Isaac
Pressure Decay Leak Tester
A User’s Guide
PD
Ver. 1.00
Isaac
Pressure Decay Leak Tester
WEBSITE:
https://zaxisinc.com
EMAIL:
info@zaxisinc.com
PHONE:
PD
A User’s Guide
Ver. 1.00
801.264.1000
HEADQUARTERS:
2442 South 2570 West
West Valley City, UT 84119
*Wall or stand mounted
*Fixture Not Included - (Example of use)
For Your Safety.
Install all equipment according to local safety codes.
Additional guidelines when working with the Isaac PD Pressure Decay Leak Tester:
» Always wear eye protection when working with compressed gas.
» Beware of possible hazardous voltages present inside the enclosure.
» Do not attempt any maintenance procedure discussed in this guide until
proper understanding of the tasks involved has been attained.
WARNING! Always disconnect power before removing cover
or fuse holder.
CAUTION! Equipment requires a clean-dry air supply. Failure
to comply may void warranty.
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
3
THREE YEAR LIMITED WARRANTY
Zaxis, Inc. Limited Warranty
ZAXIS INC. products are manufactured to a very high standard, however when
located in physically hostile environments or when operated under non-specication
voltage or pressure conditions, warranty may be voided. Please refer to your user
manual for more detailed information.
ZAXIS INC., therefore, warrants only as follows: Supply clean dry air only to the unit.
Each unit is identied by serial number in a permanent record of the company. If at
any time with-in three years after any ZAXIS INC. product has been shipped to a
customer (user), it fails to perform according to ZAXIS INC. literature, the product,
with written explanation of the problem, may be returned, freight prepaid, to ZAXIS
INC. for examination, repair or replacement at ZAXIS INC. expense (labor and
material). All such returns must have prior ZAXIS INC. customer service authorization
before returning. If, upon examination, ZAXIS INC. determines that abusive
practices, non-ltered and dried air or destructive environment of operation or a
combination of these factors is responsible for improper performance of the product,
all labor and materials costs involved shall be at the expense of the customer.
ZAXIS INC. is not liable for special, indirect or consequential damages that may result
from use, failure or malfunction of the product and any recovery against ZAXIS INC.
may not be greater than the purchase price paid for the product.
No person is authorized to change the terms of this warranty.
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
4
Introduction
The Isaac PD Leak Tester is the latest product from Zaxis designed to meet today’s
quality assurances demands.
The compact size of the Isaac PD makes it easy to use in a variety of testing situations.
By reducing the internal and connection volumes, the test sensitivity will increase and
test times can be reduced. This small internal volume, combined with integrated sensors
and a 24bit analog to digital convertor, allows Zaxis to offer a leak tester with the
highest sensitivity on the market.
This guide covers the standard Isaac PD Leak Testers. All the current functions and features are found in this guide. Your tester could differ in installed features.
Safety and Emissions
Operating Environment Conditions:
Indoor Use Only
Operating Temperature Range: 5-40° C
Maximum relative humidity: 80%
Main supply voltage: 120 V ~ 60 Hz ± 10%, 2A
Or 230 V ~ 60 Hz +/- 10%, 1A
Altitude: up to 2000 meters
Supply Air Pressure: 8.3 bar max. (unless otherwise specied)
◊ Supply air must be clean and dry.
◊ (10-micron ltration minimum, 5-micron recommended)
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
5
Table of Contents
1. Front Panel
2. Bottom Panel
3. Control Screen
3.1) Data Input
3.1) Run Mode Screen
4. Conguration
4.1) Pressure
4.2) Fixture
4.3) Settings
4.4) Units
4.5) Calibrate
5. Options
5.1) Touchscreen Calibration
5.2) Clock
5.3) I/O Setup
5.4) Data Logging
5.5) Lock Tester
5.6) Change Pin
5.7) Ethernet Settings
6. Reference
6.1) Test Tooling and Fixtures
6.2) Engineering Data
6.3) Physical Laws
6.4) Glossary
7. Maintenance/Troubleshooting
7.1) Internal Leaks
7.2) Valve Cleaning
7.3) Filter
7.4) Fuse
8. Mount Installation
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
6
1
1
Front Panel.
2
1. Touch Screen Interface (TSi) — The liquid crystal touch screen
display is the primary control of the leak tester.
2. Start Button — Push to Start. Push again during test to Abort.
3. USB Port — Port for USB storage media, such as a ash drive or
portable hard drive.
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
3
Fig. 1. Front Panel of the Isaac PD.
7
2
Bottom Panel.
1
2
3
1. Air Supply — (air or other test gas) Con-
nection is 1/8”-27 F NPT (Similar to R1/8
BSPT British Standard Pipe Thread) Supply gas must be clean and dry.
2. External Clamp — This space is used
for Clamping (pneumatic outputs) or I/O
connection (shown)
3. Ethernet COnnector — ASCII communication, data output and command string
input.
