Manual 6820

WARNING
THE OPERATIONS MANUAL DETAILS SAFE OPERATING

PROCEDURES AND RECOMMENDED SAFETY EQUIPMENT
FOR THE OPERATOR.
TO AVOID POSSIBLE PERSONAL INJURY AND DAMAGE TO EQUIPMENT;

COMPLETELY FAMILIARIZE YOURSELF WITH THE CONTENTS OF THIS
OPERATIONS MANUAL BEFORE TURNING ON POWER OR OPERATING THIS
EQUIPMENT.
FOR OPERATOR SAFTEY, HEARING AND EYE

PROTECTION MUST BE USED WHILE OPERATING
THIS TEST STATION.
THE SOUND LEVEL EMITTED DURING TESTING

CAN EXCEED 122 DBA. BECAUSE THE NOISE IS
GENERATED BY THE PART UNDER TEST, IT IS THE
CUSTOMERS RESPONSIBILITY TO MAKE SOUND
PRESSURE LEVEL MEASUREMENTS AND TAKE
NECESSARY ACTIONS TO PROTECT OPERATORS
AND BY-STANDERS FROM NOISE RELATED
INJURIES AND TO COMPLY WITH ANY LOCAL OR
COMPANY REGULATIONS
Project No. 3380 Low Flow Air Test Systems Configuration B Page 1
FOREWORD
This manual has been designed for easy reading and short learning curve of the information
contained within this manual. A screen is considered to be what the operator would see as he/she is
looking at the computer monitor. When we talk about specific screens, we give the screens individual,
unique titles and we also under line the screens title in the documentation (ex. Main Menu screen).
When we talk about buttons on the screens, we put the button names in quotes and Italics (ex.
Continue (F4)). This was implemented so learning the new software would be as painless as
possible. The distinction between buttons and screens is made obvious to make the manual easier to
follow and to make the information within the manual easier to learn and apply.
To provide easier use of the control software, important control buttons have been provided with
keyboard shortcuts. This provides the operator with the option of pressing the button on the computer
screen (with the mouse) or pressing the appropriate computer keyboard key. All software buttons that
have a shortcut key have the shortcut key listed in parentheses following the button name. For
example, either pressing the Continue (F4) button on the computer screen, or pressing the F4 key
on the computer keyboard will activate the Continue (F4) button.
TABLE OF CONTENTS
1 Introduction ............................................................................................................ 5
1.1 Purpose .............................................................................................................. 5
1.2 Safety ................................................................................................................. 5
1.2.1 Operator Safety Equipment ............................................................................. 5
1.2.2 Safety Procedures ........................................................................................... 5
1.2.3 Safety Features ............................................................................................... 5
1.3 General Description ............................................................................................ 6
1.3.1 Flow Measurement .......................................................................................... 6
1.3.2 Air Flow Test Station Test Measures ............................................................... 7
1.4 Facilities Requirements ..................................................................................... 12
1.4.1 Power ............................................................................................................ 12
1.4.2 Air Supply ...................................................................................................... 12
1.5 Test Station Specifications ................................................................................ 13
1.5.1 Flow Specifications ........................................................................................ 13
1.5.2 Technical Specifications................................................................................. 13
1.5.3 Transporting and Storage .............................................................................. 13
1.5.4 Test Stand Accessories ................................................................................. 14
1.5.5 General Information ....................................................................................... 14
1.5.6 Maintenance and Cleaning ............................................................................ 14
2 Operation ............................................................................................................. 16
2.1 Start-up ............................................................................................................. 16
2.2 Log On .............................................................................................................. 16
2.3 Operator Interfaces .......................................................................................... 17
2.3.1 Main Screen................................................................................................... 17
2.3.2 Operation ....................................................................................................... 18
2.3.2.1 Test Types .................................................................................................. 18
2.3.2.2 Nominal Flow Measure Specification .......................................................... 21
2.3.2.3 Automated Sequential Flow Testing............................................................ 21
2.3.2.4 Test Configuration Record Parameters ....................................................... 21
2.3.2.5 Control Variables ........................................................................................ 23
2.3.2.6 Test Stop Modes ......................................................................................... 23
2.3.2.7 Work Order Number ................................................................................... 23
2.3.3 Production ..................................................................................................... 25
2.3.3.1 Production Screen Features ....................................................................... 26
2.3.3.2 Select Test .................................................................................................. 32
2.3.3.3 Select Test Schedule .................................................................................. 33
2.3.3.4 Graph Output .............................................................................................. 34
2.3.3.5 Edit Test Configuration (Only available for Administrators) ......................... 34
2.3.3.6 Select Part Number..................................................................................... 38
2.3.3.7 Pressure Probing Configuration Screen ...................................................... 39
2.3.3.8 Test Schedule Management Screen ........................................................... 40
2.3.4 Test Measure Finder ...................................................................................... 42
2.3.5 PID Auto Tune ............................................................................................... 43
2.3.7 Test Results Data Record Configuration Screen ............................................ 45
2.3.8 Test Coupon Configuration Screen ................................................................ 46
2.3.9 NCR Template Configuration Screen ............................................................. 47
2.3.10 System Diagnostic ....................................................................................... 48
2.3.10.1 System Leak Test: .................................................................................... 48
2.3.10.2 CFV Valve Leak Test: ............................................................................... 48
2.3.10.3 Flow Restriction Test: ............................................................................... 49
2.3.11 Maintenance (Only available for Flow Systems Engineers) .......................... 51
2.3.12 User Accounts (Only available for Flow Systems Engineers) ....................... 52
2.3.13 Instrument Calibration Coefficients (Only available for Administrators) ........ 53
2.3.14 Instrument Calibration (Only available for Flow Systems Engineers) ........... 54
2.3.15 Option Screen .............................................................................................. 57
2.3.15.1 SPC Configuration .................................................................................... 58
2.3.15.2 SPC Charts ............................................................................................... 60
2.3.15.3 Report Screen ........................................................................................... 61
1 Introduction
1.1 Purpose
This instrument, called the Air Flow Test Station, is a critical flow venturi based airflow test instrument
for measuring the flow parameters of flow circuits. The test station consists of two critical flow venturi
manifolds, piping and pneumatic control hardware, a data acquisition and switching control hardware,
pressure and temperature measurement instrumentation, and a computer with control software.
The computer software handles the opening and closing of critical flow venturi flow paths and
calculates airflow rates based on sensor inputs. The software also monitors the airflow conditions to
insure the nozzles are choked and that the flow is stable at the control set point. The software allows
for generating, saving, and recalling test configuration data as well as configuring, saving and printing
test results data.
1.2 Safety
1.2.1 Operator Safety Equipment
1. Safety eye glasses with side shields

2. Foam or rubber ear plugs or hearing protection head sets
1.2.2 Safety Procedures
1. Never try to remove test items or test item fixturing while the test section is pressurized.
2. Never service the test station pneumatic components while the main supply air connection is
pressurized.
3. Never service the test station electrical components while the main electrical supply is active.
(Follow proper lock-out tag-out procedures)
4. Do not remove the station body panels while the instrument is in production service. Only
technical personnel trained in the appropriate trade should perform internal access and
maintenance.
1.2.3 Safety Features
The test will stop, inlet air supply will be shut-off, and pressurized air in the station will be vented
whenever the following happens:
The emergency stop button is pressed.

The computer determines a problem exists.
Communication between the control software and the stations instrumentation is lost.
Power to the station is lost.
The mechanical over pressure switch reaches its threshold
The station is only pressurized during a test.
One emergency stop button is provided. Depressing it will abort testing and relieve the pressurized air
in the station at any time. The operator must acknowledge that the emergency stop button has been
depressed by physically lifting the E-STOP button and resetting the RESET button, and via
software. Once the E-STOP is lifted and the station has been reset, normal operation may continue.
If, during a flow test, the computer is turned off, the software or operating system crashes, or the
computer looses communication with the data acquisition system, the system will automatically E-
Stop. At this point, airflow will cease, all trapped pressure will be vented, and the inlet air will be shut
off to the station. It is crucial that the situation that caused the problem be remedied. Once the
problem is solved, a proper restart on the computer needs to occur before further testing or
production.
1.3 General Description
1.3.1 Flow Measurement
The Air Flow Station uses a critical flow venturi manifold to set and measure airflow rates through the
Units Under Test (UUT). A critical flow venturi is a primary flow element that, when choked,
accelerates the gas particles to sonic velocity in the throat of the nozzle. Once this sonic flow is
established, the flow element is robustly unaffected by downstream variations in pressure or
temperature. Only the inlet pressure and temperature of the gas define flow rate through the venturi.
There are no moving parts in a critical flow venturi and all surfaces are smooth and rounded, so the
sonic nozzle predictably maintains its accuracy for long periods of time.
A critical flow venturi manifold has one or more venturis arranged with a common inlet and exit
plenum and a means of opening or blocking any combination of nozzles. The plenums are designed
so that the flow rate through any one nozzle is unaffected by flowing or blocked neighboring elements.
When more than one venturi is flowing, the total flow rate is the sum of the flow rates in each
individual venturi. Each venturi block valve is placed downstream of the flow so that the presence of
the valve cannot influence the gas flow.
The test station system controller handles the opening and closing of venturi flow paths and calculates
flow rates based on sensor readings. The controller also monitors the flow conditions to insure the
elements are choked, that the flow is steady, and that the controlled parameter is within 0.10% of the
set point.
1.3.2 Air Flow Test Station Test Measures
The airflow test station supports measuring flow passage Effective Area, Reduced Mass Flow, Flow
Function, Flow Function referenced to ambient conditions, Corrected Mass Flow and Pressure Ratio.
Each listed item is categorized to as a "test type" and refers to the response variable produced by the
flow passage. Every test type has a controlled variable as well as a response variable:
Controlled Variable Response Variable

PR or Ppart (inHga, InHg, psia, psig) Effective Area
PR or Ppart (inHga, InHg, psia, psig) Reduced Mass Flow
PR or Ppart (inHga, InHg, psia, psig) Flow Function referenced to inlet conditions
PR or Ppart (inHga, InHg, psia, psig) Part Flow Function referenced to ambient
PR or Ppart (inHga, InHg, psia, psig) Corrected Mass Flow
Part Flow Function referenced to Part Pressure Ratio
ambient
Formulas:
Mass flow rate through a critical flow venturi:
Units: English = lbm/sec, Metric = kg/sec.
where:
w - Mass flow rate

P - Inlet absolute gas pressure to critical flow venturi
A - Throat area of sonic nozzle
C* - Critical flow function. (Property of a gas)
Cd - Coefficient of discharge (From CFV Calibration)
gc - Unit conversion constant
R - Gas constant for flow gas
T - Inlet absolute gas temperature to critical flow venturi
Effective Area: AE
2 2
Units: English = in , Metric = cm .
where:
AE - Effective Area
w - Mass flow rate
Tp - Part inlet air absolute temperature
Pp - Part inlet air absolute pressure
M - Part inlet air Mach number
PR - Ratio of part inlet to exhaust absolute pressure
Effective Area: Ae_mm2

