08-01-2003 - F21 User Manual

SENTINEL F-21
MASS FLOW TEST INSTRUMENTS
Instruction Manual
SENTINEL F-21
INSTRUMENT
CINCINNATI TEST SYSTEMS, INC.

5555 Dry Fork Road
Cleves, OH 45002
(513) 367-6699
FAX (513) 367-5426
EMAIL sales@cincinnati-test.com REV. 08/03
Information in this document is subject to change without notice and does not represent a
commitment on the part of Cincinnati Test Systems, Inc. No part of the manual and/or
software may be reproduced or transmitted in any form or by any means, electronic or
mechanical, including photocopying, recording, or information storage and retrieval
systems, for any purpose, other than the purchaser’s personal use, without the express
permission of Cincinnati Test Systems, Inc.
No patent liability is assumed with respect to the use of the information contained herein.
While every precaution has been taken in the preparation of this book, Cincinnati Test
Systems, Inc. assumes no responsibility for errors or omissions.
Because of the variety of uses for this equipment and because of the differences between this
solid state equipment and electromechanical equipment, the user of and those responsible for
applying this equipment must satisfy themselves as to the acceptability of each application
and use of the equipment. In no event will Cincinnati Test Systems be responsible or liable
for indirect or consequential damages resulting from the use or application of this
equipment.
The illustrations, charts, and layout examples shown in this manual are intended solely to
illustrate the text of this manual. Because of the many variables and requirements associated
with any particular installation, Cincinnati Test Systems cannot assume responsibility or
liability for actual use based upon the illustrative uses and applications.
Table of Contents
SENTINEL F-21 INSTRUMENT
Chapter 1 .................................................................................................. 1-1
Introduction
Accessories
Chapter 2 .................................................................................................. 2-1
Installation
Chapter 3 .................................................................................................. 3-1
Instrument Overview
Chapter 4 .................................................................................................. 4-1
Start Up
Summary of Instrument Setup
Chapter 5 .................................................................................................. 5-1
Review or Change Test Parameters
FLOW, PRESS, TIMERS
Explanation of Test Parameters
Chapter 6 .................................................................................................... 6-1
Automatic Calibration (AUTO CAL)
Chapter 7 .................................................................................................... 7-1
SELF TEST (Leak Check Test Pneumatics)
Chapter 8 .................................................................................................... 8-1
Communication (COMM)
Chapter 9 .................................................................................................... 9-1
COUNTERS Display (COUNT)
Chapter 10 ................................................................................................ 10-1
Instrument Configuration (MISC)
Date/Time
Auto Test
Modify Instrument Setup
CHG Part Configuration
Test Circuit Version and Test Type Configuration
Machine Control Configuration
RS485 Communication Configuration
Security Configuration
Units of Measurement Configuration
Transducer Configuration
Chapter 11 ................................................................................................. 11-1
Tooling Control
Example Interface Wiring Diagrams
Internal Instrument Wiring Diagrams
Chapter 12 ................................................................................................ 12-1
Preventive Maintenance
Spare Parts
Chapter 13 ................................................................................................ 13-1
Error Messages
Appendix .................................................................................................. A-1
Instrument Specifications
Instrument Setup Summary Chart
Calibration Parameter Summary Chart
Setting Test Parameters (Description of Parameters)
Optimizing Test Performance
Warranty ................................................................................................... W-1
Index ........................................................................................................ I-1
CHAPTER 1
INTRODUCTION
Congratulations! You now own the new Sentinel F-21 high performance, mass flow leak
test instrument. These instruments incorporate the latest in micro-machined mass flow
sensor technology, high-resolution analog-to-digital conversion, microprocessor technol-
ogy, automatic calibration, and easy-operator interface. The economics and compact pack-
aging of these new instruments make them affordable solutions to many assembly verifica-
tion applications. The integral tooling control further reduces the cost of solving various
quality control problems.
INSTRUMENT CONFIGURATIONS
Depending on the tests required, the Sentinel F-21 instruments are configured in one of
three versions.
(S) Single pressure mass flow test
(F) Single pressure mass flow test with pre-fill or integrity test
(D) Dual pressure mass flow test utilizing a single mass flow sensor
The microprocessor, I/O circuitry, and power supply are common components within each
instrument. The pressure and flow transducers and regulators are selected to match the
application’s pressure range, flow range, and instrument version.
Figure 1 Version S Pneumatic diagram and manifold layout

Single pressure mass flow test instrument
The most common version for leak or flow testing is the single pressure mass flow test
instrument. A preliminary regulator controls the supply pressure to a precision test regula-
tor. The precision regulator controls the test pressure throughout the test cycle. Upon
initialization of a test cycle the exhaust valve is closed and the test part is pressurized through
an energized fill valve. Once the pressure is stabilized within the test pneumatics, the
isolation valve is energized and the fill and exhaust valves are de-energized. The flow of
makeup air required to maintain a constant pressure in the part is measured through the
mass flow sensor. At the end of the test cycle the isolation valve is de-energized to exhaust
the part.
1-1
Figure 2 Version F Pneumatic diagram and manifold layout
Single pressure mass flow test with pre-fill or integrity test
Some applications require a fast fill or high pressure integrity test prior to a normal leak or
flow test. The objective of the fast fill is to use a higher pressure to quickly charge air into
a large volume part. This enables the instrument to get air into the part faster than when
using a regulator set to the lower test pressure. For high pressure integrity tests the instru-
ment pressurizes the part to some minimum high pressure within a set time to verify prod-
uct integrity prior to leak testing. After meeting the minimum pressure limit and maintain-
ing minimum pressure for a set amount of fill time, the instrument cycles the valves to vent
the part. It then switches the pressure select valve and initiates a typical flow/leak test as
described above (for the version S instrument.)
Figure 3 Version D Pneumatic diagram and manifold layout

Dual pressure mass flow test utilizing one mass flow transducer
For products requiring leak/flow testing at two different test pressures, the Sentinel F-21
instrument is configured with two precision pressure regulators. Version D utilizes just one
pressure transducer and one flow transducer ranged to the highest test pressure and highest
flow rate for both tests. The instrument conducts two separate tests. A pressure select valve
isolates the separate regulators which control the two test pressures. The leak/flow tests use
the same sequence as the version S instrument with the activation of the pressure select
valve during the second test.
1-2
ADDITIONAL ACCESSORIES
Several helpful accessories are available to provide additional capabilities to the instru-
ment. They include:
* Portable, battery-powered printer

- Prints at 1 line/sec
- 1500 lines per charge
- 21 characters per line
- plugs into 9 pin serial connector on terminal
- used for quick data or setup download
- supplied with AC charging unit.
* Laptop computer pre-loaded with “Microsoft Works” (for statistical analysis) and “CTS
Talk” (a communications program designed to talk with the Sentinel B-21, I-21, and
F-21 instruments through the RS-232 port). The computer uses "Accessories
(Hyperterminal) to download Data files (up to 1000 test values, calibration information,
and counter information) to the lap top as ASCII formatted data files. The computer
uses "CTS Talk" to upload calibration information, new test setup information, and flow
sensor calibration data (Sentinel F-21 only) to the Sentinel F-21, B-21 and I-21 instru-
ments.
º
* Transducer verification gage
Gauge snaps onto the test port to indicate the test pressure. It is useful for verifying
proper transducer readings. Available ranges include 2, 30, and 100 psi.
* Inlet air filter set (0.3 and 5.0 micron filters)

Cincinnati Test Systems highly recommends installing a very good filter set on the inlet
air for mass flow instruments. By filtering dirt and water from the source air, many
maintenance problems are eliminated. (This is recommended for instrument air supplies
as well.)
* "CTS Talk" software described above within laptop computer can be supplied separately
when user already has a DOS based computer with Windows 95 or higher software.
1-3
1-4
CHAPTER 2
INSTALLATION CONCERNS
The Sentinel F-21 mass flow test instrument is a compact, lightweight instrument designed
to operate in a factory environment. To operate, it requires:
* clean, dry instrument air

* 110 VAC electrical power.
* (For 24 VDC models) additional 24 VDC supply for inputs and outputs (except test
result lights and test valves.)
Because it is a precision instrument, it is preferable to locate the instrument at least 15 feet

away from high electromagnetic energy devices (induction heat treat equipment, welders,
portable radios, etc.) whenever possible. Also, plants having poor quality electrical power
or ground systems should consider using isolation transformers on their power drops.
UNPACKING
Carefully remove the instrument from the shipping carton. Locate the quick connect fitting
and door keys (Sentinel F-21) supplied with the instrument (see Figure 4). The fitting is
provided for your test line connection. Open the instrument and inspect for damage before
progressing any further.
Figure 4 Quick connect fitting and door keys
MOUNTING CONSIDERATIONS
The Sentinel F-21 instruments perform best when located as close as possible to the test
parts. The Nema 12 enclosure of the Sentinel F-21 should be mounted above the test part
to framing, panels, or pipes. The top and bottom brackets allow for drilling holes as re-
quired. U bolts (not supplied) would allow for mounting to a pipe. Select a mounting
location that gives access to the bottom, top and front of the enclosure. Don’t forget to
allow room for the door swing. If required, the regulator knob(s) can be unscrewed and
removed temporarily for better access to mounting bolts and inlet pneumatic connections.
2-1
Figure 5 Sentinel F-21 top and bottom mounting brackets
2-2
PLUMBING RECOMMENDATIONS
This pressure decay instrument needs clean, dry air in order to provide trouble-free opera-
tion. Good plumbing practices will greatly enhance the quality of the test air.
Recommendations on plant plumbing
Figure 6 Plant plumbing recommendations
2-3
PNEUMATIC CONNECTIONS
There is one supply inlet port on the bottom left side of the Sentinel F-21 enclosure. The
inlet port is 1/4" FNPT. After mounting or locating the instrument, connect the inlet air
supply to the inlet port shown in Figure 7. To reduce future maintenance requirements use
the recommended plumbing detailed in Figure 6 and utilize the 0.3 and 5.0 micron coalesc-
ing filters. Be sure to replace the filter elements on at least a quarterly basis as preventive
maintenance.
The single male quick connect fitting located on the bottom right side of the enclosure is the
test port. Use flexible tubing to connect to the mating female quick connect fitting (sup-
plied with the instrument) via the 1/4" NPT connection. Use enough flexible tubing to
allow easy connect and disconnect action on the test port. It is recommended to use Parker
1/4" 2000 lbs tubing and Swagelock or Parker CPI fittings to provide rugged flexibility and
eliminate any volumetric change within the tubing during test.
The quick connect fitting supplied with the Sentinel F-21 instruments allows the operator to
manually disconnect the test line and easily attach the quick connect plug for the SELF
TEST function. The SELF TEST function is a standard routine to make it easy to check for
leaks inside the instrument.
Do not tighten the male quick connect fitting of the Sentinel F-21 instrument
into the pneumatic block. The assembly process utilizes lock tight. Tighten-
ing the fitting may crack the pneumatic block and void the warranty.
2-4
Figure 7 Bottom view of Sentinel F-21 instrument
2-5
ELECTRICAL CONNECTIONS
WARNING: TURN POWER OFF BEFORE OPENING ENCLOSURE TO WORK
ON ELECTRONICS.
The electrical connections for input power and interface wiring are made directly to termi-
nals on the input/output board located inside the instrument enclosure. Wiring should be
brought through conduit fittings placed through the top surface or on the right or left sides
(avoiding wiring from door) of the instrument enclosure (see Figure 8). Drill the holes for
inlet power and control interface wiring in the areas indicated. (Be careful not to drill the
holes too close to the circuit boards located in the upper right side of the enclosure. Figure
9 shows the terminations for inlet power and control interface. For additional information
about interfacing to tooling and/or a PLC, please refer to Chapters 10 and 11.
Figure 8 Areas on Sentinel F-21 enclosure for electrical inputs
2-6
The inlet power and interface wiring connections for the Sentinel F-21 are made directly
to terminals on the input/output board located in the upper half of the instrument
enclosure. (For 24 volt models, the 24 volt supply must be wired to the 24 volt terminal
which is the middle terminal on the left side of the board. Figure 9 below shows the
terminal for the 110 volt power and control interface.) Figure 9A on page 2-8 shows the
terminations for the 24 VDC models. For additional information about interfacing to
tooling and/or a PLC, please refer to Chapters 10 and 11.
Figure 9 Input/Output and power terminations for Sentinel F-21
2-7
On the 24 volt models, the input terminals have sockets for 1/4 watt drain resistors when
required for solid-state input devices.
Figure 9A Input/Output and power terminations for 24 volt model
2-8
Clock and transducer verification terminals
Terminals for monitoring the A-to-D converter clock output and transducer output
voltages are available on the side of the bottom circuit board. The clock output is a
frequency signal (9.216 MHz).
There are four sets of transducer output terminals. The diagram below indicates the
appropriate terminal for the single pressure transducer. The amplified transducer output
is 0 to 5 volts.
The flow transducers' output terminals are also indicated. Flow transducer 1 is the single
flow transducer supplied in version S, F, and D. The output voltage is 1 to 5 volts.
Figure 10 Clock and transducer output terminals for Sentinel F-21
2-9
2-10
CHAPTER 3
INSTRUMENT OPERATION
The Sentinel F-21 instruments are compact, state-of-the-art leak/flow test units which will
verify the integrity of your products. The software is multi-tasking so it performs several
tasks at the same time. Therefore, the information display functions can be reviewed and
changed without interfering with the testing functions. Calibration and many setup func-
tions are not accessible during testing because they change the fundamental way the system
works. Attempting to use a conflicting function causes the “WAIT FOR TEST TO END”
message to appear.
The basic instrument software performs different types of tasks.
Leak/flow test operation including tooling control

