperature reference. The

temperature reference provides the stable temperature required for sensor calibration. The
IRTD, a self-contained precision measurement standard that provides data directly to the
Validator, accurately measures the temperature of the reference. The IRTD provides a
traceable standard that is used to correct the temperature readings of your thermocouples.

This chapter provides instructions on performing a standalone sensor calibration. For
instructions on performing a PC-controlled sensor calibration, see the Validator online Help.

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Chapter 4. Calibrating Sensors

4.2 Performing a Standalone Calibration

You can perform standalone calibration only if your validation system includes a Kaye
temperature reference and IRTD. The Validator automatically sets the temperature reference
to the specified setpoint (Low , High, Check), and automatically reads the value of the IRTD at
that setpoint.

In this section you:

• Load a setup into the Validator

• Select sensors to calibrate

• Run calibration

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Chapter 4. Calibrating Sensors

4.2.1 Selecting the Disk Storage

To set the type of disk on which you will store data (either floppy (for units built before July

2011) or USB):

1. Press the Security Key.
The System Login screen, shown in Figure 38 below, displays.

System Login

User ID: 1
>
Password: 2

3

4

5

ENTER

Figure 38: System Login Screen

2. Key in your user ID and press

ENTER.

3. Key in your password and press ENTER.

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Chapter 4. Calibrating Sensors

4.2.1 Selecting the Disk Storage (cont.)

The Password Operations screen, shown in Figure 39 and Figure 40 below , displays. To select
the type of storage you need (floppy or USB Disk), press the Select (Floppy or USB) Disk

Storage entry to alternate to the desired storage medium.

Password Operations

Load Setup

Calibrate Sensors

Start Qualification

Select Floppy Disk Storage

Main Menu

Figure 39: Password Operations Screen

(for Selecting Floppy Disk Storage)

Password Operations

Load Setup

Calibrate Sensors

Start Qualification

Select USB Disk Storage

Main Menu

Figure 40: Password Operations Screen

(for Selecting USB Disk Storage)

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Chapter 4. Calibrating Sensors

4.2.2 Loading a Setup

The first screen you see after the unit has been powered up is the Validator screen. This screen
lists the setup currently loaded in the Validator. If the Validator screen is not the current
screen, press Main Menu. From the Main Menu, press Setup Review, and then press Summary.
The currently loaded setup displays on the Validator screen, shown in Figure 41 below.

Kaye Validator
Setup:
Default Setup
Date: 28-Jan-05

G1: Distribution
G2: Penetration
G3: Pressure
G4: Contact

Copyright© 1998-2006

Kaye

Main Menu

Figure 41: Summary Screen

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Chapter 4. Calibrating Sensors

4.2.2 Loading a Setup (cont.)

If the setup loaded in the Validator is the one you are going to use for calibration, go to the
next section, Selecting Sensors.

IMPORTANT: When you load a setup with a different calibration signature (calibration

parameters and/or temperature units) than the setup currently in memory, any
sensors already calibrated will be marked as uncalibrated. If you reload the
original setup, and you have not calibrated sensors using the new setup, the
offsets are restored and the sensors are marked as calibrated.
When you load a setup with a different line fr equency than the setup curr ently in
memory, you must wait for the Validator to stabilize (approximately 2 - 3
minutes) before calibrating sensors or you may see invalid sensor data
displayed. You can also turn the Validator off and then back on, and then
calibrate your sensors.

To load a setup:

1. Insert the USB flash or floppy disk that contains your setup into the Validator USB flash

drive interface or floppy disk drive.

In addition to setup data, the disk contains the user list and the machine ID of the PC that
saved the file to floppy or flash.

2. Press the Security Key.

When you press the Security Key, the Validator reads the machine ID of the PC from the disk.

• If the machine ID on disk is the same as the machine ID in internal memory, the

Validator compares the date of the user list on the disk to the date of the user list in

internal memory. If the user list on the disk is more recent than the one in internal
memory, the Validator replaces the user list in internal memory with the one from the
disk.