2
Units: Metric = mm .
AE
AE _ mm2
100
where:
Ae_mm2 - Effective Area in mm2

Ae - Effective Area in cm2
Reduced Mass Flow and Flow Function: M red, FFi

1/2 1/2
Units: English = (lbm * R ) / (sec * psia), Metric = (Kg * K ) / (sec * Bar).
Flow Function referenced to ambient or atmospheric conditions: FF a

1/2 1/2
Units: English = (lbm * R ) / (sec * psia), Metric = (Kg * K ) / (sec * Bar).
where:
Mred - Reduced Mass Flow

FFi - Flow Function
FFa - Flow Function referenced to ambient (atm) conditions
w - Mass flow rate
Tatm - Test station ambient air temperature
Flow Function
3 1/2
Units: English = Metric = (m ) / (sec * K
P
PPP
PPP
PPP
PPP
).
where:
*
m R T p
FFSIE
Pp
FF SIE
BBB BBB - Flow Function

- Mass flow rate
m
Tp BBB
- Part inlet air absolute temperature
R - Gas constant for flow gas
Flow Function: FFsne

1/2 1/2
Units: English = (lbm * R ) / (sec * psia), Metric = (Kg * K )/ (sec * Pa).
where:
FFsne - Flow Function

w - Mass flow rate
Flow Function: FFMHI

1/2 2 1/2 2
Units: English = (lbm * R * in ) / (sec * lbf), Metric = (Kg * K * cm / (sec * Kgf).
where:
FFMHI - Flow Function

w - Mass flow rate
Flow Function: FFtst

1/2 1/2
Units: English = lbm-R / sec-psia, Metric = kg-K / sec-KPa.
w Tp
FFtst
Pp
where:
PR - Pressure Ratio
Patm - Test station ambient air absolute pressure
Ppg - Part inlet air gauge pressure
Flow Function: FFic
Units: English = lbm/sec, Metric = kg/sec.
w Tp
FFic
Pp
where:
PR - Pressure Ratio
Standard Cubic Feet Per Minute: SCFM
Units: English = SCFM.
w 60
SCFM
STD
where:
SCFM - Standard Cubic Feet per Minute

w - Mass flow rate
STD - Density at user defined standard Temperature and
Pressure
Pressure Ratio: PR
Units: English = psia / psia, Metric = Bar / Bar.
where:
PR - Pressure Ratio
Pounds Per Second: PPS
Units: English = lbm/sec.
where:
PPS w
PPS - Pounds Per Second

w - Mass flow rate
Corrected Mass Flow: Wcor
Units: English = lbm / sec, Metric = Kg / sec.
where:
W corr - Corrected Mass flow
w - Mass flow rate
Bstd - Standard barometric absolute pressure
Patm - Ambient air absolute pressure
Pset - Control gauge pressure setpoint
T - Part inlet air temperature
P - Part inlet air gauge pressure
Corrected Mass Flow: WHWcor
Units: English = lbm/sec

P Ttest 459.67
WHWcor w std
Ptest Tstd
where:
WHWcor - Corrected mass flow rate

w - Mass flow rate
Pstd - Standard pressure (14.696 psia)
Ptest - Part inlet air pressure (psia)
Tstd - Standard Temperature (518.67 R)
Ttest - Part Temperature (deg F)
1.4 Facilities Requirements
1.4.1 Power
Conditioned 100 240 V~, 1, 50/60Hz, 15 - 10A.
CAUTION: COMPUTER POWER SUPPLY SWITCH NEEDS TO BE IN CORRECT
POSITION FOR VOLTAGE LEVEL (115 OR 230 VAC)
CAUTION: POSITIVE EARTHING TERMINAL MUST BE POSITIVELY CONNECTED
Note: Main supply voltage fluctuations are not to exceed of the normal supply voltage.
It is recommended that the main power supply connection be made with flexible conduit. A
suitable sized conduit entry opening has to be punched in the Supply Connection/Disconnect
Switch Box for the main power supply conduit. A conduit hub fitting is required to connect the
flexible conduit to the Supply Connection/Disconnect Switch Box. After final installation is
completed, the shipping casters need to be locked.
Note: If the main power supply connection is by means of rigid conduit, the user needs to
supply suitable leveling feet that will raise the casters off of the floor.
1.4.2 Air Supply

90 psig (6.2 bar) minimum, 125 psig (8.6 bar) maximum
100 SCFM (170 SCMH) airflow @ 90 psig (6.2 bar)
60F (15.6C) to 90F (32.2C)
Dry air with moisture dewpoint less than39F (3.9C)
Particulate matter in flowing air less than 10 microns in size
Oil content in flowing air less than 10 PPM by weight
Inlet connection: FNPT
1.5 Test Station Specifications
1.5.1 Flow Specifications
1. Capability:
*based on air at 68F (20C), Pamb = 14.7 psia (1.0135 bar), and Pressure Ratio = 1.25
Mass Flow Range: 0.002 to 0.42 lbm/sec (0.907 to 190.51 g/sec)

2 2
Effective Area: 0.0056 to 1.17 in (0.036 to 7.57 cm )
1/2 1/2
Reduced Mass Flow: 0.00252 to 0.53 lbm*R /(sec*psia) (0.012 to 2.57 kg*K /(sec*bar))
Pressure Ratio: 1.03 to 4.0 psia/psia (1. 03 to 4.0 bar/bar)
2. Mass flow measurement accuracy of 0.42% of reading

3. Measurement repeatability of 0.25%, 2 sigma / mean of 20 samples.
4. Each critical flow venturi discharge coefficient is calibrated to 0.35% maximum uncertainty
traceable to N.I.S.T.
1.5.2 Technical Specifications
1. The test station is intended for indoor use only.

2. Ordinary Protection (Not protected against harmful ingress of moisture.).
3. Class I Equipment (Grounded Type).
4. Electrical rating: 100 - 240V~ 50/60 HZ 15 - 10A. CAUTION: COMPUTER POWER
SUPPLY SWITCH NEEDS TO BE IN CORRECT POSITION FOR VOLTAGE LEVEL
(115 OR 230 VAC)
5. Pollution degree 2
6. Installation (Over voltage) category II for transient over voltages.
7. Maximum Relative Humidity: 20% - 80% for temperatures up to 88F (31C) decreasing
linearly to 50% relative humidity at 104F (40C).
8. Operating temperature range: 55 95F (13 - 35C).
9. Maximum altitude: Sea level 10000ft (Sea level - 3050m).
10. Main supply voltage fluctuations are not to exceed 10% of nominal supply voltage.
11. The sound pressure level emitted during testing can exceed 122 dBA and is dependent
on the nature of the flow through the part under test.
12. The test stand is suitable for continuous operation.
1.5.3 Transporting and Storage
Transportation
Minimum shook and vibration are required during transportation. Transportation vehicle
should be equipped with Electronic Air-Ride suspension.
Because of the weight of the test stand (~1000 lbs or 455 kg), a forklift truck is required to
load and unload the test stand.
When using the forklift truck to move the test stand, the forks must be positioned underneath
the main structural frame of the test stand. The stand should be centered over the forks and
the forks must extend past the edge of the frame. If the forks do not extend past the edge of
the frame, the forks will damage the test stand.
Shipping casters have been provided for easy mobility on smooth level surfaces.
Storage
Maximum Relative Humidity: 80%.
Temperature range: -4 to 95F (-20 to 35C).
1.5.4 Test Stand Accessories
Computer and power cord.

Computer Video monitor with power cord.
Computer keyboard.
Computer mouse with mouse pad.
Operation manual.
1.5.5 General Information
COMPUTER: All of the software human interface screens have a standard format. The top section
contains a title bar. The middle section contains controls, process indicators, and information
pertinent to the current process sequence. Buttons for navigating around the program are located at
the bottom. To activate buttons, place the mouse cursor over the button and press the left mouse
button, or press the appropriate function key (indicated in parenthesis on the button) on the keyboard.
E-STOP: The E-STOP is intended to give the operator the ability to instantly stop the stations
operation, releasing the pressurized air and placing the station in a safe state. The E-STOP is located
on the top of the station on the console panel. Pressing the E-STOP button activates the E-STOP.
Normal production/operation may be resumed by lifting the E-STOP Button, pressing the Reset
Button, and acknowledging the E-STOP in the software.
GREEN RESET BUTTON: The green reset button is located directly to the right of the E-STOP.
When the light is green on the button, it is in the reset state and the station is ready to flow. If the light
is not present on the reset button, the station needs to be reset (done by pressing the reset button) in
order to flow.
RELATIVE HUMIDITY SENSOR: A Relative Humidity Sensor analyzes the moisture content of the
air supply. If the humidity of the air is above a configurable limit (Line 18 of the ProductionConfig.txt
File), an error occurs and the test is stopped. This feature is implemented to prevent inaccurate
calculations due to wet air effects.
TEMPERATURE CONTROLLED PRESSURE TRANSDUCERS: The stations pressure transducers