Information displays
Timers, pressures, flow parameters, counters
Serial communication with printer/computer
Test data, calibration information, counter, setup parameters
Calibration/self test
Automatic calibration sequence and system self leak test
Instrument Configuration (setup for general instrument operation)
Controls, security, test method, transducer setup, units of
measurement, and automatic self cycling
The instrument is setup for basic operation at Cincinnati Test Systems before shipment. To
change the setup to match your requirements refer to the appropriate chapters:
Chapter 10 INSTRUMENT CONFIGURATION (MISC)

Chapter 5 REVIEW OR CHANGE TEST PARAMETERS
(change test parameters for individual parts)
The default setup is summarized on the “INSTRUMENT CONFIGURATION (MISC)”

sheet in Chapter 4 INSTRUMENT STARTUP. The initial test parameters are summarized
on the “EXPLANATION OF PART TEST PARAMETERS” sheet found in Chapter 5.
Review these sheets and plan the changes required to meet your test specifications before
operating the instrument. The Appendix has additional information on initially “SETTING
TEST PARAMETERS” on pages A-6 through A-12 and “OPTIMIZING TEST PERFOR-
MANCE” on pages A-13 through A-15.
3-1
INSTRUMENT FEATURES
Figure 11 Overview of Sentinel F-21 instrument
3-2
INTERNAL INSTRUMENT LAYOUT
Figure 12 Internal layout of the Sentinel F-21 instrument
3-3
OPERATION PANEL
HOLD function manually pauses the test sequence. Pushing the button will pause the test
sequence in any step. Pushing the button again allows the test sequence to continue.
LED for HOLD indicates that the test sequence is paused.
CHG PART facilitates quick and easy selection of up to seven stored part test parameters.
Pushing the button will step through stored part names and parameters.
SELF TEST is a pre-programmed test sequence that allows an operator to test the internal
pneumatics for leaks without changing part parameters.
AUTO CAL automatically sequences through a calibration routine for leak test applica-
tions only to determine the flow offset value for a non-leaking part. The test is conducted
on a master test part.
LED for AUTO CAL indicates that unit is performing an automatic calibration sequence.
START initiates a test sequence (except with tooling control when 2 inputs to start test is
designated).
STOP interrupts the test sequence and resets for a new test.
(All of these functions are accessible for remote actuation via the input terminals on the
input/output board of Sentinel F-21 instrument.)
Figure 13 Operations Panel
3-4
PROGRAMMING PANEL
The PROGRAMMING Panel is laid out to give the operator easy and quick access to re-
view or change the test information stored in the instrument. (Access to change the stored
information can be protected by a security password. The selection of what information is
to be protected by password is programmed within the MISC function, Security Configura-
tion described in Chapter 10.) To sequence through the displays of information within each
area, push the desired PROGRAMMING panel button repeatedly. The values displayed
can only be changed if there is a blinking cursor below the numbers. To change a value or
setting that does not have a blinking cursor, push either the up or down arrow buttons. This
will initiate the password display if the value is editable. Enter the correct password using
the arrow buttons and then push ENTER. The displays will now have a blinking cursor
below the first character. Use the arrow buttons to move the cursor and scroll the characters
to the desired values. Push the ENTER button on the PROGRAMMING panel to store the
new values into memory. The function will automatically index to the next display. To
backup to a previous display, push the PREV button. To review parameters in another
PROGRAMMING display function just push that button repeatedly. To exit the display
functions, push the EXIT button.
Figure 14 Programming Panel
3-5
Up and Down arrow buttons scroll through letters and numbers to change the characters
of a value on the display, toggle Yes or No decision choices, and scroll through program
choices.
Left or right arrow buttons move the cursor on the display to select characters for change.
ENTER button processes any changes made to programmed parameters, Yes or No toggled
choices, or programmed choices into memory.
TIMERS button accesses timer parameters of the selected part for display or change.
COUNT button accesses stored counter information.
PRESS button accesses pressure parameters of the selected part for display or change.
COMM button allows selection of data for transfer to a printer or computer through the
RS232 or RS485 ports. Test and setup parameters can be uploaded from a computer.
FLOW button accesses flow/leak values of the selected part for display or change.
MISC button accesses the date/clock, Auto Test, security configuration, test configuration,
machine control configuration, RS485 setup, format & unit of measurement configuration,
and transducer setup.
PREV button steps back to the previous display within a function.
EXIT button steps out of the current display function and returns to the test sequence dis-
play.
3-6
Mass Flow Leak Testing Technology
A mass flow test instrument measures the flow rate of the makeup air required to
maintain a constant pressure in the test part during the test cycle. Flow will occur when
the pressure in the test part is different than the output pressure of the precision test
regulator due to a leak, part expansion, temperature changes, seal movement, or air
absorption in the test part. It is important to establish consistent process conditions that
effect part temperature, part elasticity, part absorption, and sealing force in order to
reduce the influence of these factors on the flow measurement.
The micro-machined mass flow sensor determines flow by measuring the thermal transfer
characteristics of the makeup air. The makeup air passes over a heating element which is
positioned between two temperature sensors. With a constant current applied to the
heating element, the sensor's bridge circuit outputs a voltage signal that is proportional to
the temperature differential between the temperature sensors. The design of the sensor
provides a very fast response time to changes in flow rate. The sensor's wide flow range
and Cincinnati Test Systems' unique calibration procedure provides accurate flow or leak
measurement from 1 to 1000 sccm or 5 to 6000 sccm. The wide flow range also reduces
the possibility of overranging the sensor during the transition from filling the part to
testing the part.
The test procedure utilizing a mass flow sensor involves quickly filling the test part to a
stabilized pressure while bypassing the flow sensor. The fill time must be long enough
for the makeup air flow to stabilize at a flow that is below the range of the flow sensor.
After the pressure within the part has stabilized, the makeup air from the test regulator is
directed through the flow sensor which measures any residual makeup air flow going to
the test part. Shortly after switching to the flow sensor, the instrument reads the flow and
compares it to the limits established for the test.
3-7
3-8
CHAPTER 4
INSTRUMENT STARTUP
After the instrument is mounted, plumbing connections completed, and inlet power connec-
tions made, you are now ready to turn on the instrument.
Turn on power
* Use the power switch located on the front panel to turn the power on to the instrument.
* The instrument software goes through a startup procedure that checks the RAM memory,
input/output module, operator display, transducers' zeroes, and calibration status. At the
end of the computer startup procedure the test “READY” display comes on the 40 char-
acter display.
Review SELF TEST specifications
* Push the CHG PART button on the OPERATION panel until “Self Test” appears on the
display.
* Push the PRESS button on the PROGRAMMING panel to view and possibly edit the
“MIN PRES” value. Push the PRESS button again and view “MAX PRES” value. The
test pressure setting of the regulator must be within the MIN and MAX PRESS values.
* Push the PRESS button to view the "TARGET PRES" value. The "TARGET PRES"
value must equal the regulator setting. The actual pressure at the end of the fill cycle
must be within +3% or +1 psi (whichever is greater) of the TARGET PRESSURE in
order to enter the test cycle. Edit this value if necessary to match the regulator setting.
* Push the EXIT button. Push CHG PART button repeatedly to return to desired part
parameters.
Conduct a self test on the instrument to verify its leak integrity
* Push SELF TEST button on the OPERATION panel and follow the display instructions:
“SELF TEST: (Cap Test Port, Push “START”)”.
* Unplug the test line at the quick connect and connect the self test plug (attached to the
bottom of the Sentinel F-21enclosure) to the quick connect. See Figure 15.
Figure 15 Self test connections for the Sentinel F-21
4-1
* Push the START button. The instrument conducts a preprogrammed leak test on the
instrument’s pneumatics.
* If there is no internal leak:
“.0x ccm No Leaks

Fix Test Port, “EXIT”
will appear. Reconnect the test line to the quick connect test port and push the EXIT
button.
* If the instrument displays "severe leak", check that the test port is plugged and that the
pressure regulator is set to a value between "MIN PRESS" and "MAX PRESS" and equal
to the "TARGET PRESS". If it is not, refer to "Set regulator to desired test pressure"
found on page 4-3.
* If there is an internal leak:
XX ccm: INT LEAK

FIX PNEUMATICS!
will appear. Check all the plumbing connections for possible leaks using a soaping agent.
If it is difficult to see all the fittings, you can remove the pneumatic manifold block while
still connected to the regulator and more easily check for leaks with the soaping agent.
After fixing the leak, reconnect the test line to the quick connect at the test port.
Do not tighten the male quick connect fitting of the Sentinel F-21 into the pneumatic
block. The assembly process utilizes locktight. Tightening the fitting may crack the
pneumatic block and void the warranty.
To initially use the Sentinel F-21 instruments, the following steps should be taken:
* Review “Instrument Configuration” parameters for any changes required to meet your
application. (These functions are all preset before shipment.) A table with “Instrument
Configuration” explanations is located on pages 4-4 and 4-5. There is also a summary
sheet of “Instrument Setup Parameters” in the Appendix on page A-4. Fill out the setup
sheet found on pages 4-4 and 4-5 or A-4. Make notations of changes. If additional
technical details are required about how any of the many functions work, go through the
step-by-step review of each function within “Instrument Configuration” in Chapter 10.
- CHG PART Configuration

- Test circuit version and test type configuration
- Machine tool control configuration
- RS485 communication setup
- Security configuration
- Unit of measurement configuration
- Transducer configuration
4-2
* Review and change initial test parameters to meet your actual test requirements. A table
with the “Part Test Parameter” explanations is located in Chapter 5 on pages 5-6 through
5-9. There is also a summary sheet for seven test parts, “Part Calibration Parameters”, in
the Appendix on page A-5. A complete technical explanation for each variable is provided
in Chapter 5. There is more technical discussion on “SETTING TEST PARAMETERS”
on pages A-6 through A-12 and an additional section on “OPTIMIZING TEST
PERFORMANCE” on pages A-13 through A-15.
- Pressures
- Flow values
- Timers
* Set the pressure regulator to the "TARGET PRESS" which should match the actual test
pressure specification. For instructions on how to set regulator, see section below in this
chapter on “Set regulator to desired test pressure.
* Make appropriate wiring connections to interface the tooling control (if selected).
(see Chapter 2 and 11)
* Make pneumatic connections to instrument (see Chapter 2).
Set regulator to desired test pressure
* Either connect a part to the test fixture or unplug the test line at the quick connect and
connect either the self test plug (attached to the bottom of the Sentinel F-21 enclosure -
see Figure 15) or the transducer verification gage accessory to the quick connect.
* Check the gage on the preliminary regulator. It should set at a pressure at least 10 - 20 psi
higher than the test pressure but not greater than 110 psi. This pressure should remain
fixed and secured by a locknut.
* Push the START button and then push the HOLD button immediately to stop the test
sequence in either the gross or fill segment of the test cycle. The display will show the
transducer’s output indicating the active test pressure being applied to the system through
the test regulator. If the system does not begin a test cycle and displays, “ERROR; CAL
REQUIRED”, push CHG PART button until “Self Test” appears. Then push the START
and HOLD buttons as described above.
* Adjust the test regulator knob until the pressure reading matches the "TARGET PRESS"
which should be the desired test pressure specification. (It must be between “MIN PRESS”
and “MAX PRESS”).
* Push the HOLD button a second time to allow the test sequence to continue and then
push the STOP button to reset the test sequence.
* Reconnect the test line to the quick connect test port.
4-3
INSTRUMENT CONFIGURATION (MISC.)
(Setup routine for basic instrument operation. A summary table for the instrument
configuration is located in the Appendix on page A-4.)
Setup function Factory setting Changes
Date (current year, month,

and day) ............................................. Reflects current date ________
Time (current hour, minute,
and second) ........................................ Reflect current time ________
Auto Test routine (skip for setup) 0 ________
Modify instrument setup options? ............(Change to Y to access ________

following setup functions
Enter password (Initially blank) ________
Number of parts to test (1 - 7)
Sets storage registers for number of
test parameters viewed with CHG PART ________
Update zero shift on part change? N ________
Pneumatic circuit (S,F,or D) (Set per version ordered) ________
(For S,F) Test Style (Leak or Flow) Leak ________
Test evaluation REJ<low<ACC<high<REJ ___<low<___<high<___
(For D) 1st Test Style (Leak or Flow) Leak ________
2nd Test Style (Leak or Flow) Leak ________
1st Test Evaluation REJ<low<ACC<high<REJ ___<low<___<high<___
2nd Test Evaluation REJ<low<ACC<high<REJ ___<low<___<high<___
Run 2nd test if 1st test was a reject? N ________
Machine controls? (N,YNF,YSF,YCF,YBF?)
N - No control
YNF - Yes tooling control w/no feedback
YSF - Yes tooling control w/seal feedback
YCF - Yes tooling control w/clamp feedback
YBF - Yes w/both clamp & seal feedback N ________
Use 2 Inputs to Start Test N ________
(Only appears if Y above)
Anti-tie-down? (For 2 button start) N ________
Unclamp part if it is rejected? N ________
Utility input: (Hold, Part Present to Start) HOLD ________
Utility output: (In Second Test, In Calibration,
Gross Timer, Test Timer) In Second Test_ ________
4-4
Exhaust Operation:
(Exhaust, Accept Mark, Reject Mark) Exhaust _______
Hold Limit Output Past End of Test N _______
IEE 485 address? (01-32) 01 _______
Modify instrument security Options? N _______
Secure calibration process
(No Calibrations, No Parameter Edits)? N _______
Secure test information
(Calibrations, No Parameter Edits)? N _______
Secure self test parameters? N _______
Secure counters? N _______
Secure transducer values (zero & span)? N _______
Secure runs to calibration? N _______
Secure CHG PART? N _______
Password (Initially blank) _______
Leak rate units (ccm, ccs, cis, cch, lpm, lps, lph) ccm _______
Pressure units (atm,bar,mbr,iHg,
mHg,kPa,MPa,iWC,psi,ozi) psi _______
Pressure transducer zero range 3.0 mv _______
Pressure transducer span for 100 mv? 100 psi _______
Check Pressure Transducer? N _______
Flow Transducer Zero Range (100 mv, custom) 100 mv _______
Flow Transducer Span for 5 volts (1000, 6000) 1000 ccm _______
Record all changes to the original factory settings. It is important to know