• If the machine ID on disk does not match the machine ID in internal memory, the user

list on the disk replaces the user list in internal memory.

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Chapter 4. Calibrating Sensors

4.2.2 Loading a Setup (cont.)

When the Validator finishes comparing the machine IDs and user lists, the System Login
screen, shown in Figure 42 below, displays.

System Login

User ID: 1
>
Password: 2

3

4

5

ENTER

Figure 42: System Login Screen

3. Key in your user ID and press

ENTER.

4. Key in your password and press ENTER.

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Chapter 4. Calibrating Sensors

4.2.2 Loading a Setup (cont.)

The Password Operations screen displays, as shown in Figure 43 below.

Password Operations

Load Setup

Calibrate Sensors

Start Qualification

Select Floppy Disk Storage

Rewrite Report to USB Disk

Main Menu

Figure 43: Password Operations Screen

5. Press

Load Setup.

The Validator displays the setup files that reside on the disk and, for each setup, displays the
setup name, the name of the Supervisor who last saved the setup, and the date and time the
setup was saved, on the Setup List screen, shown in Figure 44 on the next page. The setup
names appear in reverse video.

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Chapter 4. Calibrating Sensors

4.2.2 Loading a Setup (cont.)

>Steam Sterilizer Prev
John Doe
03-Apr-2005 Mon 10:34:55 Next
Penetration Study
John Doe Load
31-Apr-2005 Fri 14:32:44
Distribution Study
John Doe
31-Apr-2005 Fri 14:02:25

 Main Menu

Figure 44: Setup List Screen

Setup List

6. If there are multiple setups on the disk, use the up and down arrow keys on the Validator

keypad, or the Next and Prev buttons on the Setup List screen, to select your setup. The
pointer (>) appears to the left of the selected setup.

7. Press Load.
It takes a few seconds for the Validator to load the setup. When complete, the Sensor

Inputs-Real Time screen displays.

The next step is to select the sensors to be calibrated.

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Chapter 4. Calibrating Sensors

4.2.3 Selecting Sensors

The sensors you select for calibration will have any previous calibration offsets deleted from
the SIMs when you start calibration.

To select sensors for calibration:

1. If you have not entered the Password Operations screen, press the Security Key to enter the

System Login screen, shown in Figure 38 on page 76.

2. Key in your user ID and press ENTER, and then key in your password and press ENTER.

3. Press Calibrate Sensors.

The Sensor Selection screen displays. This screen, shown in Figure 45 below, lists all the
temperature sensors defined in your setup. The SIM numbers and sensor locations of
uncalibrated sensors display in reverse video.

Sensor Selection

>All Sensors Criterion

I-01 Temp 01
I-02 Temp 02 Select
I-03 Temp 03
I-04 Temp 04 Deselect
I-05 Temp 05
I-06 Temp 06 Continue
I-07 Temp 07
I-08 Temp 08

 Main Menu

Figure 45: Sensor Selection

4. Select the sensors you are going to calibrate. You can select sensors individually or select

all sensors in one step.

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Chapter 4. Calibrating Sensors

4.2.3 Selecting Sensors (cont.)

• To select sensors individually, use the up and down arrow keys on the Validator keypad

to position the pointer on the individual sensor and press
to the right of the selected sensor, indicating this sensor is to be calibrated.

Select. An asterisk (*) appears

• To select all sensors in one step, use the up and down arrow keys on the Validator

keypad to position the pointer on
the right of each sensor, indicating all sensors are to be calibrated.

Note: You can deselect sensors individually or deselect all sensors in one step using the

Deselect button.

In the example shown in Figure 46 below, sensors 1-01 through 1-04 have been selected.

>All Sensors Criteria

I-01 Temp 01*
I-02 Temp 02* Select
I-03 Temp 03*
I-04 Temp 04* Deselect
I-05 Temp 05
I-06 Temp 06 Continue
I-07 Temp 07
I-08 Temp 08

All Sensors and press Select. An asterisk (*) appears to

Sensor Selection

 Main Menu

Figure 46: Sensor Selection Screen

5. After you have selected the sensors to calibrate, press

84 Kaye Validator User’s Manual

Continue.