4. M12 — Femail I/O connector.
5. Test Port — This component includes the
power cord socket, on/off switch, and the
West Valley City, UT 84119
fuse holder. Power entry is capable of a
range of 109-255~VAC. 2A Fuse (Service
Instructions)
6. Power Entry Module — This component includes the power cord socket, on/
off switch, and the fuse holder. Power entry is capable of a range of 109255~VAC. 2A Fuse (Service Instructions)
7. Leak Test Port — supply positive pressure or vacuum for a variety of leak and
ow test.
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
4
5
6
7
Fig. 2. Bottom Panel of the Isaac PD.
8
3
Control Screens.
Run Mode — Press this button to change to the run mode to begin testing.
Prog
Units
Calibrate
Options
About
Program — Contains three sub-menus (Pressure, Fixture, and Settings) that
control the parameters of the test.
Units — Engineering units and the displayed sensor resolution.
Calibrate — Calibration settings.
Options — Contains eight user options (Touchscreen Calibration, Clock, I/O
Setup, Data Logging, Change PIN, Serial Port, Ethernet Settings).
About — Lists the rmware revision level, serial number, and contact info for
Zaxis. (see Fig 3.)
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
Fig. 3. About Screen for the Isaac PD.
9
3.1
Two data input screens are used throughout the tester’s setup and operation:
1. Numeric keypad screen — used to input values for the timer and limit elds.
2. Alpha-Numeric keypad screen — used in text elds
» Example: The Program Name Field.
Examples of each are shown below:
Data Input.
Fig. 4a. Numeric Keypad Screen.
To access: press desired data eld with your nger or stylus.
Press the SHIFT key to change case.
!
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
Fig. 4b. Alpha-Numeric Keypad Screen.
10
3.2
Run Mode Screen.
1
2
3
4
5
6
7
Fig. 5. Run Mode Screen.
1. Test Fail
2. Test Pass
3. Access Conguration Mode
4. Pressure over Time test graph
5. Test Result Value
6. Timer
7. Pressure in psig
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
11
4
The conguration of this unit is separated into four main menus with user
congurable settings:
Conguration.
Prog
Units
Calibrate
Options
Program Settings
Engineering Units and Resolution
Sensor Calibration Settings
User options (Touchscreen Calibration, Clock, I/O Setup,
Data Logging, Change PIN, Serial Port, and Ethernet
Settings)
CAUTION! Unauthorized changes in the calibration menus will
affect the functionality of the test.
!
Program Settings
Three menus control all the parameters associated with the test process:
Pressure
Fixture
Settings
Pressure test settings
Fixture valve settings
Test parameters
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
12
LEGEND
Positive/Negative
±
USB not plugged in
Tester unlocked
Test type: Pressure
Δ
P
Decay
More Info
Next Program
Previous Program
4.1
1
2
3
Pressure.
6
!
!
Entering the same
number as the
current test will not
loop tests.
A test failure will
cancel the jump to
the next program
4
7
5
Fig. 6. Pressure Settings Screen.
1. Test Pressure — Press the Test Pressure data eld and
enter desired test pressure on the numeric keypad screen.
2. Next Program — Link programs together by entering the
number of the next program (upper left corner) in the Next
Program data eld. This allows the tester to jump to the de-
sired next program upon a pass result in the current test.
3. Pressure Tolerance ± — The amount of tolerance on the
test pressure. Enter positive (+) and negative (-) limits in the
data eld to the right of the Test Pressure data eld.
4. Current Pressure — Displays the current pressure when
Valve On is check and test port is capped.
5. Valve On — Check box the opens the test port valve.
6. Stats —
7. Loops — Loops programs however many times
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
13
Setting Test Pressure
To set the test pressure, place a master part or plug onto the test port.
1. Press the Test Pressure data eld with your nger or stylus and enter the test
pressure value on the numeric keypad screen.
2. Set the desired ± Pressure Tolerances.
3. Check the Valve On box.
4. The internal pneumatics will open to allow the pressure from the regulator out
to the front port.
5. The pressure sensor will show the current pressure in the Curr. Pressure data
eld.
6. Adjust the regulator until the specied pressure from the Test Pressure value
eld is achieved.
7. Uncheck the Valve On box when nished.
Parameters to USB
The parameters of test can be either saved to or loaded from an external USB plugged
into the USB port on the front of the tester.
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
14
LEGEND
Positive/Negative
±
USB not plugged in
Tester unlocked
Test type: Pressure
Δ
P
Decay
Next Program
Previous Program
4.2
1
2
Fixture.
3
4
Fig. 7. Fixture Settings Screen.
Clamps, Coupling
outputs, and Fixturing Timers are all
similar terms used to
!
!
describe pneumatic
outputs that can
be used for various
functions.