these values if troubleshooting is required.
4-5
4-6
CHAPTER 5
REVIEW OR CHANGE TEST PARAMETERS
CHG PART
Select different stored part parameters by repeatedly pushing CHG PART button on
the OPERATION panel until the desired part name appears on the display. A password
may be required to change parts. The stored part parameters can also be selected
remotely by a binary signal to the three “PART SELECT” inputs on the input
terminals. (Review “Remote Change Part” diagram in Chapter 11.) The number of
part parameters displayed (from 1 to 7) is setup within MISC, CHG Part Configuration
- see Chapter 10. If the part name needs to be established or changed, its setup routine
is accessible at the end of the FLOW functions. (See the section on FLOW below for
instructions on how to set or change the part name/number - 12 characters.) The
following sections for TIMERS, PRESSURES, and FLOW will describe how to
review and edit the stored part test parameters.
PART 5: BRASS VALVE2
READY
All the test parameters are accessed for review or change by repeatedly pushing the
appropriate button on the PROGRAMMING panel. A password may be required to
change these values. (See the Chapter 10, MISC, for instructions on how to select or
change security options.)
TIMERS PRESS FLOW
[Clamp] Min Press Low Limit
[Seal] Max Press High Limit
Gross TargetPres *Calibr'n
Fill (Min Pres 2) *MaxCalFlow
Test (Max Pres 2) *MinCalFlow
Exhst (TargetPres2) Zero Shift Pct
(Gross 2) {Zero Shift Value}
(Fill 2) (Low Lim 2)
(Test 2) (High Lim 2)
(Exhst 2) (*Calibr'n 2)
Relax (* MaxCalFlow2)
(* MinCalFlow2)
(Zero Shift Pct2)
({Zero Sh Val 2})
{Zero Shift Quan}
Change Part Name
Parameters within parenthesis ( ) are available when pneumatic version F or D is
supplied. Parameters within brackets [ ] are displayed if tooling control is selected.
Parameters within brackets { } are displayed if zero shift % is non-zero. Parameters with
† are calculated or measured values. Parameters with * appear if test type is LEAK.
5-1
To change parameters when the cursor is not blinking, push either the up or
down arrow buttons. The display will request a password, “ENTER
PASSWORD:XXXX”. Use left, right, up, and down arrow buttons to enter the
password and then push ENTER button. When a correct password is entered, the
original display will return with a blinking cursor below the first character. Once
a password is entered, changes can be made to all other parameters. Access to
change parameters will remain on for five minutes after the last key has been
pushed. The selection of security options to protect the part parameters is made
within the MISC button, Security configuration.
Use up, down, left, and right arrow buttons to select and scroll through the
numbers to set the TIMER/PRESS/FLOW values desired. Enter the values into
the memory by pushing either the ENTER, TIMERS, PRESS, or FLOW
buttons.
TIMERS
Push the TIMERS button on the PROGRAMMING panel repeatedly to review or
edit the stored time parameters for the selected part. The function will review the
following TIMERS values utilizing the following format.

Clamp XXX sec
“Clamp” [Appears only when tooling control is selected.] Delay after initiating clamp
output signal before starting next step in sequence. Or if clamp feedback is
selected, the maximum allowed time to receive feedback without generating a
clamp feedback error message.
“Seal” [Appears only when tooling control is selected.] Delay after initiating seal
output signal before starting next step in sequence. Or seal feedback is selected,
the maximum allowed time to receive feedback without generating a seal
feedback error message. Timer for sealing equals timer for unsealing.
“Gross” Maximum allowable time for measured test pressure to reach “Minimum Test
Pressure” setting during testing sequence. This is a not-to-exceed timer and only
the actual time needed is used.
“Fill” Time allowed for regulated air to charge and stabilize the pressure in the test part
after reaching Minimum Test Pressure. At the conclusion of the fill timer, the
instrument switches the flow of regulated air through the mass flow sensor.
“Test” Time delay after switching regulated air flow through mass flow sensor before
reading the flow rate of the makeup air. (Time must be greater than 1 second.)
“Exhst” Time delay after end of test in order for the part pressure to vent before advance
seal output is released or before the second test starts. When exhaust operation is
set to "Accept Mark" or "Reject Mark" in MISC, “Exhst” timer will control how
long an accept or reject stamp output stays on.
5-2
(The following SECOND TEST timers will only appear for dual pressure or fast fill/integrity
test systems - versions F or D.)
“Gross 2” Time to reach Minimum Test Pressure in second test.

“Fill 2” Time to fill and stabilize part pressure in second test.
“Test 2” Time delay after switching makeup air flow through mass flow sensor to
measure flow. (Time must be greater than 1 second.)
“Exhst 2” Time delay before releasing advance seal output in order to relieve pressure
in part. Also controls how long an accept or reject stamp output stays on.
“Relax” Time between tests only during AUTO TEST cycle. This timer should be at
least 20 seconds.
Push TIMERS button to step forward through TIMERS functions, PREV button to
step backward through the sequence, and EXIT button to leave the TIMERS
functions at any time. Push ENTER, TIMERS, or PREV buttons to enter new values
into memory. Push PRESS, FLOW, COUNT, COMM, or MISC buttons to enter
new parameters into memory and switch to different functions.
PRESSURES
Push PRESS button on the PROGRAMMING panel repeatedly to review or edit the
stored test pressure parameters for the selected part. The function will review the
following PRESSURES values using the following format.

Min Press: XXXX psi
“Min Press” Minimum test pressure that must be reached before gross timer elapses
and must be maintained at the end of fill cycle.
“Max Press” Maximum test pressure allowed at end of fill cycle.
"Target Press" Actual pressure (+3% or +1 psi, whichever is greater) that must be
maintained at the end of the fill cycle.
(The following SECOND TEST pressures will only appear for dual pressure or fast fill/
integrity test systems - versions F or D)
“Min Pres 2” Minimum test pressure to reach before Gross 2 timer elapses and to
maintain by end of fill cycle.
“Max Pres 2” Maximum test pressure allowed at end of 2nd test fill cycle.
"Target Press2" Actual pressure that must be maintained at the end of the fill cycle.
5-3
Push PRESS button to step forward through PRESSURE functions, PREV button to
step backward through the sequence, and EXIT button to leave the PRESSURES
functions at any time. Push ENTER, PRESS, or PREV buttons to enter new values
into memory. Push TIMERS, FLOW, COUNT, COMM, or MISC buttons to enter
new parameters into memory and switch to different functions.
FLOW
Push FLOW button on the PROGRAMMING panel repeatedly to review or edit the
stored flow parameters for the selected part. The function will review the following
FLOW values using the following format.

Rej Rate: XXXX ccm
“Low Limit”* Specified low limit flow used to evaluate parts.

“High Limit”* Specified high limit flow used to evaluate parts. (Setting must be non
zero.)
(For Test Style - Leak only)
“Calibr'n” Flow offset (or tar value) for a non-leaking part measured in AUTO
CAL routine for leak testing applications only. It represents the
baseline flow due to temperature, expansion, absorption, etc.
"Max Cal Flow" Maximum flow allowed for "Calibr'n during AUTO CAL routine.
Maximum flow amount prevents mistakenly calibrating to a leaking
part or fixture.
"Min Cal Flow" Minimum flow allowed for "Calibr'n during AUTO CAL routine.
Prevents calibrating to capped off test line.
“Zero Shift Pct” Percent variation allowed around "calibr'n" for dynamic compensa-
tion (zero shift) due to process fluctuations. (Percentage calculated on
“high limit” value as a plus and minus range around "calibr'n".)
"Zero Shift" {Appear only if "zero shift percent" is set greater than zero.) Amount
of compensation calculated and stored for a no-leak part due to process
variations like temperature.
(The following SECOND TEST flow parameters will only appear for dual pressure test
systems — versions F or D)
“Low Limit2” Specified low limit flow used to evaluate parts in second test
"High Limit2" Specified high limit flow used to evaluate parts in second test
(For Test Style - Leak only)
"Calibr'n 2" Flow offset (or tar value of the second pressure test for a non-leaking
part measured during AUTO CAL routine (for leak testing applications
only.) It represents the baseline flow due to temperature, expansion,
absorption, ect.
*See page A-6 and A-7 in Appendix for description of high and low limit
settings.
5-4
"Max Cal Flow2" Maximum flow allowed for Calibr'n2 during second pressure test in
AUTO CAL routine. Maximum flow amount prevents mistakenly
calibrating to ta leaking part of fixture.
"Min Cal Flow2" Minimum flow allowed for Calibr'n2 during second pressure test in
AUTO CAL routine. Prevents calibrating to capped off test line
"Zero Shift2 Pct" Percent variation allowed around "calibr'n" for dynamic compensa-
tion (zero shift) due to process fluctuations. (Percentage calculated
on “high limit2” value as a plus and minus range around "calibr'n".)
"Zero Shift2" {Appear only if "zero shift2 percent" is set greater than zero.)
Amount of compensation calculated and stored for a no-leak part due
to process variations like temperature.
"Zero Shift Quan" {Appear only if "zero shift percent" or "zero shift2 percent" is set
greater than zero.) The number of tests which must fall within the
zero shift percentage that are used to calculate for "zero shift values".
The last menu under FLOW is :
Part name setup

Use up and down arrow buttons to scroll through letters and numbers to set up part
name and number desired, maximum of 12 characters. Use left and right arrow
buttons to move cursor under character for changes.
Push FLOW button to step forward through the FLOW values, PREV button to step
backward through the sequence, EXIT button to leave the FLOW functions at any
time. Push ENTER, FLOW, or PREV buttons to enter new values into memory. Push
TIMERS, PRESS, COUNT, COMM, or MISC buttons to enter new parameters into
memory and switch to different functions.
5-5
EXPLANATION OF PART TEST PARAMETERS
(A summary part test parameter table for up to seven parts is located in the Appendix
on page A-5 .)
Test Parameters Factory settings Changes

TIMER VALUES
Clamp time - time delay before initiating
seal output signal or receiving clamp
feedback signal 1.0 _____
Seal time - time delay before initiating
start test signal or receiving seal
feedback signal 1.0 _____
Gross fill time - maximum allowable time
to reach minimum test pressure before
starting fill timer 2.0 _____
Fill time - additional time to fill
part with regulated air and allow
adiabatic temperature effect, part
expansion and absorption to stabilize
8.0 _____
Test time - delay period after switching makeup
air flow to mass flow sensor before measuring
precise flow going to part 1.0 _____
Exhaust time - time after switching test and exhaust
valves to allow pressure to escape from
part before unsealing or output time for part marking 1.0 _____
(Optional timer settings for versions F or D)
Second test gross fill time - maximum
allowable time to reach 2nd test minimum
test pressure 2.0 _____
Second test fill time - additional time to
fill part with regulated air and allow
adiabatic temperature effect, part expansion,
and absorption to stabilize during 2nd test. 6.5 _____
Second test test time - delay period after switching
makeup air flow to mass flow sensor before measuring
precise flow to going to part during the 2nd test 1.0 _____
Second test exhaust time - time after
switching test and exhaust valves to allow pressure
to escape from part before unsealing or output
for part marking 1.0 _____
Relax time - time between tests during
auto run routine 20.0 _____
5-6
PRESSURE VALUES
Minimum test pressure - pressure at which
gross timer is stopped and fill timer
begins. Minimum pressure that must be
maintained in the part at the end of
fill cycle. (based on instrument ordered) _____
Maximum test pressure - part pressure
that can not be exceeded at the end of
fill cycle. (based on instrument ordered) _____
Target pressure - part pressure that must
maintained (+3% or +1 psi, whichever is
greater) at end of fill cycle. (based on instrument ordered) _____
(Optional pressure settings for versions F or D)
Second test minimum test pressure - pressure
at which 2nd test gross timer is stopped
and 2nd test fill timer begins, 2nd test
minimum pressure that must be maintained
in part through fill2 cycle. (based on instrument ordered) _____
_____
Second test maximum test pressure - 2nd test
part pressure that can not be exceeded at
the end of the 2nd test fill cycle. (based on instrument ordered) _____
Second target pressure - part pressure that
must maintained (+3% or +1 psi, whichever is
greater) at end of fill2 cycle. (based on instrument ordered) _____
FLOW VALUES
Low Limit - specified low flow value to reject parts ______ _____
High Limit - specified high flow value to reject parts
(setting must be non-zero) ______ _____
(For test style - leak only)
Calibration value - measured offset for master no-leak
part during AUTO CAL ______ (measured value)
Maximum Calibration Flow value - high limit for
measured Calibration flow value in AUTO CAL to prevent
using leaking master parts or leaking fixtures. ______ _____
Minimum Calibration flow value - low limit for
measured Calibration flow value in AUTO CAL to prevent
testing capped off or blocked test line _______ ______
Zero shift percentage - the percent variation
around zero or "calibr'n" value used for calculating
dynamic compensation (zero shift) due to process
fluctuations. Percentage calculated on
"high limit" value 0 _____
Zero shift value - calculated value reflecting
drift in measured flow for non-leaking parts due
to changing temperature and elasticity effects on test ______ (calculated value)
5-7
(Optional flow settings for versions F or D)
Second test low limit - specified low limit value
for 2nd test to reject parts 4.0 _____
Second test high limit - specified high limit value
for 2nd test to reject parts
(setting must be non-zero) 10.0 _____
(For test style - leak only) _____