Chapter 4. Calibrating Sensors

4.2.3 Selecting Sensors (cont.)

The Sensor Confirmation screen (shown in Figure 47 below) displays. This screen lists all the
sensors selected on the Sensor Selection screen.

Sensor Confirmation

Reselect

I-01 Temp 01
I-02 Temp 02 Cancel
I-03 Temp 03
I-04 Temp 04 Run Calibration

Run Verification

 Main Menu

Figure 47: Sensor Confirmation Screen

6. If the sensors you selected are not the ones you want to calibrate, press

Reselect, and repeat

steps 5 and 6.

Now you are ready to calibrate the sensors.

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Chapter 4. Calibrating Sensors

4.2.4 Calibrating Sensors

The Validator automatically calibrates sensors at the setpoints defined in your setup. Before
starting calibration, make sure you have a USB flash or floppy disk in the disk drive. If you are
printing calibration data to an attached printer, make sure the printer is connected to the
Validator and powered on.

In the following example, you perform a two-point calibration (low setpoint and high setpoint)
and a one-point check (check setpoint).

To calibrate sensors:

1. From the Sensor Confirmation screen (shown in Figure 48 below), press Run Calibration.

Sensor Confirmation

Reselect

I-01 Temp 01
I-02 Temp 02 Cancel
I-03 Temp 03
I-04 Temp 04 Run Calibration

Run Verification

 Main Menu

Figure 48: Sensor Confirmation Screen

The Validator clears calibration offsets stored in the SIMs for the selected sensors, and
establishes communications with the temperature reference and the IRTD. When this is
accomplished, the

Sensor Calibration screen (Figure 4-11 on the next page) displays. The

sensor locations and IRTD title display in reverse video until they reach stability.

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Chapter 4. Calibrating Sensors

4.2.4 Calibrating Sensors (cont.)

IMPORTANT: All calibration offsets will be deleted from the SIMs if the calibration

parameters or temperature units of the new setup are different than the
calibration parameters or temperature units of the setup currently in memory.

Sensor Calibration

Automatic

Stabilizing Low Setpoint

IRTD 89.861C ------------

Setpt 90.00C Elapsed Time: 0000:00:00
LOC TEMP STABILITY

I-01 89.98C ------------
I-02 89.97C ------------
I-03 89.98C ------------
I-04 89.96C ------------ Criteria

STOP

Figure 49: Sensor Calibration Screen

Note: Calibration offsets for sensors at each setpoint are written to the SIM when the

calibration process is complete. If you stop calibration, calibration offsets already
calculated are not written to the SIMs, and the calibration report file is deleted.

For example, if you have completed low setpoint calibration, and then stop the
calibration process during high setpoint calibration, the sensors ar e marked UNCAL'D
in the SIMs and the calibration report file is deleted.

Calculating Stability

The first step in the calibration process is to verify that the sensors and IRTD are stable.
Stability is the maximum allowable change in temperature for each sensor and the temperature
standard over a specified time interval. The maximum allowable change in temperature for the
IRTD is fixed at 0.012°C (0.022°F) if all temperature setpoints are equal to or greater than

0.0°C (32.0°F). If any temperature setpoint is less than 0.0°C (32.0°F), you can enter the IR TD
stability value manually in your setup.

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Chapter 4. Calibrating Sensors

4.2.4 Calibrating Sensors (cont.)

The stability calculation begins once the temperature reference is within 5 degrees of the low
setpoint. Stability is computed at the scan rate.

To achieve stability, the IRTD and all sensors must meet the stability criteria defined in the
setup. The IRTD and sensors display in normal video when they reach stability. If any sensors
fail to reach stability, the calibration process remains here. To end the calibration process,
press STOP.

Note: You can display the temperature setpoints and the stability and deviation criteria

defined for this setup at any time by pressing Criteria on the Sensor Calibration screen,
as shown in Figure 50 below. Press Sensor Cal to redisplay the sensor readings.