These outputs are
used to actuate
tooling, manipulate
a part, or activate
a pneumatic seal
around a part.
The xture menu controls the xturing valves. These valves can
be used to activate pneumatic xturing tools or seals to capture
the part for testing.
All outputs are supplied as four-way valves with one normally
open and one normally closed port. The outputs can be used
as a three-way valve by plugging the normally open port. The
normally open port will be plugged from the factory.
1. Pre-Test Op 1 — The amount of time the output will be set
prior to test start.
2. Post-Test Op 1 — The amount of time until the valves
de-energize at the end of the test.
3. Hold Clamps on Fail — Keeps the clamps in their test po-
sition and the fail indicator LED will ash to alert the user of
failure.
4. Output Results — Output the results via USB or Ethernet.
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
15
Setting Fixture Timers
To set the test pressure, place a master part or plug onto the test port.
1. Press the Pre-Test Op 1 data eld with your nger or stylus and enter your val-
ues with the numeric keypad screen.
b. A minimum value of 0.1 sec. must be entered in the data eld. This time is
the amount of time the output will be set prior to test start.
3. Press the Post-Test Op 1 data eld with your nger or stylus and enter your val-
ues with the numeric keypad screen.
a. Leaving the Post-Test Op 1 timer at zero will de-energize all valves at the end
of the test.
2. Under Hold Clamps on Fail, select the on or off radio buttons.
c. Select this option to keep the clamps in their test position and the fail indica-
tor LED will ash to alert the user of failure.
d. The user can acknowledge the failure by pressing the fail LED and the
clamps will then follow the original set release timer.
The Pass/Fail results sent out to the I/O will not be posted
until the failure has been acknowledged.
!
Output Results
Select the check boxes for USB or Ethernet, in conjunction with set Data Logging op-
tions (discussed in Data Logging section) to output the desired results to either a USB
drive or over Ethernet.
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
16
LEGEND
Positive/Negative
±
USB not plugged in
Tester unlocked
Test type: Pressure
Δ
P
Decay
More Info
Next Program
Previous Program
4.3
1
2
3
4
5
6
Settings.
7
8
9
Fig. 8. Settings Screen.
1. Pre-Fill — Allows the test device to
be lled via a second regulated source,
typically at a higher pressure for increased air volume.
2. Fill — The amount of time the pneumat-
ic outputs will be active to ll the test
part with regulated pressure.
3. Settle — The amount of time the pneumatic outputs have to isolate the test
part from any incoming pressure.
4. Test — The amount of time the test will
measure the change in pressure.
5. Data Logging — Output the results via
USB or Ethernet.
6. Vent — A safety mechanism to allow
test pressure to be evacuated form the
test part before the user removes the
part from the tester.
7. Pre Fill Settle — A settling time
during ll before pressure tolerance
limits are measured (typically half of
the total ll time).
8. Test Limits — A limit amount of decay before the timer expires.
a. Increase: pressure increase during
test timer to trigger failure (if Enabled Increase Limit checkbox is
checked).
b. Decay: pressure decrease during
test timer to trigger failure.
9. Volume — Combined product and
tester air volume used to calculate
approximate leak rate.
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
17
Setting Testing Parameters
The following parameters control test air presented to the test part:
1. Press the Pre-Fill data eld with your nger or stylus and enter your values with
the numeric keypad screen.
b. Used with larger part volumes (greater than 300cc).
2. Press the Pre-Fill Settle which is a settling time during ll before pressure tolerance limits are measured (typically half of the total ll time).
3. Press the Fill data eld and enter the amount of time the pneumatic outputs will
be active to ll the test part with regulated pressure.
4. Press the Settle data eld and enter the amount of time the pneumatic outputs
have to isolate the test part from any incoming pressure.
a. This allows for the thermodynamics and/or compliance of the part to
reach equilibrium.
2. Press the Test data eld and enter the amount of time the test will measure the
change in pressure.
c. This test observes for a decay in pressure.
d. The decay is evaluated against the test limits to determine a Pass/Fail
state.
6. Under the Vent data eld, select either the Timed or Auto radio boxes.
1. Timed: vents the pressure for the amount of time inputted.
2. Auto: releases pressure to a safe limit (typically 0.5 psi).
3. Once the pressure is released, the test is concluded.
7. In the Test Limits section, values (in psig) can be entered in the Increase and
Decay data elds.
h. Enter an increase limit to verify that no external or thermal dynamic
forces cause the pressure to increase over the test time.
i. If the increase limit is used, the Evaluate at End of Test checkbox must
also be checked.
j. With a decay limit set and the limit is reached before the timer ends, the
test will short cycle and result in a fail condition.
k. To see the decay in the full timer length, check the Evaluate at End of
Test checkbox.
Zaxis Inc. LLC
801.264.1000
2442 South 2570 West
West Valley City, UT 84119
18
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