Second calibration value - measured offset for master no-leak
part measured during 2nd pressure test of AUTO CAL
(for leak testing applications only.) _____ (measured value)
Second Maximum Calibraton Flow value - high limit for
measured Calibration flow value in 2nd pressure test of
AUTO CAL to prevent using leaking master part or
leaking fixtures. _____ _____
Second Minimum Calibration Flow value - low limit for
measured Calibration flow value in 2nd pressure test of
AUTO CAL to prevent testing capped off or blocked test line._____ _____
Second test zero shift percentage - the percent
variation around zero or "calibr'n" value of _____ _____
2nd test used for calculating dynamic compensation
(zero shift) due to process fluctuations. Percentage
calculated on "high limit 2" value for the 2nd test. _____ (calculated value)
Second test zero shift value - calculated value reflecting
drift in measured flow for non-leaking parts due
to changing temperature and elasticity effects
on the second test _____ (calculated value)
Zero shift quantity - specified number of test
results that must fall within the specified
zero shift percentage area before calculating the
zero shift value (dynamic compensation). 0 _____
Part Name - up to 12 alpha/numeric characters

to identify stored part parameters. Part 1 _____
CHAPTER 6
AUTOMATIC PART CALIBRATION (AUTO CAL)
The Sentinel F-21 instruments have a unique calibration procedure which simplifies cali-
bration for leak testing applications and assures greater accuracy. This procedure is only
applicable when the "Test Style" is set to "Leak" under the MISC menu. The calibration
procedure is not required when "Test Style" is set to "Flow.
When leak testing parts, there may be residual flow after the fill cycle due to adiabatic
temperature effects, part expansion, absorption, or a shortened fill cycle. If this residual
flow is consistent from good part to good part, it is desireable to correct subsequent flow
measurements to zero to represent a zero flow part. The AUTO CAL routine tests a non-
leaking master part once and stores the measured flow as "Calibr'n". This value is dis-
played within the "flow" menu by pushing the FLOW button. Following the AUTO CAL
routine, all the flow readings within the leak testing applications will be offset by the amount
of the "Calibr'n" value.
(Refer to the MISC menu, Test Circuit Version and Test Type Configuration, to set whether
the Test Style is LEAK or FLOW.)
Calibration routine for a part:
* Push CHG PART button on the OPERATION panel to select the desired part
parameters for calibration.
* Push the AUTO CAL button on the OPERATION panel to begin the calibration
procedure. After loading the master no-leak part into the fixture, push the START
button to initiate the test procedure.
* The system will test the master no-leak part to measure the residual flow within the
"test cycle" and will store this residual flow value as "Calibr'n".
* Print or write down the calibration parameters for PRESS, TIMERS, and FLOW for
later reference.
Multiple Part Calibrations

The Sentinel F-21 instrument has seven part holders to store the independent calibration
and test parameters for seven part families. Each set of stored calibration values includes
the "Calibr'n" value for the different parts if set for "Leak Test" .
6-1
6-2
CHAPTER 7
SELF TEST
In order to verify that the Sentinel F-21 test pneumatics are not leaking, the instrument has
a self test routine.
The Min and Max Press limits for the SELF TEST parameters are initially set to match
the limits of the transducer supplied. The "Target Pressure" must be set to match the
pressure setting of the test regulator. Push CHG PART until SELF TEST appears.
Review the parameters under PRESS, FLOW, and TIMERS. The SELF TEST
parameters should be protected by the security password. It is not recommended that
you change these parameters unless the transducer is changed or the "Target Pressure"
does not match the regulator setting.. Push the CHG PART button repeatedly to return
to the desired test part parameters.
* Push SELF TEST button on the OPERATION panel or remotely activate with a contact
closure on input terminal SELF TEST. The display will prompt:
SELF TEST: (Cap Test

Port, Push “START”)
* Remove the test line quick connect fitting and plug in the test line plug mounted on the
under side of the Sentinel F-21 instrument. Push the START button. The instrument will
run a leak test cycle using the stored program to determine if the pneumatics have an
acceptable maximum flow (high limit). At the end of the test the display will indicate:
.xx ccm -No Leaks (max. allowed flow is preset.)

Fix Test Port, “EXIT”
for an acceptable non-leaking test pneumatics, or
.xx ccm, INT LEAK, (if flow exceeds “high limit” value in SELF TEST)
FIX PNEUMATICS!
for a leaking test pneumatic panel.
* The operator should fix the pneumatics and return to testing the previous part. The
operator will need to remove the test line plug and reconnect the test line quick connect
fitting. Push EXIT and the system will automatically return to the last part tested. To
select a new part push CHG PART button.
7-1
7-2
CHAPTER 8
COMMUNICATIONS (COMM)
To output information to a printer (via RS232) or a computer (via RS232 or RS485), there
are RS232 and RS485 ports on the Sentinel F-21 instrument. The RS232 port is on the
operator panel and the RS485 port is on the bottom computer board inside the enclosure.
* Push the COMM button on the PROGRAMMING panel. The display prompts the
operator to connect the printer or computer via the RS232 9 pin D connector or the RS485
commercial phone jack connector.
* Select either the “Printer or RS485 Network” or “Computer (RS232 only)” by using the
up or down arrow buttons and then push ENTER or COMM button.
* If “Printer or RS485 Network” is selected and output to a printer is desired, the following
outputs are available. Push the up or down arrow buttons until the desired output is
displayed.
“XFER DATA EACH TEST”

“XFER DATA LAST 20”
“XFER DATA CAL INFO”
“XFER DATA COUNTERS”
“XFER DATA SETUP”
Push ENTER button to send the data to the printer.
* For version D the Sentinel stores two test results for each part tested. Therefore when 500
parts are tested, 1000 test results are stored for output. If “LAST 1000” is selected, it will
output the dual pressure test results for the last 500 parts. “EACH TEST” will output the
two test results for each part after it is tested.
* If communication with an external computer using the RS485 port is desired, push the
ENTER or COMM buttons to select “Printer or RS485 Network” and then push the EXIT
button. The display will return to the “Ready” condition, and the Sentinel will be ready to
communicate to commands from the computer via the RS485 port or RS232 port.
* If “Computer (RS232 only)” is selected in order to communicate with a computer using

CTS Talk software. Push the EXIT button after pushing the ENTER or COMM buttons.
The display will return to the “Ready” condition, and the Sentinel will be ready to
communicate with CTS Talk in a remote computer. Commands within CTS Talk will
send “data request” messages to the Sentinel instrument for data download or upload.
8-1
The printer/computer interface is set to work with the following RS232 parameters.
9600 baud No parity 8 bits 1 stop bit
continuous retry
Standard RS232 interface cable for the portable printer is a 9 pin female to 9 pin male serial
cable. The RS232 interface cable for a computer is a 9 pin female to 9 pin female serial cable.
If a 25 pin serial cable is required for another printer, there is a pin-to-pin cable diagram as
part of the circuit diagram on page 11-23 so that the user can wire a special cable.
Communication with other serial devices

The Sentinel F-21 instruments have the ability to communicate with other printers or
compatible devices (such as computers or PLCs). Communication can either be one way
with the instrument sending information on command using the menus under the
instrument's COMM button or two way with an external device programmed to request
specific information. The following application bulletins are available upon request to
explain how to implement these features.
AB104 Continuous Logging of Test Results to a Computer

AB 105 Serial Communications
AB 112 Using Visual Basic to Communicate with Sentinel B-21/I-21 instruments
AB 116 Communication with GageTalker
AB 117 Communication with DataMyte
Transferring data from the Sentinel F-21 to computer with Windows 95

1. Connect null-modem cable to comport of computer.
2. Start Windows 95.
3. Choose START, PROGRAMS, Accessories, Hyperterminal.
4. Choose Hyperterminal icon
5. Enter a connection description name like "F-21 port" and choose desired icon, OK.
6. Within phone number, set "connect using" to "direct to com2" (or your appropriate com
port), OK
7. Adjust "com2 properties" to 9600 bps, 8 data bits, no parity, 1 stop bit, and flow control
of "none", OK.
8. Choose File, Save As, Save.
9. The hypertermimal is ready to receive data from the Sentinel F-21 instrument now and
in the future.
10. For future data transfers, the computer will have a dedicated icon on hyperterminal
setup to receive data.
11. On the Sentinel F-21, push COMM, select "Printer or RS485 Network", and select the
desired output for transfer and push ENTER.
12. To transfer the data to a spreadsheet program like EXCEL, highlight the data on the
computer screen, select Edit menu and Copy the information.
13. Open the spreadsheet program.
14. Select Edit and Paste the information into the spreadsheet.
15. Highlight the data within EXCEL (for example) and select Data, Text to Columns,
"Fixed Width", NEXT, and FINISH.
16. Remember the test result files have the most recent results at the top or first.
8-2
CHAPTER 9
COUNTERS
To display the counter information stored in the system, push the COUNT button on
the PROGRAMMING panel repeatedly. The displays will show the following:
“TOTAL ACCEPTS” Number of accept results based on low and high limit setup
“TOTAL REJECTS” Severe leaks and number of reject results based on low
and high limit setup
(for version S and F)
“Severe Leaks” Rejects during gross timer, at end of fill cycle, or during
test timer.
“<Low Limit” Number of flow test results that are below the low limit value
“Between Lim” Number of flow test results that are between the low and high
limit values
“>High Limit” Number of flow test results that are above the high limit value
(for versionD)
“Severe Lks 1” Rejects during gross timer or at end of fill cycle for 1st test
“<Low Limit 1” Number of flow test results that are below the low limit value
for the first test
“Between Lim 1” Number of flow test results that are between the low and high
limit values for the first test
“>High Lim 1” Number of flow test results that are above the high limit value
for the first test
“Severe Lks 2” Rejects during gross timer or at end of fill cycle for 2nd test
“<Low Limit 2” Number of flow test results that are below the low limit value
for the second test
“Between Lim 2” Number of flow test results that are between the low and high
limit values for the second test
“>High Lim 2” Number of flow test results that are above the high limit value
for the second test
“Stops or test errors” Number of times tests were interrupted by either stopping
the test or a test error (see chapter 13)
After displaying all the counter information, there is an option to clear the counters.
“Clear Counters? N”
Use the up or down arrow buttons to select “N” or “Y”. Push the ENTER button or the
COUNT button. A security password may be required to clear the counters.
Continue to index to the remaining displays by pushing COUNT button.
“Tests Since Last Calibration” Number of tests performed since the last time
the instrument was calibrated.
“Total Tests for CAL REQD Warning” Limit on number of tests performed
after last calibration before “CAL REQD
Warning” messages are displayed.
“Total Tests for CAL REQD Error” Limit on number of tests performed
after last calibration before “CAL REQD
Error” message is displayed and instrument
stops testing.
“Total Tests Since New” Total test performed by instrument.
9-1
The CAL REQD Warning and CAL REQD Error limits are control limits on the number of
tests that can be run before the instrument must be recalibrated. The “Warning” limit will
alert the operator that he should be calibrating the instrument soon. Exceeding the “Error”
limit will stop the instrument from testing until it is recalibrated. Setting these limits to
“999999” will defeat these error functions. The instrument may require a security password
to change these values. Security configuration is performed within the MISC function,
Security Configuration as explained in Chapter 10.
(Use any arrow button to initiate the password entry process.)
Use the up or down arrow buttons and left and right arrow buttons to change the “Warning”
or “Error” values. Then push ENTER button or COUNT button.
9-2
CHAPTER 10
INSTRUMENT CONFIGURATION (MISC)
(Instrument Setup Routine)
The MISC button on the PROGRAMMING panel accesses several function and
configuration routines. The basic areas are:
* Time functions (year, month, day, hour, minute, second)

* Auto Test (Programmed routine to perform repeatability testing)
* Instrument Setup
- Part change configuration
- Test circuit and test type configuration
- Machine control configuration
- RS485 communication configuration
* Security configuration
* Units of measurement configuration
* Transducer configuration
Push the MISC button repeatedly to step through the routines. Press the ENTER or
MISC button when any changes are made. Push the PREV button to backup to the
previous display. Push the EXIT button to escape the MISCELLANEOUS routines.
DATE/TIME
Push the MISC button to enter “date” display.
To change any variables use the left or right arrow buttons to move the cursor under
the digit to be changed. Use the up and down arrow buttons to change the digits up
or down to the desired number. Press the ENTER or MISC button to register changes
in memory. Either button will advance to the next display.
Make changes as appropriate on second display for “time”.
AUTO TEST
AUTO TEST: 0 Parts