are contained in a temperature controlled enclosure. If the temperature of the transducer is out of the
configurable limits (Line 15 of the ProductionConfig.txt File), an error occurs and the test is stopped.
This feature is implemented to prevent inaccurate results due to temperature changes of the
transducers.
1.5.6 Maintenance and Cleaning
Maintenance:
Air Supply Filter: The inlet air supply filter should be periodically inspected for particles or oil that may
have been trapped. Under correct operating conditions, there should be no visible particles or oil. If
any is found, notify the facility manager.
Note: Under normal operating conditions, the nozzles and nozzle seals should not require any
maintenance. Removal of nozzles for inspection or cleaning should only be necessary after
diagnostic tests or audit flow tests show reason to suggest failure.
Critical Flow Venturis: Remove the nozzles to inspect and clean them. Clean the nozzles with a
soft cloth and a mild detergent. Do not use abrasive cleaners of any kind on the sonic nozzles. On
reassembly, replace the sonic nozzle o-rings with new lightly greased o-rings.
Critical Flow Venturi Seals: Removal of the actuator cylinder is necessary to inspect the flow
blocking cap seals. The seals are located at the end of the pneumatic cylinder rods. Replace any
seals that are damaged or worn with new cap seals. Upon reassembly, replace the pneumatic cylinder
rod seals, mounting gaskets and o-rings with new ones.
Cleaning:
Test Stand: Clean the test stand external surfaces with a soft cloth and a mild detergent.
Calibrations:
Every Air Flow Test Stand that is manufactured by Flow Systems is comprised of components that
should be calibrated and tested periodically to ensure that the result reported is accurate.
During the first year of service, each pressure transducer and thermocouple should be calibrated
every 6 months. After the second calibration, a comparison to the previous data can be made to
determine how much the device has drifted. If the drift is within the accuracy tolerance of the device,
yearly calibrations may be considered. Flow System also recommends that the instruments be
calibrated using the Calibrate Instruments feature provided in the software. This allows the
instrument to remain in the bench and effectively results in an end-to-end calibration which includes
the data acquisition system. It also minimizes the possibility of introducing leaks.
Besides pressure transducers and thermocouples, each Air Flow Test Stand utilizes sonic nozzles to
measure flow. To ensure the performance of the sonic nozzles, only dry and clean air should be
connected to the flow stand, 0 deg F dewpoint and particles less than 10 micron. However, Flow
Systems also recommends that the flow stand be flow tested at a yearly interval. This can be
accomplished by using a set of standard nozzles that covers the entire flow range of the flow stand.
This direct comparison or audit, allows all components within the entire system to be checked:
instrumentation, sonic nozzles, and data acquisition system. A set of standard nozzles or the auditing
services are options available through Flow Systems.
For the highest level of confidence in the performance of your Air Flow Test Stand, standard nozzles
or master parts should be run daily. And if the quantity of tests are large, testing a master part at the
beginning and end of a group of parts may be considered. The ability to recognize a problem with the
flow measurement quickly, improves as you increase the frequency of tests with a master part. The
data gathered using a master part or standard nozzle can be trended to identify drift over a period of
time.
2 Operation
2.1 Start-up
To start up the station:
1. Turn on the electrical power by rotating the rotary switch to the ON position (the switch is
located on the station console).
2. Lift the emergency stop button to the up position and depress the green power reset
button.
3. Confirm adequate supply air pressure is present in the station with the Inlet Pressure
Gage.
4. Turn on the computer. The Test Station operating system will start automatically.
2.2 Log On
When the system is turned on the operator must input his/her user name and password to log on to
the system.
Note: This screen can also appear if the operator presses the User Logon button under the Option
page at the top of the User Interface screen. The User Name is kept in memory and stored in the test
results database as the operator ID with each test record.
Button Descriptions
Log On (Enter): After the operator inputs his/her user name and password in the Log On
screen and presses this button or presses the Enter key on the computer keyboard this
program will check if the User Name and Password combination exists and is correct. If
correct the Work Order screen will appear. If the User Name and Password are not correct
an error message will appear and the operator can input his/her user name and password
again.
Log Off (Esc): When this button is pressed or the Esc key on the computer keyboard is
pressed the software will be shut down.
2.3 Operator Interfaces
2.3.1 Main Screen
When the station is turned on the system will restore all devices to their default states and display this
Main Menu screen.
Button Descriptions
Production Testing (F1) is where normal production testing and test development is
performed.
Manage Testing Parameters (F2) is the database interface for managing test configuration
data. This button is only available for administrators.
Configure Test Results Reporting (F3) is used for configuring the format test results
reporting.
System Diagnostic (F4) is used to check the system plumbing for leaks, and flow restrictions
caused by the part fixtures.
System Maintenance (F5) is used as an aid for system hardware troubleshooting. This
button is only available for Flow Systems engineers.
Instrument Calibration Coefficients (F6) is used for entering new pressure transducer,
humidity sensor, and thermocouple calibration data.
Instrument Calibration (F7) is used to calibrate the stations pressure and temperature
transducers.
User Accounts (F8) is used to change user account information. This button is only available
for administrators.
User Logon (F9) is used to log off the current user and log on a new user.
FSI DATA UTILITY (F10) is used to manage critical data for the system. This button is only
available for Flow Systems engineers.
EXIT (Esc) terminates the program.
2.3.2 Operation
Flow testing is performed within the Production screen, which is selected by pressing the Production
(F1) button from the systems Main Menu screen. The operator must connect the appropriate Test
plenum and part fixture to the station outlet, and connect the pressure and temperature feedback
lines. The operator uses the Test Selection screen, which is activated with the Select Test (F8)
button of the Production screen, to find the test configuration record that matches the flow test
operation of the part to be tested. If the required test configuration record is not included in the
database, a new record can be added using the Edit Test Configuration screen. The operator then
must enter a part serial number in the Part Serial Number (F10) field of the Production screen. The
part serial number is required so that the test results can be associated with a unique UUT. The
software will not perform a test until a part serial number has been provided. The part serial number
will be cleared at the end of a flow test that is within specification.
There are four types of tests that can be performed within the Production screen, the part flow test,
part leak test, CFV valve leak test, and fixture flow restriction test. Select the parts test configuration
record from the Test Selection screen and then pressing the start button to the test procedure.
2.3.2.1 Test Types

Within the production test environment there exists nine testing procedures: Standard Flow Test,
FC500 Audit Flow Test, CFV Audit Flow Test, Master Flow Test, GE90 Flow Test, Virtual Test, Leak
Test, CFV Valve Test, and Flow Restriction Test.
The Standard Flow Test is a flow test where the test measure and the mass flow are
measured/calculated by the station. Standard flow tests include effective area, reduced mass flow,
flow function, corrected mass flow and pressure ratio. For each standard flow test performed, the
items selected in the Test Data Record Configuration screen are recorded to the current output file.
The FC500 Test is a series of flow tests performed using independent instrumentation to measure the
pressure, temperature, and mass flow at a calibrated sonic nozzle. A network connection allows for
communication between the FC500 and the bench computer. This connection can be made over a
local network or with a crossover cable. This test allows for an independent audit of the accuracy
and repeatability of the airflow stations flow measurements. The test configuration record must
contain the key word FC500 (without the quotes) in the operation description. When this test is
selected, the software will provide a Start Audit Flow Test (F1) button. Once the file has been
selected, the audit flow testing is ready to begin by pressing the Start Audit Flow Test (F1) button.
When Start Audit Flow Test (F1) button is pressed, the software uses the test configuration data to
flow the nozzle a specific number of times while waiting a specified time between each test. The
number of tests and wait time can be changed inside the HWConfigFile.ini. When the FC500 flow test
is complete, the software will add four fields to the audit summary report file. These fields are the
average of the Test Measure, the 6 sigma repeatability of the Test Measure, the average of the
percent deviation for all runs, and the maximum percent difference between the station mass flow
measurement and the mass flow determined from the FC500. When performing the FC500 audit flow
test, the serial number of the audit nozzle must be entered in the part serial number field. The serial
number must match an entry in the Audit CFV.txt file. This file contains a list of nozzle serial numbers
and their calibration data. The software uses the calibration data of the nozzle to calculate audit mass
flow rates.
Note: The FC500 Test is not a method of calibration. The FC500 Test is not a substitution for
calibration of the systems pressure and temperature transducers.
The CFV Audit Test is a series of flow tests performed using a calibrated sonic nozzles as the test
part. This test allows for an audit of the accuracy and repeatability of the airflow stations flow
measurements. The test configuration record must contain the key word cfv audit (without the
quotes) in the operation description. When this test is selected, the software will provide a Start Audit
Flow Test (F1) button. Once the file has been selected, the audit flow testing is ready to begin by
pressing the Start Audit Flow Test (F1) button. When Start Audit Flow Test (F1) button is pressed,
the software uses the test configuration data to flow the nozzle a specific number of times while
waiting a specified time between each test. The number of tests and wait time can be changed inside
the file HWConfigFile.ini. When the cfv audit flow test is complete, the software will add four fields to
the audit summary report file. These fields are the average of the Test Measure, the 6 sigma
repeatability of the Test Measure, the average of the percent deviation for all runs, and the maximum
percent difference between the station mass flow measurement and the mass flow determined from
the calibrated audit nozzle. When performing the audit flow test, the serial number of the audit nozzle
must be entered in the part serial number field. The serial number must match an entry in the Audit
CFV.txt file. This file contains a list of nozzle serial numbers and their calibration data. The software
uses the calibration data of the nozzle to calculate audit mass flow rates.
Note: The CFV Audit Test is not a method of calibration. The CFV Audit Test is not a
substitution for calibration of the systems pressure and temperature transducers.
The Master Test or Audit Test is a series of flow tests to a standard part or orifice. This test allows
comparison of the of the airflow stations measurements to the expected value of a standard part.
Selecting the audit test configuration record performs audit part testing. This records operation
description must contain the key word audit (without the quotes). After pressing the Start Audit Flow
Test (F1) button, the software will test a specific number of times while waiting a specified time
between each test. The number of tests and wait time is set inside the file HWConfigFile.ini file. Once
complete, the system will add five fields to the audit test result data file. These fields are as follows:
the nominal or expected value, the average of the measured values, the 6 sigma repeatability of the
measured values as a percent of the average, the average percent deviation from expectation, and
the maximum percent deviation for all runs.
The GE90 Test is a sequence of tests performed on the same part at three different setpoints. The
test uses the test measures obtained in the three tests to calculate the test measure at the exact
setpoint of the second test using regression. The ge90 test requires three separate part test
configuration records, for the same part, at different setpoints. Each operation description must
contain the key word GE90 (without the quotes). To run the test, select the first GE90 record and
press the Start Flow Test (F1) button. After the test is completed, select the second test (this test
record also has GE90 in the description), and then press the Start Flow Test (F1) button again.
After the second test is completed, select the third test (this test record also has GE90 in the
description), and then press the Start Flow Test (F1) button. The part serial number must remain the
same for all three GE90 flow tests. Once the three tests are complete, the software will update the
report file with a new entry containing the flow calculations based on the result of the regression
calculation.
The Virtual test is not actually a flow test. It is a means of determining the pass/fail status of a part
based on a mathematical combination of actual flow test results. The tests configuration record must
have the following brackets {} surrounding the test equation in the operation description. The
methodology is best described by example:
A virtual tests test Operation Description might be:

Before Plating config C {( b+c+d)/3}
i.e. {( b+c+d)/3} is the average of b,c and d
The test configurations records nominal value can be a constant numerical value or can also be
used as a symbolic representation of a previous flow result.
i.e. {a} is entered in the Nominal Value field
The test equation uses alphabetical characters to represent the past test measures of the part. The
test measure of the most recent test (excluding the virtual test) is represented by a, the second test
value is b, and so on.
For the following testing sequence:

1: Flow test # 1
2: Flow test # 2
3: Flow test # 3
4: Flow test # 4
5: Virtual Test result = {((b+c+d)/3)}, compare to a
a = flow results of test # 4, b = flow results of test # 3, and c = flow results of test # 2, d = flow results
of test # 1.
The Virtual Test would report the average of tests # 1, # 2,and # 3 and compare the value to the
upper and lower limits applied to the value of flow test # 4.
i.e. (1 LL/100)*a <= (b+c+d)/3 <= (1 UL/100)*a
The Leak Test is a procedure that tests for leaks between the bench nozzle valves and the part to be
tested. This includes the bench exit plenum, connective hose, and part fixture. Typically, a blanking
plate or part is installed in the fixture. Volumes must be estimated determined for the connective hose
and part fixture and entered in the test configuration screen. At the end of the test the determined
leak rate is compared to the leak rate limit stored in the test configuration database. If no leak rate
limit is present then the software will take the lower test measure limit and divide it by 1000 to
determine a leak rate limit. If the operation description contains the key word Leak Test (without the
quotes), then the software will provide a Start Leak Test (F1) button. The other method for running a
leak test is to press the Diagnostic Test (F2) button and then press the System Part Leak Test
button.
The CFV Valve Test is a procedure that tests for a leak thru the nozzle air valves. To perform this
test the operate must install leak plates at the exit of the plenum(s). With all nozzle air valves closed
the inlet section is pressurized and the test stand looks for a pressure rise on the exit section. The
determined mass flow thru the closed nozzle valves is compared to a pre-configured value to
determine if the test passes or fails. If the operation description contains the key word CFV Valve
Test (without the quotes), then the software will provide a Start CFV Valve Test (F1) button. The
other method for running a leak test is to press the Diagnostic Test (F2) button and then press the
Shutoff Valve Leak Check button.
The Flow Restriction Test is a test for the part fixture. It determines the flow restriction of the part
fixture to determine if the part fixture will have an influence on the part flow test results. For this test
there must be a good test configuration for the particular part and part fixture combination. Once this
is complete, the software estimates the mass flow needed to test the part. Then without a part
installed on the fixture, the test stand runs at the nominal mass flow and looks for a pressure rise at
the fixture. If the operation description contains the key word Flow Restriction (without the quotes),
then the software will provide a Start Flow Restriction Test (F1) button. The other method for
running a leak test is to press the Diagnostic Test (F2) button and then press the System Flow
Rest. Test button.
2.3.2.2 Nominal Flow Measure Specification

Normally a part flow path is in conformance when its flow measure is within a tolerance percentage of
a known numerical value. This numerical value is specified in the part inspection document supplied
by the parts design team. The numerical value is entered in the NOMINAL field of the test
configuration record of the flow station software. There are some instances where the result of an
actual flow test (not a virtual test) has a nominal conformance value that depends on a previous flow
test result. The same method can be used, as demonstrated in the last section in the description of
the Virtual Test, to designate that the nominal conformance value is to be found from the results from
a previous test. Thus, a symbolic value is entered in the NOMINAL field of the test configuration
record and enclosed in curly brackets { } (an example was given previously).
2.3.2.3 Automated Sequential Flow Testing

The software has a feature that allows a series of flow tests to be performed without operator
intervention between each test. Sequential tests can be run by selecting a Test Schedule from the
Select Schedule screen (Test Schedule are created within the Edit Test Schedule screen) and
pressing the Run Test Schedule (F3) button. When the Run Test Schedule (F3) button is pressed,
the software uses the Test Schedule (a list of part test configuration records) to run the tests
sequentially.
2.3.2.4 Test Configuration Record Parameters

The Edit Test Configuration screen provides control of the test configuration data. The Edit Test
Configuration screen can be launched by either pressing the Manage Testing Parameters (F2)
button in the Main Menu screen or by pressing the Edit Test Configuration (F5) button in the
Production screen. The Edit Test Configuration screen is interface within the software where test
configurations can be modified, added or deleted. The editor is password protected to limit access to
responsible/authorized personnel.
The test configuration data is as follows:
Label Description
Part Number a number used to identify a test part ( Limited to 30 Characters)
Operation a variable, single line of text used for a description of the test being performed. It also
Description can contain key words used to perform specific tests or functions. (limited to 30
Characters)
Test Measure Specifies the test measure:
Effective Area (Ae), Flow Function Inlet (FFI), Flow Function Atmospheric (FFA)
Mass Flow Corrected (Wcor), Mass Flow Reduced (Mred), Pressure Ratio (PR):
Unit System Specifies the desired units:
PSIA, Deg F = {Temperature: R; Pressure: PSIA; massflow: lbm/s}
Bar, Deg C = {Temperature: K; Pressure: Bar; massflow: Kg/s}
KPa, Deg C = {Temperature: K; Pressure: KPa; massflow: Kg/s}
2 2
Ae: English = in , Metric = cm .
1/2 1/2
FFI, FFA, Mred: English = Mred:(Lbm*R )/(sec*psia), Metric = (Kg*K )/(sec*bar).
Wcor: English = Lbm/sec, Metric = Kg/sec.
PR: English = psia/psia, Metric = bar/bar.
Nominal Specifies the nominal test measure value for part test measure conformance.
Lower Limit Specifies the lower specification limit of the flow test in % of Nominal Test Measure
value
Upper Limit Specifies the upper specification limit of the flow test in % of Nominal Test Measure
value
Master Offset Offset added to the parts test measure. Used to implement correlation values to the
stations results from a master part tested on a master Test Flow Station.
Leak Limit Specifies the upper limit for a leak test:
When empty or zero the default is 0.1% of the lower limit of the flow test.
When greater than zero the value specifies the leak limit in test measure units.
Test Setpoint The controlled variable value (i.e. pressure ratio = 1.400) used for the flow and leak
tests.
Standard ATM The numerical value is used in the Wcor correction when Corrected Mass Flow is the
selected test measure (not visible otherwise)
Averaging Sets the time interval for process measurement averaging at test capture. It is a
Time parameter that can be used to adjust the repeatability of the test. When left blank, the
value in the Production Configuration text file is used.
Stability Level Sets the process measurements stability level required for test capture. It is a another
parameter that can be used to adjust the repeatability of the test. When left blank, the
value in the Production Configuration text file is used.
Flow Path Used to select the output flow path for the test station. The test station is not equipped
with multiple flow paths. The test station is currently configured to use the only
available flow path.
Pressure Port Used to sense the pressure at the part. The test station is currently configured to use
the only available pressure port.
Proportional Specifies the tuning parameter for the proportional component of the PI controller
Band
Integral Time Specifies the tuning parameter for the integral component of the PI controller
Sonic Nozzle Specifies which sonic nozzles are combined and used as the flow meter.
Pattern
Probe Points Total number of taps to be measured using the pressure probe. The value is
associated with the pressure probing configuration information.
ABB NCR Instructs the production software to report flow test results to the ABB NCR Microsoft
Reporting Excel templates
Fixture a variable, single line of text used for a description the part fixture used in the test.
Number (Limited to 20 Characters)
Fixture Specifies the volume (ft^3 or m^3) of the part fixture. This volume is used in the
Volume pass/fail calculation of the leak test.
Instructions Instructions or comments for the part test. (limited to 250 Characters)
The task of the test development personnel is to create test configuration records for the software to
use. This involves the following:
Translating the information provided in the test specification document for the component (i.e.
test measure, unit system, test setpoint, nominal test measure value, upper specification limit,
lower specification limit, leak upper specification limit, etc.)
Choosing the appropriate sonic nozzle pattern for expected flow conditions. Assistance is
available from the sonic nozzle calculator or the Test Measure Finder.
Choosing the appropriate PID tuning parameters. Assistance is available from the PID Tuner.
Perform trial testing, and use the guidelines in the appendix to fine tune the PI controller
parameters.
2.3.2.5 Control Variables
The station has been programmed to determine when the controlled variables meet measurement
specification and that the dependent variables are stable. These factors are displayed as Nozzles
Choked, Control within Setpoint, CFV Inlet Pressure Stable, and Part Pressure Stable. Indicator
lights on the Production screen turn green when the conditions are met.
Label Description
Nozzle Pe / Pi <= 70%
Choked
Pe: Exit Manifold Absolute Pressure
Pi: Inlet Manifold Absolute Pressure
Control within ((PR PR Setpoint) / PR ) < Maximum difference from PR setpoint
Setpoint
PR: Pressure Ratio
PR Setpoint: Pressure Ratio Setpoint
Maximum difference from PR setpoint (row 6 of ProductionConfig.txt)
CFV Inlet (Sigma / Mu) < Stability Limit
Pressure
Stable Sigma: Standard Deviation of Pi measurements
Mu: Mean of Pi Array
Stability Limit: Flow stability Limit (in ProductionConfig.txt; row 8 is for low flows, row 9
is for medium flows, & row 10 is for high flows. Row 11 is the Low/Medium flow
threshold, and row 12 is for Med./High flow threshold. Row 13 is the Array Size.)
Part Pressure (Sigma / Mu) < Stability Limit
Stable
Sigma: Standard Deviation of Ppart measurements
Mu: Mean of PR Array
Stability Limit: See Pi Stable (above) for Stability Limits.
2.3.2.6 Test Stop Modes

Test completion can be set to Automatic Stop or Manual Stop. Stop Mode selection is made using the
Automatic Stop (F11)/Manual Stop (F11) control switch on the Production screen. When the control
switch is set to Automatic Stop the test will stop automatically when stability criteria are met, and the
test measurement will be matched to the test criteria (Upper and Lower Limits) to determine pass/fail
of the test. When the switch is on the Manual Stop position the software will wait for the Stop Test
(F3) button. Pushing the Stop Test (F3) button at any time before the Nozzles Choked, Control
within Setpoint, CFV Inlet pressure Stable, and Part Pressure Stable lights are green will be treated as
an abortion of the test. Thus, the test can be stopped at any time, even with Auto Stop active. Each
time a test is completed (without being interrupted by the Stop Test (F3) button or any other system
interrupt), the operator is asked to acknowledge the test outcome (pass/fail) by pressing the Continue
(F4) button. When the operator acknowledges the test outcome, then the test results are saved to the
output data file and the station places itself in a state to be ready for another test. After the test has
completed, the operator has the option of printing a flow test report. The only time an operator has the
option to print a report is after a test is completed and before the next test is started. During a FC500
Audit Test, CFV Audit, Audit Test or while running a test schedule, the operator is not required to
acknowledge the test outcome. The operator will not have the option to print a report for each
individual test of a FC500 audit test, CFV audit test, audit test, or a test schedule.
2.3.2.7 Work Order Number