Sensor Calibration

Automatic

Stabilizing Low Setpoint

IRTD 89.861C ------------

Setpt 90.00C Elapsed Time: 0000:00:30
LOC TEMP STABILITY

I-01 89.94C 0.02C
I-02 89.99C 0.03C
I-03 89.93C 0.03C
I-04 89.92C 0.01C Criteria

STOP

Figure 50: Sensor Calibration Screen

Calculating Deviation of Uncalibrated Sensors

When the IRTD and all sensors reach stability, the Validator calculates uncalibrated deviation
by comparing each sensor to the IRTD, and then logs the stability and uncalibrated deviation
data to the calibration report file. The Validator marks any sensor outside the deviation criteria
as failed. When uncalibrated deviation is complete, the Validator calibrates the sensors at the
low setpoint.

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Chapter 4. Calibrating Sensors

4.2.4 Calibrating Sensors (cont.)

Calculating Deviation of Calibrated Sensors

The Validator then calculates calibrated deviation. The corrected results for each sensor are
compared to the IRTD, and logged and displayed every 30 seconds for the time period
specified in the setup. Sensors that fail the calibrated deviation evaluation are displayed in
reverse video and marked as failed in the calibration report file.

Data Logging Complete at Setpoint

When the Validator finishes logging the corrected results at the low setpoint, it automatically
sets the Kaye temperature reference to the high setpoint and repeats the calibration process.

When the calibration process is complete for the high setpoint, the Validator automatically sets
the Kaye temperature reference to the check setpoint. The only difference between low and
high setpoint calibration and the check setpoint is that calibration offsets are not changed
during check setpoint.

Calibration Complete

When calibration is complete, the System Message screen in Figure 51 below displays.

System Message
MESSAGE TIME: 13-Apr-2005 Tues 10:49:51
MESSAGE LEVEL: Warning Continue
MESSAGE DESCRIPTION:
Floppy Disk Recording Complete

Figure 51: System Message Screen

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Chapter 4. Calibrating Sensors

Calibration Complete (cont.)

IMPORTANT: Do not remove the disk until you acknowledge that the disk write is complete by

pressing Continue. If you remove the disk before the disk drive light goes out,
you may lose data.

2. Press Continue and then remove the disk from the drive.
The USB flash or floppy disk contains the calibration report file. Now that calibration is

complete, you can take the disk to your PC to generate a Calibration Report. See the Validator

online Help for information on generating a Calibration Report.

4.2.5 Rewrite Report to Disk

You can write an additional copy of the calibration report file to a USB flash or floppy disk
using the Rewrite report to disk option.To rewrite the calibration report file to a disk:

1. Insert a USB flash or floppy disk into the appropriate Validator drive.

2. Press the blue security key. Enter your user ID and password on the System Login screen.

The Password Operations screen, shown in Figure 52 below and Figure 53 on the next page,
displays.

Password Operations

Load Setup

Calibrate Sensors

Start Qualification

Select USB Disk Storage

Rewrite Report to Floppy

Main Menu

Figure 52: Password Operations

90 Kaye Validator User’s Manual

4.2.5 Rewrite Report to Disk (cont.)

Password Operations

Figure 53: Password Operations

3. Press Rewrite Report to Disk

Chapter 4. Calibrating Sensors

Load Setup

Calibrate Sensors

Start Qualification

Select Floppy Disk Storage

Rewrite Report to USB Disk

Main Menu

The Validator copies the calibration report file to the disk. While the file is being saved, the
green indicator light on the drive is lit. After the calibration report file is saved, the System

Message screen displays with a verification message, as shown in Figure 54 on the next page.

Kaye Validator User’s Manual 91

Chapter 4. Calibrating Sensors

4.2.5 Rewrite Report to Disk (cont.)

System Message

MESSAGE TIME: 13-Apr-2005 Tues 10:49:51

Floppy Disk Recording Complete

Verification Status: PASSED

Figure 54: Message Screen with Verification Status

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92 Kaye Validator User’s Manual