(Enter Quan. START)
To step past the AUTO TEST, push the MISC button when the quantity is zero. To run
several automatic consecutive tests or perform a repeatability test on one part, set the number
of tests to run by using the arrow buttons and push the ENTER button. The system will use
the “Relax timer” (set within the TIMERS function) as the delay timer between tests. If the
system is using internal tooling controls, the tooling will not unclamp between tests.
If the Sentinel F-21 instrument is in the process of testing parts when the auto test is selected,
10-1
the display will indicate:
PART 4: FORD 1234

WAIT FOR TEST TO END
and return display to AUTO TEST: 0 Parts

(Enter Quan. START)
After placing the test part in the fixture, push the START button to initiate the auto test
routine. After sequencing through each test, the instrument will display the measured flow
rate.
PART 4: AUTO RESULT 1 = 1.01 sccm

RESULT = 0.04 ccm RESULT 2 = 5.36 sccm
After five seconds the display will indicate how many tests remain to be conducted under the
auto test routine and the remaining delay time between tests.
Auto Runs To Go: XXX

Time Until Test XXX
After completing the tests, the Sentinel instrument will return to the “READY” condition to
run tests.
To stop the AUTO TEST routine, push the STOP button at any time.
MODIFY MACHINE SETUP/SECURITY
To skip the AUTO TEST routine, push the MISC button while “0 Parts” is displayed.
Modify Instrument
Setup Options? N
Use up or down arrow buttons to select either “Y” or “N”, then push ENTER or MISC.
N will access the following setup functions (details starting on page 10-8):
* Security configuration for protected functions and values
* Transducer configuration and check routines
Y will access the following setup functions (details found below):

* CHG Part configuration
* Test Circuit and method configuration
* Machine control configuration
* RS485 configuration
After selecting “Y” or “N”, push ENTER or MISC button.
10-2
If YES, enter password if requested by using arrow buttons. This
instrument was initially programmed with no password. If a password
is desired, security configuration is described later.
CHG PART CONFIGURATION
To change the current setting to Y or N, sequence through different choices, or select

different numbers; use the up or down arrow buttons. After selecting the desired
choice, push the ENTER or MISC button to store your choice and step to the next
option.
Number of Parts
to Test: 7
Select the number of parts with different test parameters that will be displayed
under the CHG PART function. Unused part storage registers will be skipped
when pushing CHG PART button.
Update Zero Shift

on Part Change? N
If dynamic compensation (“ZERO SHIFT PCT” AND “ZERO SHIFT QUAN”) is utilized
to maintain more accurate calibration, the Sentinel instrument can shift new part calibration
parameters recalled using CHG PART by the same correction percentage as the last part
tested without performing a new AUTO CAL. This feature allows quick change over from
one part calibration to another while maintaining relative accuracy to the current
environmental conditions.
Y will calculate a zero shift for the new part based on the zero shift
from the last part tested.
N will not update zero shift parameters for new test part parameters
when CHG PART is pushed.
TEST CIRCUIT VERSION AND TEST TYPE CONFIGURATION
Pneumatic Circuit:
(See Model Number) S
Look at the instrument model number to determine which pneumatic version was supplied.
Indicating the versions as S, F, or D will define the number of regulators and flow
transducers supplied, valve configuration, and test sequence.
S (Single pressure, single regulator)

F (Fast-fill/integrity, two regulators)
D (Dual pressure, two regulators)
Letter found in the instrument model number.
10-3
(For Versions S and F)
Test Style LEAK
LEAK Allows for calibration of the instrument to the test part using AUTO
CAL routine described in Chapter 6. The Auto Cal routine measures the flow
offset ("calibration value") while testing a good (non-leaking) part. Depend-
ing on the duration of the timers, there may be some residual flow due to
adiabatic temperature effect, part expansion, or part absorption upon
entering the "test" cycle. utilizing the programmed timers.
FLOW Turns the AUTO CAL routine off. No minor offset corrections are
required for normal flow measurements.
(For Versions D)
1st Test Style LEAK
LEAK Allows for calibration of the instrument to the test part using AUTO
CAL routine described in Chapter 6. The Auto Cal routine measures the flow
offset ("calibration value") while testing a good (non-leaking) part. Depend
ing on the duration of the timers, there may be some residual flow due to
adiabatic temperature effect, part expansion, or part absorption upon
entering the "test" cycle. utilizing the programmed timers.
FLOW Turns the AUTO CAL routine off. No minor offset corrections are
required for normal flow measurements.
2nd Test Style LEAK
LEAK Allows for AUTO CAL routine to function for the second test
FLOW Disregards the AUTO CAL routine for the second test
(For Versions S and F)
Test Evaluation:
REJ<low<ACC<high<REJ
Test results are compared to two set points, low and high, for accept and reject status.
Therefore, there are three areas in which the results can be defined as accept or reject. The
three areas are below the low limit, between the low and high limits, and above the high limit.
Use the left or right arrow buttons to highlight each area and then use the up or down arrow
buttons to select ACC or REJ.
For typical leak test applications, the high limit value is the reject leak rate. Therefore, the
area above the high limit should be designated as REJ. The low limit value is typically set at
zero or at a negative value that is 10 to 20% of the high limit value (or reject rate) below zero.
(i.e.. If the high limit or reject rate is 10 sccm, than the low limit value would be set at -1 to
-2 sccm.) The area between the limits should be designated as ACC. The low limit value can
10-4
alarm the operator by rejecting parts if the measured flow readings are significantly less than
the master calibration part or average production part. This condition may occur due to
temperature changes in the part, process, or fill air or if the part elasticity changes
significantly. Designate the area below the low limit as REJ if you want to reject parts with
significantly low or negative leak rate values. If the area is of no concern, designate the area
as ACC. Typical set up would be either REJ<low<ACC<high<REJ or
ACC<low<ACC<high<REJ.
For typical blockage or some flow applications, the high limit value is the minimum flow
rate expected through the part. The low limit has no real value; therefore, it is set to zero. The
typical set up would be REJ<low<REJ<high<ACC.
For typical flow applications, the test verifies that acceptable flow occurs between a low
and high flow limit. The typical set up would be REJ<low<ACC<high<REJ.
(For Version D)
1st Test Evaluation:

The first test results are compared to two set points, low and high, for accept and reject status.
Therefore there are three areas in which the results can be defined as accept or reject. The
three areas are below the low limit, between the low and high limits, and above the high limit.
Use the left or right arrow buttons to highlight each area and then use the up or down arrow
buttons to select ACC or REJ. Review the discussions for leak, blockage and flow tests
above to guide the setup.
2nd Test Evaluation:

The second test results are compared to an additional pair of set points, 2nd low lim and 2nd
high lim, for accept and reject status. Again, there are three areas depending on the function
of the test (leak, blockage, or flow) to define as ACC or REJ. Use the left and right arrow
buttons to highlight each area and then use the up and down arrow buttons to select ACC or
REJ.
(For Versions D)
For pneumatic version D which runs two sequential tests, setup whether to reject and stop
testing if the first test fails or continue with the second test even if the first test fails.
Run 2nd Test if 1st

Test was Rejected N
Y will conduct 2nd test even if 1st test rejects.
N will set instrument to stop testing and reset after first test
rejects.
10-5
MACHINE CONTROL CONFIGURATION

option.
Use Instrument for

Macbine Control? N
The Sentinel F-21 instruments have outputs available to provide basic machine control of
test tooling. The control outputs will step through a fixed sequence (found on page 11-6) of
tooling actions using either feedback signals or programmable times to control when some
functions sequence to the next event. When a timer with no feedback is used, the Sentinel
instrument turns on an output for a clamping action. After (ccc) seconds (set in the
TIMERS), the instrument turns on an output for the sealing action. After (sss) seconds (set
in the TIMERS), the Sentinel instrument begins the flow test sequence. If feedback is
requested, the instrument will wait for an input contact closure from a pressure switch, prox
head, or photo eye to confirm that the clamping and/or sealing action occurred. The
feedback signal must be received before the clamp and/or seal timers expire. The following
steps determine if the Sentinel F-21 instrument utilizes machine control and if it uses timers
or feedback inputs to sequence the tooling controls. Choose one of the following.
N No machine control
YNF Yes machine control, No Feedback (uses timers only for sequenc
ing.)
YSF Yes machine control, Seal Feedback (defined feedback for advance
and retract seal which checks for input signal to advance test
sequence before seal timer expires.)
YCF Yes machine control, Clamp Feedback (defined feedback for
advance clamp only. No input required for retract clamp. Checks
for input signal to advance test sequence before clamp timer
expires.)
YBF Yes machine control, Both Feedback (defined feedback for advance
and retract seal and advance clamp. Checks for input signal to
advance test sequence before seal or clamp timers expire.)
(If Machine Tool is selected with YNF, YSF, YCF, or YBF)
Use 2 Inputs to
Start Test? N
The option provides different ways to initiate a test when tooling action is
involved. The intent is to assure that hands cannot get pinched while tooling is
moving. Two contact inputs from a part presence switch and start test button or
anti-tie-down buttons are typical configurations to start a test. The inputs must be
maintained until a feedback signal is received or the timers for clamp and seal are
expired.
10-6
Y use two contact closures or inputs to initiate test sequence.
N integral START button or one input to initiate test sequence.
If Y is selected above:
Anti-Tie-Down? N
(For 2 Button Start)
The anti-tie-down logic requires that two inputs be received

within +500ms of each other to initiate the test cycle.
Y establishes anti-tie-down logic with two start

button inputs to initiate test cycle.
N starts test with two contact closures or inputs.
A third method utilizing a programmable part presence input (selected under

Utility Input below) and the start test inputs can be selected. The programmable
part presence input must be made before the anti-tie-down buttons are pushed.
Also the part must be removed from the fixture and replaced before the next test
can start.
Unclamp Part if it’s

Rejected? N
Upon completion of a flow test cycle involving tooling control, the seal advance
signal will always turn off. In many instances it is advantageous to maintain the
clamp advance signal on for reject parts until an operator acknowledgment signal
(“release”) is received. This function defines whether the clamp signal is maintained
for reject parts until a “release” signal is received.
If “Use 2 inputs to Start Test” or “Anti-tie-down” is selected, two inputs (P.B. Com
and STOP/RELEASE) are required to release the part.
Y allows clamp advance signal to go off after reject test results.
N maintains clamp advance signal until “release” signal is received

from the operator.
10-7
Utility Input: HOLD
The utility input can be programmed to function in one of two ways.
Hold Stop the test within any segment of the test cycle to allow other
functions to take place before continuing with the test.
Part Present An additional input to verify that a part is in its fixture before
to Start a test can be started. Input must be made before start test
inputs are received. The part must be removed from the fixture
to break the contact between tests or it will not allow a new test
to start. Contact is independent of the one or two inputs to start
a test.
Utility Output: In Second Test
The utility output can be programmed to function in one of four ways.
In second test Output activates when the second test gross timer starts on
version F,D, or T models. The output deactivates at the end of
the second test exhaust cycle. The output is useful for switching
valves that select a different part cavity or part fixture to
sequentially test during the second test cycle.
In CalibrationOutput activates after START input is received within AUTO
Cal routine. The output stays active until the end of the exhaust
cycle of the second test. This output could be used to stop
normal machine cycling while AUTO CAL is being perform
Gross Timer Output is on only while the gross timer is active. Output could
be used to coordinate or activate another function during the
gross timer cycle.
Test Timer Output is on only while the test timer is active. Output could be
used to coordinate or activate another function during the test
timer cycle.
OPTIONAL PART STAMP OUTPUT
Exhaust Operation:
Exhaust
At the completion of the leak test cycle, an exhaust timer delays the control sequence to allow
the test pressure to relieve from the part before releasing the seals. The exhaust output can
be programmed to activate under different conditions to provide additional control
functions.
Exhaust Output activated after every test for duration of exhaust timer.
Accept Mark Output activated after each accept test for the duration of the
exhaust timer in order to mark accepted parts.
Reject Mark Output activated after each reject test for the duration of the
exhaust timer in order to mark rejected parts.
10-8
Hold Limit Outputs
Past End of Test? N
One of the four outputs (Severe leak, low limit, between limits, and high limit) activates
during the exhaust cycle to indicate within which range the test results fall. This is in
addition to the accept and reject outputs. These outputs will be on only during the exhaust
cycle or until the start of the next test.
N outputs are only on during exhaust cycle
Y outputs remain on until start of next test

RS 485 Address xx
There is an RS485 commercial telephone jack on the main computer board within the
Sentinel F-21 enclosure. This port supports communication to a host or central computer. In
order for a central processor to poll or quiz each Sentinel instrument, there needs to be a
unique address within the unit. Valid entries are 01 through 32.
SECURITY CONFIGURATION
To change the current setting to Y or N, use the up or down arrow buttons. After
selecting “Y” or “N”, push ENTER or MISC button to enter your choice and step to
next option.
Modify Instrument
Security Options? N
Use up or down arrow buttons to select either “Y” or “N”, then push ENTER or MISC.
N will access the following setup functions (details starting on page 10-11):
* Transducer configuration and check routines
Y will access the following security options (details found below):

* Calibration process
* Test Information (calibration parameters)
* Self test parameters
* Counter reset
* Transducer zero and span values
* Runs until calibration required value
* Change Part (CHG PART) function
* Password
After selecting “Y” or “N”, push ENTER or MISC button.
10-9
If YES, enter password if requested by using arrow buttons. This instrument was
initially programmed with no password. If a password is desired, security
configuration is described below.
Secure Cal Process N,

(no cals, no edits)
Y prevents the operator from performing auto calibration or

changing test parameters without a password.
N allows operator to change test parameters and perform auto

calibration without security protection.
If N was selected above,
Secure Test Info N

(cals but no edits)
Y prevents changes to programmed test parameters

within TIMERS, PRESS, and FLOW without a pass
word. (Note: AUTO CAL can be performed without a
password.
N allows changes to programmed test parameters and use

of auto calibration without security protection.
Secure Self Test N

(no cals, no edits)
Y prevents operator from changing the SELF TEST

parameters without a password.
N allows operator to change SELF TEST parameters without

security protection.
Secure Counters N
(password to reset)
Y prevents resetting counters without a password.
N allows resetting counters without security protection.
Secure Transdcr Zero

and Span Values N
Y prevents changes to transducer zero and span values without a

password.
N allow changes to transducer zero and span values without security

protection.
10-10
Secure Runs Until
Cal is Required N
Y prevents changing “Total tests for Cal REQD Warning and Error”
in the counter routine without a password.
N allows changing “Total tests for Cal REQD Warning and Error”
in the counter routine without security protection.
Secure CHG PART

Function? N
Y prevents operator from changing test part parameters by pushing

CHG PART button without a password.
N allows changing test part parameters by pushing CHG PART

button without security protection.
Change Password
TO: XXXXX
The password can be changed at this point for future use. Enter the new
password value using arrow buttons and push the ENTER button. Push the
MISC button.
BE SURE TO REMEMBER OR NOTE THE NEW PASSWORD.
FORMAT AND UNITS OF MEASUREMENT CONFIGURATION

option.
10-11
Define
Leak Units: ccm
Establishes the units of measurement for flow (leak rate) on the display. The
numeric values entered for high limit and low limit must be in the units of
measurement set here.
ccm (cubic centimeters per minute)

ccs (cubic centimeters per second)
cis (cubic inches per second)
cch (cubic centimeters per hour)
lpm (liters per minute)
lps (liters per second)
lph (leiter per hour)
Define
Pressure Units: psi
Establishes the units of measurement for pressure readings on the display.