This pop-up screen will appear after the operator clicks on the Production Testing (F1) button in the
Main Menu screen, but before the operator actually enters the Production screen. The Work Order
Number screen will only appear if the Work Order Number field is selected in either the Test Data
Record Configuration screen or the Test Data Report Configuration screen. If the Work Order Number
field is not chosen in either place, this screen will not pop-up, the Work Order Number will not be
saved to the output data file, or be printed in a test coupon.
NOTE: The same Work Order Number is kept in memory and stored to the database, and/or printed
in a report coupon, until changed by the operator. There are two methods of changing the Work
Order Number. The first option is to enter the Options screen (by pressing the Option Screen (F7)
button on the Production screen) and selecting the Change Work Order option (Change Work Order
Number (F4)). The second option is to exit the Production screen and entering the new Work Order
Number when re-entering the Production screen.
Button Descriptions
Work Order Input (F2) a text field used to enter the Work Order Number.
ENTER (Ent) once a valid Work Order Number is entered in the Work Order Input field,
press the ENTER (Ent) button (or press the Enter/Return key on the computer
keyboard) to continue.
ERASE (F1) if the Work Order Number that was entered is incorrect, this button is an
easy way to ERASE the contents within Work Order Number field.
EXIT (Esc) returns the operator to the Main Menu screen.
Note: The Work Order Number will be truncated after 35 characters and the field cannot be left blank
2.3.3 Production
The Production screen contains the controls and indicators necessary for part flow and leak testing.
Button Description
Select Test (F8) displays the Select Test screen.
Select Schedule (F9) displays the Select Test Schedule screen.
Part Serial Number (F10) text field used to enter the parts serial number.
Auto Stop (F11)/Manual Stop (F11) selects between the software choosing when the flow
conditions justify test completion (Auto Stop) or allow the operator make the decision when to
stop the test in progress (Manual Stop).
Start Flow Test (F1)/Start Audit Flow Test (F1)/Start Master Test (F1) starts the flow test,
audit test, or master test based on the selected test configuration and dependent on the part
description.
Start Leak Test (F2) starts a leak test based on the selected test configuration.
Stop Test (F3) will abort the test that is currently in progress if the test is in the Auto Stop
mode, and will abort the test if the flow is not stable in the Manual Stop Mode. If the station
is in the Manual Stop Mode and the flow is stable the, pressing the Stop Test (F3) button
will record the test results.
Continue (F4) is used when the system pauses. The operator continues the test by pressing
this button.
Edit Test Parameters (F5) displays the Edit Test Configuration screen. Access is limited by
requiring a password to enter. After the password is entered for the first time, the production
screen is placed in the development mode. When the production screen is in the
development mode, the operator is not required to enter the password to enter the Edit Test
Configuration screen. To remove the production screen from the development mode, press
the Options Screen (F7) button, then press the Password Protect (F7) button, or exit the
Production screen.
Graph Response (F6) displays a graph of the selected test parameters. This is helpful for
fine-tuning the PID controller parameters.
Options Screen (F7) displays the Options screen. The Option screen provides the operator
access to additional Production screen features (See the section on the Options screen).
Exit (Esc) returns the operator to the Main Menu screen.
2.3.3.1 Production Screen Features

The following list describes some of the features that are not immediately apparent in the Production
screen:
Before a test can begin, a test configuration must be selected (Select Test screen, Edit Test
Configuration screen, or Select Schedule screen) and the Part Serial Number (F10) field must
not be empty.
The following figure shows the Select Test (F8) button (used to select a part test), the Select
Schedule (F9) button (used to select a test Schedule), the Part Serial Number (F10) field, the Test
Configuration indicators, the Schedule Name indicator, the Test Number indicator, the Test
Timer indicator and the Auto Stop (F11)/Manual Stop (F11) switch. Refer to section 2.2.3.5 for a
description of the Test Configuration fields
The Schedule Name indicator is visible when a schedule has been selected
Test Number indicator shows the number of tests within the current testing procedure
The Test Timer indicator shows the elapsed time during a flow test and the count down time
between sequences
Process measurements are shown using a schematic of the flow station
The following figure shows the Production screen selection buttons. The Start Flow Test (F1) button
labeling will change to Start Audit Flow Test (F1) if the part test is an Audit test. The Start Flow
Test (F1) button labeling will change to Start Master Test (F1) if the part test is an Master test.
A test can be stopped/aborted at any time by pressing the Stop Test (F3) button.
When the system is in its default production mode the Edit Test Configuration screen requires a
password to gain access. When this password is entered correctly the system is placed in test
development mode. In the test development mode the Edit Test Configuration screen no longer
requires a password to enter the screen. Use the Edit Test Configuration screen to view or edit
the values in the test configuration record. When you are finished with the test development
effort, press the Options Screen (F7) button. While in the Options screen, press the Password
Protect (F7) button to return the system to the production (protected) mode. Press the Done
(Esc) button to return to the Production screen
If a printed report is desired for a unit, the operator needs to press the Option Screen (F7)
button to enter the Options screen. In the Options screen, the operator needs to press the Print
Report Coupon (F3) to print the report. THE ONLY TIME A REPORT COUPON MAY BE
GENERATED IS IMMEDIETLY FOLLOWING A COMPLETED TEST. Reports cannot be printed
during a FC500 audit test, CFV Audit tests, Audit tests, or while running scheduled tests.
The output file will be updated after a test is complete and the operator presses the Continue
(F4) button. All test information will continue to append to the current information in the output
data file until a new file is chosen.
When a flow test is being performed, the Test Value gauge displays the upper and lower limits as
well as the current test value of the flow through the part. The entire window in view is actually
100.1% of the upper specification limit and 99.9% of the lower specification limit. The larger
arrow indicates the current test value and it will turn GREEN when the value is in range and turn
RED when it is out of range. The Test Value indicator displays the current test measure
numerical value, the test measure descriptor (Ae, FFi, FFatm, Wcor, Mred, or PR), and the units.
The window of the gauge for the Control setpoint is a constant 0.5%. This is not dependent
upon the operator/test specified Control setpoint. The control is within setpoint and the pointing
arrow becomes green when the percent difference is inside 0.1%.
A flow test cannot pass unless the Nozzles Choked, Control within Setpoint, CFV Inlet Pressure
Stable, and Part Pressure Stable indicator lights are green.
The following figure shows the indicator lights.
Testing cannot continue if the E-stop button is pressed, the Power-On Reset button is inactive,
Low supply pressure is detected, or the test section pressure exceeds safety limits. When
detected, the following indicator lights shows the error signal
When a flow test includes pressure probing instructions, the probing assistance screen will
appear when the part flow reaches setpoint and is stable. The probing screen objects show the
probing limits and the current probe reading. The row and tap indicators give instruction to the
operator of which probe measurement to make. To record the reading the operator uses the
capture button.
Observe the System Status box for messages and instructions.
When a part test meets specification, the System Status box will turn GREEN. When a part test
fails to meet specification, the System Status box will blink RED.
The Options screen is activated with the Options Screen (F7) button
The Start New Test Group (F1) button actives a file dialog where a new file name can be
assigned to future test results. The previous test results file is closed as an archive and a report
file is generated.
The Print Test Group Results (F2) button creates a printed report for the current test group. A
pop-up screen is activated to gather additional information for the report.
The Print Test Coupon (F3) button creates a printed report for the last test.
The Show 6 Sigma Distribution Chart (F4) activates a graph screen that shows the probability
distribution function, Cpk, and PPM defect rate based on the current measurement results. A
printed copy can be generated using the Print (F1) button
The Change Work Order Number (F5) button displays the Work Order Number screen.
The Change Operator Identification (F6) button displays the Operator ID screen.
The Password Protect (F7) button returns password protection to the Test Configuration Editor.
The Done (Esc) button returns to the Production screen.
2.3.3.2 Select Test
The Select Test screen is used to activate a test configuration record from the test configuration
record database.
Button Descriptions
Enter Part Number (F4) text field used to enter the test part number. The test part number is
used to search the test record database for matching part records.
Select Operation Description (F5) menu list is used to display and select the part test
operation description for the part test record with the selected part number.
Search for Part (F1) searched the part test record database for all of the tests configured for
the part number listed in the Enter Part Number (F4) text field.
Show Parts List (F2) displays a pop-up screen that displays a list of all of the part numbers
stored in the part record database. The operator selects the desired part number from the
list. The Select Test screen will then display the first record of the list and lists the different
operation descriptions in the Operation Description Menu.
Start New Test Results File (F3) requires the operator to create a file (from the pop-up
dialog box) to save the test results to.
Select Test (Esc) returns to the Production screen selecting the record displayed on the
Select Test screen.
Results File: This indicator shows the file path where test result data is currently being
stored.
2.3.3.3 Select Test Schedule
The Test Schedule Selection screen is used to choose a test schedule from test schedule database.
Button Descriptions
Select Part Number (F1) a single selection box used to select the test part number. The
selected part number is used to search the test schedule database for matching test
schedules.
Select Schedule (F2) a pull-down menu used to select the test schedule name.
Start New Test Results File (F3) requires the operator to create a file (from the pop-up
dialog box) to save the test results to.
Select and Return (Esc) returns to the Production screen selecting the schedule displayed
on the Test Schedule Selection screen.
2.3.3.4 Graph Output
The Graph Output is helpful for viewing the performance of the pressure controller tuning parameters
during a flow test. The Graph Response (F6) button toggles the visibility of the graph. The graph is a
plot of the selected variables versus time. To select a variable, use the mouse to select the variable
from the Graph List. More than one variable can be selected by holding down the shift key while
clicking the name of the variable with the mouse. Of the selected variables, the list order (top down)
will determine the plot order. Thus if you select Setpoint and Part Pressure, Setpoint will be plot 1 and
Part Pressure will be plot 2.
Button Descriptions
Clear Graph resets the graph history.
Graph List is a multi-selection list box used to select the item/items to be displayed in the
graph.
2.3.3.5 Edit Test Configuration (Only available for Administrators)
The Edit Test Configuration screen is used to create, modify, and delete test configurations records.
Access should be limited to those who are knowledgeable and are responsible for creating and
altering test parameters.
Procedures:
Display a Record:
Enter a part number in the Enter Test Part Number (F11) text field and press the Find Part Record
(Ent) button, or press the Select Part from List (F1) button and select the part number from the pop-
up part number list. Then use the Operation Description Menu (F12) pull-down menu to select the
desired part test operation description.
Modify a Record:
Display the record to be modified, enter the modifications in the appropriate fields, and then press the
Update Record (F6) button.
Add a Record:
Choose between using a current record as a template or a blank (New Blank Record (F4)) record.
Either Modify or add the data to fields in the record and then press the Update Record (F6) button.
Delete a Record:
Display the record and press the Delete Record (F7) button. Confirm record deletion in the dialog
box.
Calculation:
Nozzle Pattern Calculator (F3) button will automatically select the Sonic Nozzle pattern for the
operator. In order for this feature to operate properly, the test measure type, unit system, nominal test
measure value, and control setpoint must be entered beforehand.
Utilities:
Pressure Probing Information (F2) button displays the Pressure Probing Procedure Information
screen.
Find Test Measure (F8) button displays the Test Measure Finder screen. The Test Measure Finder
screen will automatically flow the UUT and find the nozzle pattern and the nominal Test Measure.
Auto Tune Controller (F9) button displays the PID Auto Tuner screen. The PID Auto Tuner screen
will flow the UUT and find it natural response to a square wave flow input. From the natural response
of the part, the program will calculate the PID tuning parameters; Proportional Band and Integral Time,
for the UUT. User access to the PI controller parameters has been added because past experience
has shown that the test time can be greatly improved by tuning the controller to the conditions of each
unique test.
Schedule Generation (F10) button displays the Test Schedule Management screen.
Note: A full description of the utility screens is further described in later sections of this manual. The
Test Measure Finder and the PID Auto Tuner features are only accessible when the Edit Test
Configuration screen is called from the Main screen.
Button Descriptions
Enter Test Part Number (F11) text field used to enter the test part number. The test part
number is used to search the test record database for matching part records.
Operation Description Menu (F12) menu list used to display and select the parts test
description for the part records with the selected part number.
Start New Test Results File (Ctrl-F1) allows the operator to create a file (from the pop-up
dialog box) to save the test results to. The data column headers are created with the new file.
Do not use the same file to save data from dissimilar test measures.
Find Part Records (Ent) searched the part test record database for all of the tests configured
for the part number listed in the Enter Test Part Number (F11) text field.
Select Part from List (F1) displays a pop-up screen that displays a list of all of the part
numbers stored in the part record database. The operator selects the desired part number
from the list. The Select Test screen will then display the first record of the list and list its
different operation descriptions in the Operation Description Menu.
Pressuring Probing Information (F2) displays the Pressure Probing Procedure Information
screen. The probing information is associated with the current selected test.
Nozzle Pattern Calculator (F3) calculates a nozzle pattern based on the data entered in the
test configuration record.
New Blank Record (F4) creates a temporary record that is empty.
Undo Record Change (F5) restores the test record to its original configuration after changes
have been made, but before the record has been saved.
Update Record (F6) records any of the additions or modifications made in the EditTest
Configuration screen to the test record database.
Delete Record (F7) deletes the current part configuration record from the test record
database.
Find Test Measure (F8) sets flow through the UUT and measures the parts nominal test
measure. This feature is only active when the Edit Test Configuration screen is called from
the Main Menu screen.
Auto Tune Controller (F9) sets flow through the UUT and calculates the PID tuning
parameters (Proportional Band and Integral Time). This feature is only active when the
EditTest Configuration screen is called from the Main Menu screen.
Schedule Generation (F10) displays the Test Schedule Management screen.
Return (Esc) returns to the Production screen selecting the unit displayed on the Select Test
screen.
Refer to section 2.3.2.4 for the definition of the objects seen in the test configuration record
The Test Description is a single line of text used to describe test being performed. It also can
contain key words used to perform specific tests or functions.
Listed below is a list of the Descriptions keywords. A full description of the Description Keywords
can be found in the Operation section (Sec. 2.3.2.1) of this manual.
The keyword Virtual in the test description of the selected test performs a pass/fail calculation
of the part based on the flow results of the previous tests. The results are then written to the
data output file.
The keyword Audit or Master in the test description of the selected test will enable the Start
Audit Flow Test (F1) button and will enable the software to perform a Audit flow test procedure.
The keyword CFV audit in the test description of the selected test will enable the Start Audit
Flow Test (F1) button and will enable the software to perform a CFV Audit flow test procedure.
The keyword FC500 in the test description of the selected test will enable the Start Audit Flow
Test (F1) button and will enable the software to perform a FC500 Audit flow test procedure.
The keyword GE90 in the test description of the selected test will enable the software to
perform a GE90 (3) flow test procedure.
The keyword FC500 or FC200 in the test description of the selected test will enable the Start
Audit Flow Test (F1) button and will perform the FC500 audit test procedure.
The keyword Leak Test in the test description of the selected test will enable the Start Leak
Test (F1) button and will perform the leak test procedure when pressed.
The keyword CFV Valve Test in the test description of the selected test will enable the Start
CFV Valve Test (F1) button and will perform the CFV valve leak test procedure when pressed.
The keyword Flow Restriction in the test description of the selected test will enable the Start
Flow Restriction (F1) button and will perform the fixture flow restriction procedure when pressed.
Multiple tests can be configured for the same Part Number using different Operation Descriptions.
This allows for great flexibility in setting up part tests.
2.3.3.6 Select Part Number
The Select Part Number screen is used to select the Part Number from the list of part numbers stored
in the test configuration record database.
Button Descriptions
Registered Part Numbers (F1) list box used to display and select the part numbers for all of
the part configuration records in the test record database.
Select (Ent) used to select the part number from the Part Number list box. Pressing the
Select (Ent) button will return the Select Part Number screen to the program that called it,
and enter the part number into the Enter Part Number (F1) text field.
2.3.3.7 Pressure Probing Configuration Screen
The Pressure Probing Procedure Information screen is used to create, modify, and delete pressure
probing information associated with a test. Access this screen by pressing the Pressure Probing
Information (F2) button on the Edit Test Configuration screen. The probing data is associated with the
active test within the Edit Test Configuration screen and is shown in the Part Number and Operation
Description indicators. Every row has an individual data entry in the probing information array. The
arrow-up/down controls can be used to navigate the rows as well as the Tap Numbers within the row
element. When adding a row, the record will show up faded. Typing a number in the Row Number
field will activate the array element. When completed, the total number of Taps will show in the Probe
Points field in the test configuration record. During testing, control will be automatically transferred to
probe point acquisition.
Button Descriptions
Remove Row (F1) removes the selected row data from the row information array
Insert Row (F2) inserts an empty row element before the selected row
Clear empties the Tap Numbers array
Remove Pressure Probing (F5) clears the row information array
Save Changes (F6) implements the changes made
Return (Esc) returns to the Edit Test Configuration screen
2.3.3.8 Test Schedule Management Screen
The Test Schedule Management screen is used to create, modify, and delete test schedules.
Schedules allow the software to automatically sequence through two or more tests to the same test
part without operator intervention. Do not use schedules if physical setup changes are needed
between tests. Each schedule is associated with a unique part number. Individual tests must be
created in the Edit Test Configuration screen before they can be inserted into a schedule. Schedules
associated with different part numbers can have the same name. During testing, the schedule created
here, is activated using the Select Schedule (F9) button on the Production screen.
Control Descriptions
Enter Part Number (F7) text field used to enter the test part number. The test part number is
used to search the test schedule database for matching test schedules.
Enter Test Schedule Name (F8) text field used to enter the schedule names for the selected
part number.
Schedule Description (F9) text field used to enter the schedule description for the schedule.
Search For Part (Ent) searched the test configuration database for the entered part number
and loads the available operation descriptions for schedule generation
Select Part from List (F1) activates the Select Part Number screen.
Search for Schedule (F2) searches for the schedule data based on the entered part number
and schedule name. If found, the Test Schedule Management screen will then display the
schedule data.
Select Schedule from List (F3) displays a pop-up screen that displays a list of Part
Numbers and its associated schedules. The operator selects the desired part number and
then the schedule name from the menu list. The Test Schedule Management screen will then
display the test schedule record for the selected part number and schedule name.
Clear Screen (F4) clears the data on the screen.