Note: Changing units converts only the displayed units, not the values. The
user must convert the transducer span values to match the units of measure-
ment.
kPa(kilo pascels) mHg (millimeters of Mercury)

mbr(millibar) bar (bar)
iWC(inches of water column) atm (atmospheres)
MPa (Mega pascels) psi (lbs per square inch)
iHg(inches of mercury)
TRANSDUCER CONFIGURATION
To change the current setting to Y or N, sequence through different choices, or

select different numbers; use the up or down or left or right arrow buttons. After
selecting the desired choice, push the ENTER or MISC button to store your choice
and step to the next option.
Pressure Transducer
Zero range +-3.00 mv
Set transducer zero variation allowed and pressure range (using units of
measurement established above). The zero check verifies that the
transducer output returns to zero and that no pressure is trapped in the
part before the test begins.
Set the zero range voltage. If the blinking cursor does not appear, push
either the up or down arrow buttons. This will initiate the password
display. Enter the correct password using the arrow buttons and then
push ENTER.
10-12
Pressure Transducer
Span 100 mV = 100 psi*
*100 psi represents the approximate range of the pressure transducer.

Your instrument was set up with the pressure span at 100 mv for the
actual transduer supplied. A calibration certificate for your transducer
is included in the envelope with the flow sensor calibration
information. To accurately convert your instrument to other pressure
units, you should use the actual pressure span from the transducer for
the calculation indicated below.'
Set the transducer span based on the standard 100 psi transducer
supplied. If the blinking cursor does not appear, use the up and down
arrow buttons to initiate the password display. Enter the pressure value
for the transducer.
If pressure units (as defined) are any units of measurement other than
psi, multiple the conversion factor times the psi range of the transducer
and enter the value.
For example:
kPa
1 psi = 6.895 kPa, therefore a 100 psi* transducer (98.5 x 6.895 =
679.16) would have its span entered as:
100 mv = 679. kPa (There are only 4 places including “.” allowed.)
iWC
1 psi = 27.73 in. of water column, therefore a 100 psi transducer (98.5
x 27.73 = 2731) would have its span entered as:
100 mv = 2731 iWC
Other generally accepted conversion factors are:

1 psi = 6.89 kPa 1 psi = 51.7 mHg
= 68.9 mBr = .069 Bar
= 27.7 iWC = .068 Atm
= 2.04 iHg = 1 psi
CALIBRATION ROUTINE FOR PRESSURE TRANSDUCER
Check Pressure
Transducer? N
Y Check the transducer span and zero.
N Skip the check of the transducer span and zero.
10-13
A response of “N” will move to the flow transducer setup. The EXIT button will escape
MISC routine. “Y” will enter the transducer check routine.
The transducer calibration routine steps through a procedure to check:
zero of the transducer

span of the transducer.
OPEN TEST PORT

TO ATMOSPHERE
Disconnect the test line from quick connect and push the MISC button.
If the transducer zero is within limits set above,
Transducer
Zero Okay
will be displayed. The system reads and stores any voltage offset that
the transducer may have and corrects all future transducer readings by
that offset. In other words it automatically zeroes the transducer’s
readings to the atmospheric pressure.
If the zero voltage is greater than limits set above,
Transducer Zero Bad

Replace Transducer
appears. Check the transducer zero range value set on page 10-12.
Increase the value by 5 mv to see if system will compensate for the small
zero offset. If the offset is too great, replace the transducer.
Push the MISC button.
CONNECT CALIBRATION
GAUGE TO TEST PORT
The operator should connect a calibration gage to the quick connect test port and push
MISC button.
Does Gage Read

XXXXX PSI? (MISC)
The instrument will pressurize the system so that the operator can compare if
the gage reading and pressure display reading are within 5% of each other.
10-14
Push the MISC button.
If so Transducer
Span is Okay (MISC)
Push MISC button.
IF NOT REPLACE
TRANSDUCER (MISC)
Push MISC button. If readings do not agree, replace transducer.

Check that span value for the transducer was correctly set (page 10-
12) for the units of measurement for pressure selected and set on page
10-12.
FLOW TRANSDUCER CONFIGURATION
Flow Transducer
Zero range +-0.1 mV
Set the zero range voltage. If the blinking cursor does not appear,
activate the password message and enter the password.
Flow Transducer Span

5 volts= 1000 ccm
Set the flow transducer span based on range of transducer supplied

for the first test. If the blinking cursor does not appear, activate the
password message and enter the password.
There are two standard ranges available (1000 sccm and 6000 sccm).
The system will automatically recalculate the flow values under "Flow"
to match the engineering units designated earlier.
EXIT button will escape MISC routine.
10-15
10-16
CHAPTER 11
TOOLING CONTROL
Tooling control is included in the Sentinel F-21 instruments to simplify its application to
various test requirements. The TEST SEQUENCE CHART FOR OUTPUTS on page 11-
6 details when each of the 20 outputs occurs. The time increment along the top of the chart
is set within the TIMERS function. The sequence of events can not be altered. But there are
several outputs occurring at different times in the test process which can be utilized to
accomplish basic control of flow test tooling. On 24 volt models the Inputs and Outputs for
tooling control and test results are 24 volts. The test valves and test result lights are 110 VAC
outputs.
Start test signal(s)
The programmable control will take a single contact input, two contact inputs, two anti-tie-
down inputs, or a combination with a part presence contact to initiate a test sequence. The
two contact inputs provide safe methods to start a test while assuring that the operator keeps
his hands out of possible pinch points during the clamp and seal sequences. One or two
contact inputs can also use the addition of a part presence input to start a test. The part
presence input must be made before the other inputs are initiated. Also the part presence
input must be cleared and made again before another test can be initiated.
Clamping action (or first seal action)
The start of the test sequence will cause a clamp (or primary seal) output signal to go on (if
machine control is selected). The instrument can either delay for the CLAMP TIMER (YNF
or YSF for no clamp feedback) or wait for the CLAMP TIMER to receive an input to verify
the clamping action (YCF or YBF) before initiating the seal signal. Example wiring
diagrams and configuration suggestions for spring return 4-way solenoid and dual solenoid
3 position spring return tooling valves are provided at the end of this chapter.
Sealing action
After completing the CLAMP TIMER or receiving the clamp feedback signal, the seal
output signal will go on. The instrument can either delay for the SEAL TIMER (YNF or
YCF for no seal feedback) or wait to receive an input to verify the sealing action (YSF or
YBF) before initiating a start test signal. Example wiring diagrams and configuration
suggestions for spring return 4-way solenoid and dual solenoid 3 position spring return
tooling valve are provided at the end of this chapter. This signal remains on for the entire test
sequence and exhaust cycle.
Test Sequence
First test output activates at the beginning of the gross fill cycle and goes off at the end of
first test exhaust. It could be used to operate a solenoid valve for part selection. The
initiation of this action must be completed while simultaneously starting the pressurization
of the part.
11-1
Optional outputs (Only one can be selected within MISC, machine control
configuration.)
For version F and D a second test is automatically performed at the completion of the first
test. An optional In second test output activates at the beginning of the 2nd test gross fill
cycle and goes off at the end of the second test exhaust. It could be used to operate a solenoid
valve for part selection. The fill, test, and exhaust valves cycle through the test sequence
using the timers set in the TIMERS function. One of three other outputs is available in lieu
of the In Second test output. They are Gross Timer output, Test Timer output, or the In
Calibration output. The output of your choice is selected within the instrument setup
covered in Chapter 10, Instrument Configuration, Machine Control Configuration. The Test
Timer output activates only during the test cycle (time when instrument is measuring flow
to determine leak rate or flow) for the first test and second test (if version F or D). The Gross
Timer output activates only when the gross timer is active. The In Calibration output is
activated during the calibration process which consists of the one test on the master part
when the "Test Style" is set for "Leak". This output would signal a PLC that the instrument
is performing a calibration sequence.
Exhaust Cycle
This cycle allows the part pressure to vent so that the seals will not blow out when retracted
from the part. This output could also be used to mark the part at the completion of a test. The
exhaust output can be programmed to go on for the duration of the exhaust timer after each
test, after accept tests only, or after reject tests only.
Return Seal
After the exhaust timer is complete, the advance seal signal turns off and the retract seal
signal goes on. The instrument can either delay for the SEAL TIMER (YNF or YCF for no
seal feedback) or wait to receive an input to verify the retract sealing action (YSF or YBF)
before turning off the advance clamp signal and initiating the clamp return signal.
Return Clamp
If the part fails the flow test, the advance clamp signal can be set to remain on until a reset
signal (release) is received from the operator (if set within MISC, 10-7). Upon receipt of the
release signal the advance clamp signal will go off and the clamp retract signal will go on.
There is no feedback signal for the clamp return.
FINAL TEST RESULT OUTPUT SIGNALS
Accept signal activates at the end of the test cycle for accepted parts and remains on until the
initiation of the next test.
Reject signal activates due to gross leak failures, loss of pressure in fill, or reject test results
at the end of the test cycle and remains on until the initiation of the next test.
Malfunction signal activates when an internal software error occurs. The signal remains on
until the initiation of the next test.
11-2
LIMIT RESULT OUTPUT SIGNALS
These outputs activate only during the Exhaust Timer cycles to indicate the results of the test.
They can be programmed to remain on until the start of the next test within MISC, “Hold
Limits Outputs Past End of Test? Y”. For version F and D if the output is programmed to stay
on past the end of the test, the signal for the first test results will remain on until the end of
the second test when the appropriate limit signal will be updated during the Exhaust Timer
to reflect the second test results.
Severe Leak signal activates to indicate that the test rejected as a severe leak because the test
pressure failed to reach MIN PRESS within the Gross Timer, to stay above MIN PRESS at
the end of Fill Timer, or to remain within 3% or 1psi (whichever is greater) of the TARGET
PRESS at the end of the Fill Timer.
Below Low Limit signal activates to indicate that the test result was a value that was below
the Low Limit flow setting.
Between Limits signal activates to indicate that the test result was a value that was between
the Low and High flow setting.
Above High Limit signal activates to indicate that the test result was a value that was above
the High Limit flow setting.
INPUT SIGNALS
There are three inputs for starting a test. They are START TEST, P.B. COM, and
UTILITY INPUTS (programmed for "Part Present to Start Test"). Their use is shown in
the sample start test wiring diagrams shown at the end of this chapter. The configuration of
the instrument start-test is discussed in Chapter 10.
STOP/RELEASE input is used to interrupt a test in progress for any reason. It immediately
advances the test sequence to the beginning of the exhaust cycle (exhaust 2 for version F and
D) where it will complete the exhaust, unseal, and unclamp sequence. The part is unclamped
regardless of test result and malfunction output is activated. When a test is not in progress,
the input is used to release the tooling and unclamp the part.
AUTO CAL input remotely activates the calibration process as described in Chapter 6 and
as configured within the Instrument setup (MISC), Test Circuit Version and Test Type
Configuration, described in Chapter 10.
SELF TEST input remotely initiates the Self Test function as described in Chapter 7.
Part Select includes three inputs for remote identification of a stored part program for
testing. A binary coded input is reviewed at the beginning of each test to select one of seven
stored part programs for current test status. The binary code-to-part program table is on the
wiring diagram found later in this chapter.
11-3
Toggle Clamp and Toggle Seal inputs allow the operator to manually change the state of the
clamp or seal outputs. In conjunction with an Auto/Manual switch the operator can change
the clamp or seal position for setup or troubleshooting purposes. A sample wiring diagram
is included later.
INTERFACE TO A PLC
A PLC may be required if:

* additional control outputs are required beyond
- simple advance clamp
- advance seal
- retract seal
- retract clamp
(with or without feedback)
* more than 2 independent motions are required for clamp and seal
* different tooling sequence
* existing stand or production line already has PLC and it is desired to have control within
central PLC.
* external control sequences
Following the TEST SEQUENCE FOR OUTPUTS chart are several wiring diagrams for
typical application requirements. They include:
* Typical wiring diagram for tooling control involving clamp and seal action with
feedback (YBF), single start test push-button, and a stop test/release
push-button
* Clamp tooling using a dual solenoid 3 position spring return valve with or
without feedback
* Clamp tooling (or first seal) using a spring return 4-way solenoid valve with
or without feedback
* Seal tooling using a dual solenoid 3 position spring return valve with or without
feedback
* Seal tooling using a spring return 4-way solenoid valve with or without
feedback
* Sequential testing of two different parts or part cavities for version F or D
instruments
* Remote part parameter change via a PLC or remote switch
* Auto/Manual operator control panel for remote manual control of AUTO
CAL, SELF TEST, manual toggle clamp and seal outputs, and STOP TEST/
RELEASE.
* Single START TEST input with STOP TEST/RELEASE push-button
* Two START TEST inputs (not anti-tie-down) with STOP TEST/RELEASE
push-button
* Anti-tie-down START TEST inputs with STOP TEST/RELEASE push-button
* Internal wiring diagram for I/O board (version S,F,D)
* Internal wiring diagram for power supply board
* Internal wiring diagram for computer board
* Internal schematic of all system inputs and outputs
11-4
These diagrams serve as examples of how to wire and configure the Sentinel F-21
instruments for various applications. Utilize portions of selected diagrams that provide the
inputs and outputs needed. Refer to Chapter 10 for information referenced on the diagrams
to configure the instrument for the control functions and test schemes desired. Combinations
of tooling control outputs, feedback inputs, start test inputs, and stop test input are typically
required for most applications involving tooling control. Optional inputs involve remote
part parameter change, remote AUTO CAL, remote SELF TEST, and toggle clamp and seal
outputs. The diagrams are designed to make it is easy to wire and configure the Sentinel F-
21 instrument to meet your specific application.
11-5
TEST SEQUENCE
11-6
The Sentinel F-21 instrument has high impedance, solid-state inputs. Therefore, prox
sensors, solid-state palm buttons, and other devices that have leakage current will require a
pull down resistor (sized as required) across the input for proper operation. Consult the
sensor specifications for leakage current. Determine the resistor value based on the leakage
current and total circuit resistance. Request Application Bulletins #109 and 110 for
additional information. For 24 volt models the layout of this circuit board is different. See
page 2-8 for the actual board layout. the 16 input and 15 output terminals are 24 VDC.
Additional drain resistors across the inputs may be required as discussed on page 2-8.
11-7
11-8
11-9
Seal
11-10
Seal
11-11
11-12
11-13
11-14
11-15
11-16
11-17
11-18
11-19
11-20
11-21
11-22
11-23
120/240 VAC VAC NEUT
11-24
11-25
11-26
CHAPTER 12
PREVENTIVE MAINTENANCE
PERIODIC MAINTENANCE
* Calibrate instrument for leak testing applications only when:
- changing model of parts being tested

- after an idle period when temperature conditions of the part or
production environment have changed significantly.
* Periodically conduct visual check of clear air line going into inlet port of instrument and
check clear filter supplied inside Sentinel F-21 enclosure for dirt or water. If dirt or
moisture are visible inside the clear filter housing:
- Check the external coalescent filters (5.0 and 0.3 micron). They should filter
the air source to the instrument. If they are allowing dirt or moisture to reach
the instrument, they may need to be serviced by draining or changing the filter
elements.
- Replace the internal filter.
Replacement procedure for internal filter

- Turn off air source to instrument.
- Disconnect air line from instrument.
- Loose the nut on the bulkhead fitting inside enclosure.
- Depress red compression ring on bulkhead fitting and pull away from filter.
- Depress red compression ring on regulator fitting and pull filter out.
- Replace filter.
- Re-assemble new filter to regulator fitting and bulkhead fitting.
- Tighten nut on bulkhead fitting.
- Re-connect air line to instrument and turn on air source.
* Conduct Self Test on pneumatics weekly to verify integrity of internal pneumatics.
* Tighten the torque screws on fill, exhaust, and test valves and select valve/spacer
assembly to 8 - 10 in-lb. Also check screws on flow transducer.
- after one month of operation and
- quarterly thereafter
* Replace inlet air coalescent filters (5.0 and 0.3 micron) - quarterly
12-1
SPARE PARTS
Pressure Transducer Assembly

(Includes transducer, connector cable, and 108 o’ring.)
SENTINEL-TRANS ASSY 100 100 psi
Flow Sensor package (available after 3/98)

(Includes flow sensor, screws, o'rings, and calibration data disk. Requires
customer to have CTS Talk to upload calibration data to Sentinel F-21 eprom.)
SENTINEL-FLOW SENSOR 1000

SENTINEL-FLOW SENSOR 6000
Preliminary Regulator Assembly

(Includes regulator and mounting screws)
F-21-REGULATOR ASSY 10262-T 0-100 psi
Test Regulator Assembly

(Includes regulator and mounting screws)
SENTINEL-REGULATOR 10212-L 0-2 psi

Electronic Circuit Board Set

(I/O, power supply, and computer boards with necessary
assembly hardware)
F-21-CIRCUIT BOARD KIT

F-21-CIRCUIT BOARD KIT - 24 VDC
Pneumatic Manifold Block (Pneumatic block and all hardware fittings)

Does not include transducer, valves, or valve wiring harness
F-21-MANIFOLD ASSY MSFD (versions S,F,D)
Test Select Valve Spacer Block Assembly (Valve filler block including o'rings
and mounting screws for version S only)
F-21-SPACER BLOCK ASSEMBLY
Valves
(Replacement valves including o’rings and mounting screws.
Specify part number on valve,
SENTINEL-VALVE ASSY 450556E (fill valve)

SENTINEL-VALVE ASSY 450305K (test valve, select valve)
SENTINEL-VALVE ASSY 457952W (exhaust valve)
12-2
Valve Boot Seals
(Replacement Buna-N seal for test and select valves.)
SENTINEL-VALVE BOOT
Indicator Light Bulbs for Sentinel F-21 (Dialight,120MB)
I-21-INDICATOR LIGHT BULBS (Bag of 10)
Indicator Light Lens and Body for Sentinel F-21
I-21-INDICATOR LENS GREEN

I-21-INDICATOR LENS RED
I-21-INDICATOR LENS WHITE
Fuse Kit (10 each of three different fuses)
SENTINEL-FUSE KIT
SENTINEL-FUSE KIT-24VDC
Internal Filter
FILTER,BALSTON,9900-05-DK-F546
Quick Connect Fitting for part test line
SOCKET, HANSEN, B2-H16NV (for Sentinel F-21)
Self Test Cap Assembly for Sentinel F-21 instrument

(Cable, quick connect fitting, and plug)
I-21-SELF TEST KIT
Door Kit Assembly for Sentinel F-21 instrument

(Assembly includes keypad, display, indicator
lights, wiring cables, and door lock ready for
easy interchange.
F-21-DOOR ASSY L (14" x 17")
Extra Operator Manuals

SENTINEL-F-21 MANUAL
Services
Instrument Refurbishment
(Includes new valve boot seals and o’rings.
All components are inspected for
damage and wear. Instrument is functionally tested
to original specifications. Includes 1 year warranty.)
12-3
12-4
CHAPTER 13
ERROR MESSAGES
When a test is initiated, any of the following messages may appear:
“ERR: TIMER INFO REQD”

No timer information entered for current part program. Review FLOW, PRESS,
and TIMERS to make sure that test parameters are entered for testing.
“ERR: FLOW INFO REQD”

No flow information entered for current part program. Review FLOW, PRESS,
and TIMERS to make sure that test parameters are entered for testing.
"ERR: PRESS INFO REQD"

No pressure information entered for current part program. Review FLOW,
PRESS, and TIMERS to make sure that test parameters are entered for testing.
“ERROR: CAL REQUIRED”

No calibration information resulting from an AUTO CAL is stored for the current
part program. The operator should perform an AUTO CAL. This error can also
occur if “TESTS SINCE LAST CAL” exceeds “TOTAL TESTS FOR CAL
REQ’D ERROR”.
“ERR:COUNT INFO REQD”

Either the “TOTAL TESTS FOR CAL REQ’D WARNING” or “TOTAL TEST
FOR CAL REQD ERROR “ under COUNTERS is set to zero. Change these
counters’ registers to desired values for operator warnings.
“ERR:TRANS INFO REQD”

Transducer span and/or zero values are not entered for system. Enter MISC
function and setup transducer values.
"ERR: FLOW #1 TRANS BAD"

An initial check of the flow transducer's signal indicates that the transducer
voltage output is not within the flow transducer's zero range or there is no voltage
output.
"ERR: FLOW #2 TRANS BAD"

An initial check of the 2nd flow transducer's signal (if supplied) indicates that the
transducer voltage output is not within the flow transducer's zero range or there
is no voltage output.
13-1
“ERR:TRANS ZERO BAD”
Upon system startup or at the start of each test the Sentinel F-21 compares the
transducer outputs against the transducers' “ZERO RANGE” defined in MISC.
Possible problems are: the transducer zero is drifting, the zero range is set too tight,
or air is trapped at the transducer. Check transducer zero. Adjust zero range to a
higher value. Check pneumatics for blockage which is prohibiting venting the part
through the exhaust valve.
“ERR:INVALID PART”
Remote part program selection (remote 120 volt binary coded signal) requests a
part number that is not turned on (“Number of Parts to Test”). Check remote
output signal for correct binary coded signal, check the wiring to Part Select
terminals, or change “Number of Parts to Test” to a higher number and add
calibration data to stored parameters.
"INVALID PART ACC/REJ"

The test evaluation criteria for below low limit, between limits, and above high
limit is not established correctly for accept and reject results.
“WARN:CALIB SOON”
The “Tests Since Last Calibrated” exceeds the “Total Tests for Cal Req’d
Warning”. Calibrate instrument using AUTO CAL routine. Review the Cal Req’d
warning value within COUNTERS to see if it should be higher.
“WARN:CALIB ADVISED”
Changes were made to fill or test timers in calibration information. Recalibration
is suggested for correct test results. Use the AUTO CAL routine. The error
message appears only once for five seconds before starting the first test after
making changes to one of two timers.
“ERR:ANTI TIE DOWN”

The two start test buttons were not pushed simultaneously within + 500 msec of
each other or held down until final tooling confirmation was received. Push start
buttons together and hold down until sealing action is completed.
"ERR: NO PART PRESENT TO START TEST"

The utility input "Part Present to Start Test" was not received before the start
input. Check the adjustment of the input device for "Part Presence". Part must
be removed from fixture between tests. Place a new part in the fixture.
"ERR; CLAMP ADVANCED"

The clamp advanced output is held on after test for reject parts and has not been
released. Push the station reset tooling button(s) to remove the previously tested
part before starting the next test.
13-2
“ERR:CLAMP NOT ADV”
The system did not receive a clamp advanced feedback signal before the end of
clamp timer. Check the clamp advanced feedback device. Extend the clamp
timer. Look for obstructions to clamp motion.
“ERR:SEAL NOT ADV”

The system did not receive a seal advanced feedback signal before the end of the
seal timer. Check the seal advanced feedback device. Extend the seal timer.
Check pressure setting on seal advanced cylinder regulator. Look for
obstructions to seal motion.
“ERR:SEAL NOT RET’D”

The system did not receive a seal returned feedback signal before the end of the
seal timer. Check the seal retract feedback device. Extend the seal timer. Check
pressure setting on seal retract cylinder regulator. Look for obstructions to seal
motion.
“SEVERE LEAK”
The measured test pressure did not exceed the minimum test pressure within
the gross timer. Or pressure at the end of fill cycle was below minimum test
pressure.
Check for big leaks in the part. Check for damaged seals. Check regulator setting for proper
pressure. Make sure supply air is 10 psi greater than test pressure.
“SEVERE LEAK
ERR:TEST PRESS LOW”
The measured test pressure did not exceed the minimum test pressure at the end
of fill cycle.
Check for big leaks in the part. Check for damaged seals. Check regulator setting
for proper pressure. Make sure supply air is 10 psi greater than test pressure.
“ERR:TEST PRESS HIGH”

The measured test pressure exceeded the maximum test pressure limit at the end
of fill cycle. Check the regulator setting. Check for blockage in test line. Check
maximum test pressure value.
“ERR:2nd PRESS HIGH”

When exhausting after 1st test, the internal pressure did not go below the 2nd test
maximum pressure. Suggest that 1st test exhaust time be increased.
"ERR: BELOW TRG PRESS"

The test pressure at the end of the fill cycle is below the Target Pressure setting by
more than 3% or 1 psi, whichever is greater. This is an indication of excess flow
going to the part before switching to the flow test. Also the test pressure regulator
may be set below the target pressure.
13-3
"ERR: ABOVE TRG PRESS"
The test pressure at the end of the fill cycle is above the Target Pressure setting by
more than 3% or 1 psi, whichever is greater. This is an indication that the test
pressure regulator is set above the target pressure.
“STOP BUTTON PUSHED”

The STOP button or STOP TEST remote signal aborted a test before it was
complete.
“WARN:AUTO CAL HALTED”

The STOP button or STOP TEST remote signal aborted the calibration routine
before it was complete.
“INTERNAL ERROR PLEASE CYCLE POWER”