Add or Update Schedule (F5) stores the schedule data to the test schedule database
Delete Schedule (F6) deletes the test schedule record from the test schedule database.
Return (Esc) returns to the Edit Test Configuration screen.
2.3.4 Test Measure Finder
The Test Measure Finder screen was developed to assist in configuring a part test.
The program will flow the part and find a nozzle pattern that meets the test criteria and measure the
parts nominal Test Measure.
Button Descriptions
Start Test (F1) starts the Test Measure Finder routine.
Abort (F2) aborts the test.
Continue (F3) used to acknowledge system errors.
Exit (Esc) returns the user to the Edit Test Configuration screen.
Operating Procedure: Connect the UUT fixture and install a UUT. Press the Start Test (F1) button.
The test is fully automated and does not require operator input. If the operator wishes to stop the
testing procedure, he can press the Abort (F2) button. In the event of a system error, the operator is
required to push the Continue (F3) button to acknowledge a system error and reset the program.
After the test is completed, the program enters the test limits and nozzle pattern into the test
configuration array. The operator then presses the Exit (Esc) button to return to the Edit Test
Configuration screen.
2.3.5 PID Auto Tune
The PID Auto Tune screen was developed to assist the operator in finding PID tuning parameters for
a UUT test. The PID tuning parameters consist of the proportional band and the integral time. The
program will flow the UUT and use the natural response of the system to calculate the proportional
band and the integral time. After the test is completed, the program enters the PID parameters into
the test configuration array
Button Descriptions
Start Test (F1) starts the PID Auto Tune routine.
Abort (F2) aborts the test.
Continue (F3) used to acknowledge system errors.
Exit (Esc) returns the user to the Edit Test Configuration screen.
Operating Procedure:
Connect the UUT fixture and install a UUT. Press the Start Test (F1) button. The test is fully
automated and does not require operator input. If the operator wishes to stop the testing procedure,
he can press the Abort (F2) button. In the event of a system error, the operator is required to push
the Continue (F3) button to acknowledge a system error and reset the program. After the test is
completed, the program enters the PID tuning parameters into the test configuration array. The
operator then presses the Exit (Esc) button to return to the Edit Test Configuration screen.
2.3.6 Test Data/Results Configuration Menu Screen
The Test Data/Results Configuration Menu screen is provided to give access to the interfaces that
control test results and data. This screen is launched by pressing the Configure Test Results
Reporting (F3) button on the Main Menu screen.
Button Descriptions
NCR Excel Template Configuration (F1) displays the NCR Template Configuration screen,
which allows the filename and path to be set for the templates to be utilized.
Saving to File Configuration (F2) displays the Test Result Data Record Configuration
screen, which allows selection of items to be recorded in the current Flow Test Data File.
Printing Configuration (F3) displays the Test Coupon Configuration screen, which allows
selection of items to be printed on the report coupon.
Exit to Main Menu (Esc) returns to the Main Menu screen
2.3.7 Test Results Data Record Configuration Screen
The Test Result Data Record Configuration screen is used to select the items/values to be recorded
in the current output data file. By clicking in the circles to the left of the data item description, a black
dot will either appear or disappear. A black dot indicates that the data item is selected will be
recorded in the test data results file. The absence of a black dot indicates that the data item is not
selected and will not be recorded.
Button Descriptions
Cancel & Exit (F1) returns to the Test Results Configuration Menu screen without making
changes
Enter (Esc) indicates that modifications have been made and will occur next time a data is
recorded to the Current Data File.
2.3.8 Test Coupon Configuration Screen
The Test Coupon Configuration screen is used to select the items/values to be printed in the flow test
report coupon. By clicking in the circles to the left of the data item description, a black dot will either
appear or disappear. A black dot indicates that the data item is selected will be printed on the test
report. The absence of a black dot indicates that the data item is not selected and will not be printed.
Button Descriptions
Cancel & Exit (F1) returns to the Test Results Configuration Menu screen without making
changes.
Enter (Esc) indicates that modifications have been made and will occur next time a coupon is
printed.
2.3.9 NCR Template Configuration Screen
The NCR Template Configuration screen is used to establish the path and filename of the general air
flow test and pressure probing Excel templates. This utility allows for new templates to be used if an
upgrade is required
Button Descriptions
Browse (F1) displays a file dialog that allows the General Air Flow Test Template file to be
selected by navigating to it.
Browse (F2) displays a file dialog that allows the Pressure Tapping Test Template file to be
selected by navigating to it.
Cancel & Exit (Esc) returns to the Test Results Configuration Menu screen without making
changes.
Accept & Exit (Enter) indicates that modifications have been made and the new templates
will be used for NCR.
2.3.10 System Diagnostic
The System Diagnostic screen contains several routines aimed at maintaining the station. These
routines are the System Leak Test, the CFV Valve Leak Test, and the UUT part fixture Flow
Restriction test.
2.3.10.1 System Leak Test:

A system leak test routine is provided so that the station can be checked periodically for leaks. The
test involves capping the part flow paths, connecting a pressure line to a pressure port, and
pressurizing the system. After the system has reached the leak test pressure, the air supply is shut
off, and the system is allowed to stabilize. After the system has stabilized, the program records the air
pressure and air temperature. The system is then allowed a period of time for the pressure to decay.
The program then records the air pressure and temperature. The two pressures and temperatures
are used to calculate the system leak. The system leak will be compared to a configurable limit (Line 6
of File LeakTestConfig.txt), and the system pass/fail status is determined. The leak rate will be
reported in the System Status as a leak mass flow. The leak test results are also logged to a leak test
log file on the system.
Install the part inlet manifold caps and connect a pressure line to a pressure port to seal the system.
Start the test by pressing the System Leak Test (F1) button. The test is fully automated and does not
require any inputs from the operator. If the operator wishes to abort the leak test, he can push the
Stop Test (F4) button. In the event of a system error, the labeling on the Stop Test (F4) button will
change to Continue (F4). The operator is then prompted to either press the Continue (F4) button
and reset the software, or press the Exit (Esc) button and return to the Main Menu screen. After the
program has completed the test, it indicates the pass/fail status and the system leak value, and logs
the test results to the system leak test log.
2.3.10.2 CFV Valve Leak Test:

A CFV Valve Leak Test routine allows the operator to check the Sonic Nozzle Control Valves for
leaks. This test verifies that no air is leaking through a closed CFV valve to influence the flow test
results. The test involves capping the part flow paths, connecting the pressure line to the pressure
port, and pressurizing the system up to the CFV valves. After the system has reached the leak test
pressure, the air supply is shut off, and the system is allowed to stabilize. After the system has
stabilized, the program records the air pressure at the part fixture. The system is then allowed a
period of time for the fixture pressure to change. The program then records a second fixture air
pressure. The two pressures are compared and a CFV valve leak is computed. The valve leak is
compared to a limit, calculated from the Flow Parameter of the part, and the system pass/fail is
determined. The leak rate will be reported in the System Status as a Reduced Mass Flow. The cfv
leak test results are logged to the CFV valve leak test log file on the system.
The test involves capping the part flow paths, and connecting a pressure line to a pressure port (to
seal the system). Pressing the CVF Valve Leak Check (F2) button starts the test. Enter the Flow
Parameter for the part to be tested. The flow parameter should be given in the part specifications.
The test is fully automated and does not require any additional operator inputs. If the operator wishes
to abort the leak test, he can push the Stop Test (F4) button. In the event of a system error, the
labeling on the Stop Test (F4) button will change to Continue (F4). The operator is then prompted
to either press the Continue (F4) button and reset the software, or press the Exit (Esc) button and
return to the Main Menu screen. After the program has completed the test, it indicates the pass/fail
status and records the cfv valve leak value to the cfv valve leak log.
2.3.10.3 Flow Restriction Test:
The Part Fixture Flow Restriction Test is provided for testing the air flow restriction caused by the Part
(UUT) Fixture. This test verifies that the part fixture is not causing a flow restriction that will influence
the flow test results. The operator is required to connect the part fixture, for the UUT that will be
tested, to the flow path and pressure port. The program is then stated and the operator is required to
select the UUT part test from the Select Part Test Screen, The system then establishes a mass flow
that is appropriate for the test. After the mass flow becomes stable, the system then records the part
fixture pressure ratio signature. The flow restriction pressure ratio will be compared to a configurable
limit (Line 5 of File FlowRestConfig.txt), and system Pass/Fail will be determined. The flow restriction
pressure ratio will be reported in the System Status box. The flow restriction test results are also
logged to a flow restriction test log file on the system.
Install the UUT fixture to the test station by connecting the flow path lines to the flow path, and the
pressure line to the pressure port. The operator then selects the flow path and the pressure ports
(from the pull down menus on the screen) that the part is connected to. Press the Fixture Flow
Restriction (F3) button to start the test. Select the part configuration test for the UUT. The test itself
is fully automated and does not require any additional operator inputs. If the operator wishes to abort
the Flow restriction test, he can push the Stop Test (F4) button. In the event of a system error, the
labeling on the Stop Test (F4) button will change to Continue (F4). The operator is then prompted
to either press the Continue (F4) button and reset the software, or press the Exit (Esc) button and
return to the Main Menu screen. After the program has completed the test, it indicates the pass/fail
status and the UUT fixture flow restriction. The flow restriction test results are also logged to a flow
restriction test log.
Button Descriptions
System Leak Test (F1) starts the stations leak test.
CFV Valve Leak Check (F2) starts the CFV control valve leak test.
Fixture Flow Restriction (F3) starts the UUT Fixture Flow Restriction test.
Stop Test (F4)/Continue (F4) aborts the current process when a test is in progress or
changes to the Continue (F4) button when a system error must be acknowledged. The error
will be displayed in the System Status message
Exit (Esc) returns the user to the Main Menu screen.
2.3.11 Maintenance (Only available for Flow Systems Engineers)
A system exerciser is provided under System Maintenance (F5) that is launched from the Main
Menu screen to allow manual control of all system I/O. This feature is helpful when trouble shooting
hardware problems or component failures. The operator actuates the test stations control valves by
pressing their control buttons. RED indicates the de-energized state, (flow blocked) and GREEN
indicates the energized state (flow enabled). After opening the main air valve (MAV), pressing the
Flow Regulator control button activates the flow regulator. Entering a value in the Regulator %
Output numerical control box creates pressurization. BE EXTREMELY CAREFUL - the system
cannot protect itself from a very fast, and large pressure surges, so raise the regulator output gently.
ONLY THE MOST KNOWLEDGIBLE AND TRAINED TECHNICAL PERSONNEL SHOULD USE
THIS UTILITY!
Button Descriptions
Reset (F1) is used to return all hardware to their default state.
Continue (F2) is used to acknowledge system errors.
Exit (Esc) returns to the Main Menu screen.
2.3.12 User Accounts (Only available for Flow Systems Engineers)
A User Account screen is provides a way to manage the FSI air flow test stand software user
accounts. It only allows the operator to change his/her password. It allows the administrator to add
new user to the system and to delete old user from the system. It can be launched by clicking User
Accounts button under Options tab at the top of the User Interface screen.
Operating Description:
Add New User: Pressing the Add user (F1) button or pressing the F1 key on the computer
keyboard will pop up a New User screen:
In the User Name field, input the new users name.

In the Password field, input the new users password. This password can be changed by clicking the
Password (F2) button on the User Accounts screen.
In the Confirmation field, input the same password as that in the Password field, otherwise an error
message will be showed up.
In the User Level field, select Administrator or Operator. An administrator has more power than an
operator. An operator only can select a test configuration record from the input database to run,
he/she cant create or modify any test configuration records. Also an operator cant add new user to
the system or delete old user from the system. But an administrator can do all of these.
If everything is OK, pressing the ADD (Enter) button or pressing the Enter key on the computer
keyboard and the new user will be added to the system, and the operator will be return to the User
Accounts screen.
When theCancel button or Esc key on the computer keyboard is pressed the operator will be return
to the User Accounts screen..
Change password: Clicking Password (F2) button or pressing F2 key on the computer keyboard
will pop up the Change Password screen:
In the User Name field, The user name will be filled in automatically if the operator height lines a
user in the User Accounts screen. The operator can change the user name in this field.
In the Old Password field, input the users original password.
In the New Password field, input the users new password.
In the Confirmation field, input the same password as that in the New Password field, otherwise an
error message will be showed up.
If everything is OK, Clicking Change (Enter) button or pressing the Enter key on the computer
keyboard will change the password of the user listed in the User Name field to the new password.
Delete users: Select (Height line) the user to be deleted from user list on the User Accounts screen,
then Click Delete User (F3) button or pressing F3 key on the computer keyboard will pop up Delete
Confirmation screen: Clicking Yes button on this screen will delete the user from the system,
Clicking No button will return to the User Accounts screen and no user is deleted.
Exit : Clicking Exit (Esc) button or pressing Esc key on the computer keyboard will exit the User
Accounts screen and return to the User Interface screen.
2.3.13 Instrument Calibration Coefficients (Only available for Administrators)
Instrument Calibration Coefficients Screen is used for change the transducer and thermocouple
calibration coefficients, and save the changes to the system calibration data file. Use the Calibration
Data Array pull-down menu to select the calibration data record for the desired instrument. Enter the
new calibration data in the appropriate fields. The instructions on the screen indicate how the
coefficients are determined.
Button Description
Calibration Data Array (F1) is a selection menu that lists the stations instruments. Use the
menu to select the appropriate instrument and the current data will be loaded. Then the
calibration record data items can be modified when necessary.
Cancel & Exit (F2) aborts the modifications and returns the Main Menu screen.
Save & Exit (Esc) saves the modifications to the calibration data file and returns the Main
Menu screen.
Calibration Record Data Items:

Tag a reference number for the instrument (often the manufacturers serial number)
Instrument ID a reference name for the instrument (often the instruments function)
Units The physical units for the scaled reading
Range The physical range of the instrument in Units
Accuracy The percent of full scale rating for the instrument
Vo The raw reading electrical units offset before scaling (i.e. volts or amperes)
C(0) through C(4) The polynomial coefficients for scaling the offset raw electrical units reading to
create a measurement in physical (engineering) units
2.3.14 Instrument Calibration (Only available for Flow Systems Engineers)
The Instrument Calibration screen provides the operator with the ability to calibrate the stations
pressure transducers and thermocouples while installed on the test station. This allows a complete
end-to-end (includes the measurement instrumentation, electrical wiring, electrical connections, and
the NI analog input or thermocouple module) calibration.
In order to calibrate the test stations instrumentation; a calibrated independent pressure or

temperature standard is used to establish reference pressures or temperatures. Setup the calibration
standard according to the manufactures instructions and connect to the test station. If the operator is
calibrating one of the test stations pressure transducer, the pressure standards pressure line needs
to be connected to the test stands Calibration Port. If the operator is calibrating one of the test
stations thermocouple, the thermocouple will need to be remove it from is mounting location and place
in the temperature bath. After the operator has setup the calibration standard, he/she can start the
calibration procedure by pressing the Start Calibration (F1) button. This prepares the software to
record the calibration information. Set the calibration standard to the first calibration point and allow
the reading to stabilize. Warning: The test instrumentation may be damaged if the calibration
standard setting is out of the range of the test instrumentation. After the reading has stabilized,
press the Record Calibration Point (F2) button. A pop-up window will appear allowing the operator to
enter the calibration standards value. After the value has been entered, the calibration information
(raw reading, scaled reading and applied standard) is added to the calibration data table. The
software then uses this information to calculate the full-scale percent deviation for the calibration
point. The operator then needs to set the calibration standard to the next calibration point and enter
the calibration standard value. Continue recording calibration points until the entire range of the test
instrumentation is covered. Although the software only needs two (2) points to calculate the
calibration coefficients, increasing the number of points that are used will increase the accuracy of the
calibration. After all of the data has been logged, the operator has the option to delete any point form
the calibration table. To delete a point, use the Point Number (F6) selector to select the line number
of the point to be deleted, and then press the Delete (F7) button. This will remove the selected line
form the calibration table. After all editing has been completed; press the Finish Calibration (F3)
button to calculate the straight-line calibration coefficients for the test instrument using the data in the
calibration table. Using the calibration coefficients and the raw readings, the software will calculate
the updated scaled reading and a new full-scale percent deviation for the each calibration points. The
software will compare the new full-scale percent deviation to the accuracy requirements of the test
instrumentation and determine if the instrument is within specification denoted by Accuracy (%). If the
instrument is within specification, the software will prompt the operator to save the calibration data to a
file. If the instrument is not in specification, the operator has the option have saving the new
calibration coefficients to the calibration file (press Update Coefficients (F4) button) or ignore the
new coefficients (press the Continue (F1) button). Following either of these actions the software will
prompt the user to save the calibration data to a file. The software will then reset itself to perform
additional calibrations.
This bench is configured to temperature compensate the pressure transducer within the software.
Temperature compensation calibrations were provided from the factory for each transducer. Forth
order polynomials are used to calculate new temperature compensated coefficients for each
transducer during the benches operation. The transducer temperature sensor (TT) is used to
measure the bench temperature and is used within the temperature compensation routine. The
transducer temperature sensor should be calibrated before calibrating the pressure transducers to
provide the most accurate calibration results. At the end of a pressure transducer calibration new
temperature compensated coefficients are written to the coefficients.txt file at the transducers
reference temperature.
1. Use the Instrument Selector (F5) pull-down menu to select the instrument to be calibrated.
2. Setup the calibration standard according to the type of instrumentation to be calibrated.
3. Press the Start Calibration (F1) button.
4. Set the calibration standard, allow the reading to stabilize, and then press the Record Calibration
Point (F2) button.
5. Enter the calibration standard value when prompted by the pop-up window.
6. Repeat steps 4 and 5 for the next calibration point.

7. After all of the data has been logged, delete any errors from the table using the Point Number
(F6) selector and the Delete (F7) button.
8. Press the Finish Calibration (F3) button.
9. If the instrument is in calibration, the operator is prompted to save the calibration data to a File. If
the instrument is out of calibration, the operator has the option have saving the new calibration
coefficients to the calibration file (press Update Coefficients (F4) button) or ignore the new
coefficients (press the Continue (F1) button). If the operator presses the Continue (F1) button,
the program will prompt the operator to save the calibration data to a file.
10. If additional instrumentation requires calibration, repeat steps 1 thru 9.
Button Descriptions
Instrument Selector (F5) is a selection menu used to indicate to the system the sensor that
the calibration procedure will be applied to.
Point Number (F6) is used to target a calibration point (row of data) from the calibration table
for deletion
Delete (F7) is used to delete the calibration point targeted. The deletion process is useful to
correct mistakes that were made during the calibration process.
Start Calibration (F1)/Continue (F1) prepares the software to accept data inputs or
continues the calibration operation.
Record Calibration Point (F2) logs the data point and calibration standard to the Calibration
Table.
Finish Calibration (F3) ends the data logging. If the test instrument is out of calibration, the
program calculates the new calibration coefficients.
Update Coefficients (F4) records the new calibration coefficients to the calibration coefficient
file.
Exit (Esc) returns to the Main Menu screen.
2.3.15 Option Screen

The Options screen displays more user controls related to testing parts.
The operator can change the work order number by pressing the Change Work Order Number
button. The SPC Control and SPC Range charts can be viewed by pressing the SPC button. The
operator ID can be changed by pressing the Change Operator button. User account information can
be changed by pressing the User Accounts button. To display the SPC charts press the SPC
Charts button. Set up the SPC Configuration by pressing the SPC Configuration button. To
generate a report press the Reports button.
2.3.15.1 SPC Configuration
The SPC Configuration Option under the options menu is used to display the SPC Configuration
Screen. This screen will allow the user to set up the statistical control fields for each part that has
been configured in the part database.
Button and selection box Descriptions

Clear (F1) resets all the dark gray fields to empty fields.
Save (F2) updates the SPC database table with the values entered into the dark gray
fields. If the fields are left blank the limits and centerlines will be calculated base on the
data provided with a sub group size of one and over 30 points.
Done (Esc) button is used to return to the Options screen.
Part Number Manu (Ctrl-F1) selection box is used to select the part number to configure
SPC limits.
Operation Description Menu (Ctrl-F2) selection box is used to select the operation
description of the selected part number to configure SPC limits.
2.3.15.2 SPC Charts
The SPC Option under the options menu is used to display the SPC Plots screen, it includes a
control chart and a range chart.
Button and selection box Descriptions

Clear (F1) resets the charts.
Generate (F2) updates both charts for changes made to the Number of Records to
Check and the Sub Group Size.
Done (Esc) button is used to return to the Options screen.
Part Number Manu (Ctrl-F1) selection box is used to select the part number for the SPC
charts.
Operation Description Menu (Ctrl-F2) selection box is used to select the operation
description of the selected part number for the SPC charts.
2.3.15.3 Report Screen
The Report Selection screen is used to select desired test results by Work Order Number, Operator
ID, Part Number, Part Serial Number, Operation Description, PASS/FAIL, Start Date and End Date
from the output database. It can be launched by pressing the Reports (F7) button or pressing F7 key
on the keyboard.
Button Descriptions
Print (F1): Pressing this button or pressing the F1 key on the computer keyboard will launch
the Report Print screen, all records selected in the Database Report Selection screen will
be sent to the Report Print screen.
At the top of the Report Print screen, there are four fields in which the operator can input or
overwrite their information:
Prepared by / Date field: In this field, the operator can input his/her companys name, the
operators name, and the date in which the report created.
Part Number field: If a part number is selected in the Database Report Selection screen, it
will be displayed in this field, but the operator can change the part number in this field, or input
one or more part numbers in this field.
Order Number field: If a Work Order number is selected in the Database Report Selection
screen, it will be displayed in this field, but the operator can change the Work Order number in
this field, or input one or more Work Order numbers in this field.
Customer Information field: This is a multi-line input box, the operator can input any
information about his/her company, or other companys information if the report is created for
that company, such as companys name, address, phone number, etc.
If everything is OK, click Print (F1) button or F1 key will print out all records showed in the
Report Print screen to the default printer.
Save (F2): A Select a File Name pop up screen will be displayed when pressing this button or
pressing F2 key. The operator will have the opportunity to select or input a file name to save
all records selected in the Database Report Selection screen. The file format is in flat text
and is tab delimited.
Configure (F3): Pressing this button or pressing the F3 key on the computer keyboard will
display the Test Results configuration screen. There are 46 selectable items in this screen.
The selected (black) items will be included in the database selection report. The un-selected
(white) items will not be included in the database selection report.
Exit (Esc): Clicking this button or pressing Esc key on the computer keyboard will exit this
screen and return to the User Interface Screen.

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Manual 6820

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WARNING

THE OPERATIONS MANUAL DETAILS SAFE OPERATING

TO AVOID POSSIBLE PERSONAL INJURY AND DAMAGE TO EQUIPMENT;

FOR OPERATOR SAFTEY, HEARING AND EYE

THE SOUND LEVEL EMITTED DURING TESTING

1.2.1 Operator Safety Equipment

1. Safety eye glasses with side shields

1.2.2 Safety Procedures

1.2.3 Safety Features

The emergency stop button is pressed.

The station is only pressurized during a test.

1.3 General Description

1.3.1 Flow Measurement

Controlled Variable Response Variable

Mass flow rate through a critical flow venturi:

Units: English = lbm/sec, Metric = kg/sec.

w - Mass flow rate

Effective Area: Ae_mm2

Ae_mm2 - Effective Area in mm2

Reduced Mass Flow and Flow Function: M red, FFi

Flow Function referenced to ambient or atmospheric conditions: FF a

Mred - Reduced Mass Flow

R - Gas constant for flow gas

Flow Function: FFsne

FFsne - Flow Function

Flow Function: FFMHI

FFMHI - Flow Function

Flow Function: FFtst

Flow Function: FFic

Units: English = lbm/sec, Metric = kg/sec.

Standard Cubic Feet Per Minute: SCFM

Units: English = SCFM.

SCFM - Standard Cubic Feet per Minute

Units: English = psia / psia, Metric = Bar / Bar.

Pounds Per Second: PPS

Units: English = lbm/sec.

PPS - Pounds Per Second

Corrected Mass Flow: Wcor

Units: English = lbm / sec, Metric = Kg / sec.

Units: English = lbm/sec

WHWcor - Corrected mass flow rate

1.4 Facilities Requirements

1.4.2 Air Supply

1.5.1 Flow Specifications

Mass Flow Range: 0.002 to 0.42 lbm/sec (0.907 to 190.51 g/sec)

2. Mass flow measurement accuracy of 0.42% of reading

1.5.2 Technical Specifications

1. The test station is intended for indoor use only.

1.5.3 Transporting and Storage

1.5.4 Test Stand Accessories

Computer and power cord.

1.5.5 General Information

TEMPERATURE CONTROLLED PRESSURE TRANSDUCERS: The stations pressure transducers

1.5.6 Maintenance and Cleaning

2.3 Operator Interfaces

2.3.1 Main Screen

2.3.2.1 Test Types

A virtual tests test Operation Description might be:

For the following testing sequence:

i.e. (1 LL/100)*a <= (b+c+d)/3 <= (1 UL/100)*a

2.3.2.2 Nominal Flow Measure Specification

2.3.2.3 Automated Sequential Flow Testing

2.3.2.4 Test Configuration Record Parameters

The test configuration data is as follows:

i.e. (1 LL/100)a <= (b+c+d)/3 <= (1 UL/100)a