The computer detected some operational error. To clear the system, turn the
power off and on.
"INVALID PASSWORD"
The wrong password was entered. Try again. Check to make sure that correct
password is used. If correct password is not known, contact
Cincinnati Test Systems.
"EXCESSIVE FLOW"
Flow exceeds range of flow transducer during test cycle. Increase
the fill timer to allow more time for pressure to stabilize in part before
switching flow through flow transducer.
"CALIBRATION ERROR Above MaxCal Flow"
During the AUTO CAL routine the measured flow at the end of the test timer
exceeded the Max Cal Flow setting within the Flow settings. Max Cal Flow is a
setting to verify that a non-leaking master part was tested in a non-leaking test
fixture. Check the part and fixture for leaks.
"CALIBRATION ERROR Below MinCal Flow"

During the AUTO CAL routine the measured flow at the end of the test timer was
less than the Min Cal Flow setting within the Flow settings. Min Cal Flow is a
setting to verify that the test line is not blocked and master non-leaking part is
testing in a typical fashion.
13-4
APPENDIX
SPECIFICATIONS
Preliminary pressure regulator
Range: 3 to 150 psig
Precision test pressure regulator (bleeding)
Ranges: 0.6 to 2, 1 to 30, 2 to 100 psi

Sensitivity 0.13 in. water column (0.0047 psi)
Gage pressure transducer
Ranges: 100 psi
Solenoid valves: Ultra low heat gain
Manual override push-button
Outputs: Optically isolated, solid-state relay, 110 VAC, 2 amps (or 24 VAC
for 24 volt models. All outputs are fused and sourcing.
Tooling control outputs:
Clamp advance Seal advance

Clamp retract Seal retract
Test sequence outputs:
In test Accept Reject

Malfunction In first test Exhaust
Utility outputs (only one selectable)
In second test Gross Timer Test Timer

In Auto Cal
Limits outputs
Severe Leak <Low Limit Between Limits

>High Limit
Total output capability: 5 amps
A-1
Inputs: 110 VAC (or 24 VDC for 24 volt models). All inputs are sinking.
Control Inputs:
Start test Start all P.B.Com
Clamp advanced Seal advanced Seal clear
Stop Test/Release Toggle clamp Toggle seal
Utility Inputs (only one selectable)

Hold Part Present to Start
Remote programming inputs:

Auto Cal Self Test Auto/Man
Remote part test program selection:

Three inputs for binary coded selection of 7 stored
programs
Communication output: Nine-pin RS232 port on operator terminal used to communicate

to a serial printer or computer with "CTS Talk" software.
Serial output to printer or portable computer

9600 baud No parity 8 bits 1 stop bit Continuous retry
Internal RS485 port on computer board (F-21) used to communicate with an

external computer
Communication input: Nine-pin RS232 port on operator terminal

Upload setup and port test parameters using "CTS Talk"
Dimensions:
Sentinel F-21 Instrument

Nema 12 industrial enclosure
Material of construction: gray polyvinyl chloride
17"H x 14"W x 6 3/4"D

Weight: 20-22 lbs. (tabs add 2" to overall height)
Ambient Conditions: 110o F (43o C)
Humidity: 90% noncondensing
Power Supply: 95-125 VAC, 6 amps

or
95-125 VAC, 600 mA
24 VDC, 5 A min depending on I/O load
A-2
INSTRUMENT SETUP PARAMETERS
Settings
Number of part programs to store (1-7) 1__2__3__4__5__6__7
Update zero on change of part ___N______Y______
Pneumatic circuit (S,F,D) __S____F____D___
Test Style ____FLOW___LEAK______
(S,F) Test Evaluation ____<low<____<high<____
(D) 1st Test Evaluation ____<low<____<high<____
(D) 2nd Test Evaluation ____<low<____<high<____
(D) Run 2nd test if 1st test rejects? ___N_______Y____
Machine control (N, YNF,YSF,YCF,YBF) N___YNF___YSF__YCF__YBF
(Use 2 Inputs to Start Test?) ___N_______Y____
Anti-tie-down? ___N_______Y____
Unclamp part if it is rejected? ___N_______Y____
Utility Input Hold Part Present to Start
Utility Output In second test_Gross Timer_ Test Timer_In Calibration
Exhaust Operation Exhaust__Accept Mark__Reject Mark
Hold limit outputs past end of test ___N_______Y____
IEEE address (01-32) __________________
Secure calibration process ___N________Y___

Secure test information ___N________Y___
Secure reset of counters ___N________Y___
Secure self test parameters ___N________Y___
Secure transducer values ___N________Y___
Secure runs until calibrate warning ___N________Y___
Secure CHG PART function ___N________Y___
Change password _________________
Leak units ccm__ccs__cis__cch__lpm__lps__lph__

Pressure units mbr__bar__atm__MPa__psi__kPa__iWC__iHg__mHg__ozi
Pressure transducer zero range (millivolts) ________3.0_________
Pressure transducer span (100 millivolts =) __100*___
Flow transducer zero range (millivolts) ________0.1_________
Flow transducer span (5 volts =) __1000__6000___
* Set to actual span of transducer supplied
A-3
Setup chart for part calibration parameters
for different parts
Calibration parameters for each part

Part #1 Part #2 Part #3 Part #4 Part #5 Part #6 Part #7 Self T
Part name
[Clamp time]
[Seal time]
Gross time
Fill time
Test time
Exhst time
(Gross 2 time)
(Fill 2 time)
(Test 2 time)
(Exhst 2 time)
Relax time
Min press
Max press
Targetpress
(Min press 2)
(Max press 2)
(Targetpress2)
Low limit
High limit
Calibr'n*^
MaxCalFlow^
MinCalFlow^
Zero Shift Pct
{Zero Shift Value}*
(Low limit 2)
(High limit 2)
(Calibr'n 2*)^
(MaxCalFlow2)^
(MinCalFlow2)^
(Zero Shift2 Pct)
({Zero Shift val2})*
{Zero Shift Quant}

Part Name
[Parameters] displayed if tooling control is selected.

( Parameters ) displayed when pneumatic version F or D is selected.
{ Parameters } displayed if “Zero shift Pct” is non-zero.
* indicates values that are measured or calculated during calibration or testing
sequence.
*Values displayed if test type set for LEAK.
A-4
APPENDIX
SETTING TEST PARAMETERS
Mass Flow Method Of Measuring Part Leak or Flow Rates
The basic principle of operation of a mass flow test instrument is to fill the test part to a
specified test pressure, continue to pressurize the part until the flow of makeup air stabilizes,
and then measure the flow of makeup air due to a leak or flow from the part. The flow
instrument displays the reading of instantenous flow measured at the end of the test cycle.
For leak test applications the displayed flow value is corrected by the flow offset value
("calibr'n") measured from the master part during the AUTO CAL process. For flow
applications the displayed flow value is the direct flow value read at the end of the test cycle.
The settings for the “Gross”, “Fill”, and “Test” timers influence the repeatability of the
instrument under test conditions. The calibration process, AUTO CAL, is needed only for
test styles designated as "Leak". In the AUTO CAL process for leak applications, the
instrument measures the residual flow due to part expansion, adiabatic temperature effects,
part absorption, etc. remaining after the instrument switches to the test cycle. This allows
the instrument to enter the test cycle faster and offset the displayed flow rates by the typical
flow value, "calibr'n", read on the master non-leaking part. The repeatability of the leak test
process is then limited by the typical part-to-part repeatability of the residual flow value.
Longer fill cycle times will improve the repeatability of the test.
For flow applications, the flow value measured in the test cycle is a direct reading of the flow
going into the part. Because of the nature of the test, it is not necessary to offset the measured
values for part dynamics (adiabatic temperature effects, part expansion, etc).
ESTABLISHING TEST PARAMETERS
Flow Values Within FLOW routine
Low Limit High Limit
The Sentinel F-21 instruments have two set points, low and high limits, with which to
compare test results. These limit values define three regions (below low limit, between
limits, and above high limit) in which to qualify the results of each test. There are four
dedicated outputs which are activated during the exhaust cycle to indicate in which
area (severe leak, below low limit, between limits, and above high limit) the test results fell.
For leak test applications, the limits define the tolerance of air leakage allowed by the part
during test. The typical configuration would have the high limit equal to the reject rate or
specified tolerance of leakage for the part. The low limit would be set at zero or a negative
value (10 to 20% of reject rate or high limit value). Within Instrument Configuration
(chapter 10, page 10-4 and 10-5), the test evaluation criteria should be set to reject test results
greater than the high limit value and accept parts between the limits. The area below the low
limit should be set to accept. If it is desirable to alert the process when parts test significantly
A-5
better than when initially calibrated, set the instrument to reject any value that is below the
low limit.
For blockage applications it would be desirable to check that the measured flow is greater
than a value. In this application all measured flows greater than the high limit should be set
to accept and all values between the limits and values below the low limit should reject.
For flow applications it is usual to accept values that are between a low and high limit. All
values greater than the high limit and less than the low limit should be set to reject.
Calibr'n, Max Cal Flow, Min Cal Flow (Zero offset value for leak test applications)
The “Calibr'n” value is a flow measured during the AUTO CAL routine when the "Test
Style" is set to "Leak" in the MISC routine, Test Type Configuration. It represents the flow
of a Master (leak free) part during the normal test process. This residual flow exists due to
adiabatic temperature effects, part expansion, part absorption, etc. In order to shorten the
overall testing cycle time, the fill cycle is reduced to a time that does not allow for all the flow
variables to stabilize. Therefore there will be some flow going into the part when the "test"
cycle begins. If that flow is consistent, the AUTO CAL process will measure the flow and
consider it a constant offset, "Calibr'n". Following the calibration process for leak
applications, all the displayed flow values are corrected by the "Calibr'n" value as follows:
Displayed flow reading = Measured flow reading - "Calibr'n"
Max Cal Flow and Min Cal Flow are comparison limits for the "calibr'n" value to check for
leaking master parts or blocked test lines.
A-6
Zero Shift Pct and Zero Shift Quan
The zero shift routine helps to maintain the calibration of the system for leak testing
applications by periodically adjusting the zero flow calibration value (calibr'n) to match the
changes in the test conditions. This routine dynamically compensates for slow changes in
the test environment like room temperature changes, part temperature changes, test air
temperature changes, part elasticity changes, etc. that influence the measured residual flow
of a non-leaking part. “Zero Shift Pct” defines how wide of a band around the “calibr'n”
value will be considered as normal variations in flow for a non-leaking part. The percent
band (+ZS%) is based on the High Limit value.
Zero Shift Band = + (Zero Shift Pct x High Limit)

i.e.
Zero Shift Pct = 20%
High Limit = 10 sccm 10 sccm
-20% +20%
instrument "calibr'n" High

zero flow flow for Limit
non-leaking part
“Zero Shift Quan” (n) defines the quantity of flow values Fn that must fall within the band
(+ZS%) about the “Calibr'n” value before the instrument calculates a new average. The zero
shift value is calculated as shown.
<n F n
Zero Shift value = ------------ - “Calibr'n”
n
Typical settings for “Zero Shift Pct” is 20% and “Zero Shift Quant” is usually 10 to 20.
Flexible parts require a greater “Zero Shift Pct” then rigid parts. The “Zero Shift Quant”
value effectively defines how responsive the system will be to environmental changes.
The “Zero Shift Pct” effectively defines how large the “Zero Shift value” can be. This limits
the routine from continuing to compensate for possible growing leaks in the seal or test
pneumatics.
Zero Shift Value
This value is calculated by the instrument and represents the average change or shift in the
normal measured flow for non-leaking parts during test. This value will only appear if the
“Zero Shift Pct” within the LEAK routine is non-zero. A description of the routine can be
found under Zero Shift Pct and Zero Shift Quant above. Each displayed flow reading is
compensated by the "Zero Shift Value" as follows:
Displayed flow reading = Measured flow reading - Calibr'n + Zero Shift value
A-7
Pressure Values Within PRESS routine
Min Press and Max Press (Test Pressure Limits)
Determine the minimum and maximum test pressure limits by calculating a +5% band about
the specified test pressure. Set the regulator to match the specified test pressure by starting
the instrument into a test cycle and pushing the HOLD button in the fill cycle so that the
display shows the fill pressure. Adjust the regulator to display the desired test pressure. Push
the HOLD button again and push STOP button to end the test cycle.
Target Pressure
This function protects the mass flow sensor from excess flow. The target pressure setting
(+3% or +1 psi, whichever is greater) is a pressure zone that must be maintained at the end
of the fill cycle before switching the makeup air flow through the mass flow sensor. The
target pressure should be set to the specified test pressure. The test pressure regulator must
be adjusted to match the target pressure.
Timer Values Within TIMER routine
The purpose of fill cycle is to increase the internal air pressure in the part from atmospheric
to test pressure and allow adequate time for the pressure inside the part and test pneumatics
to stabilize. When filling the part, the incoming compressed air collides with the
atmospheric air inside the part. This causes heat generation due to the initial air in the part
being compressed suddenly (adiabatic compression). The adiabatic heat and regulator
response will cause the pressure in the part to vary from the incoming test air pressure.
While there is an imbalance in pressure between the test regulator and the internal pressure
in the test part, there will be flow between them. The flow initially will be high and then will
taper off during the remaining period of fill cycle and continue into the test cycle.
The flow due to heat dissipation is governed by the following:

- the air volume inside the part
- the test pressure
- the thermal conductivity of the part
- the temperature of the part
- the ambient temperature conditions
The following factors will require a longer fill time:

- flexible part walls
- higher test pressures
- greater differences in temperature between the part and test air supplied
- larger part air volumes
- lower thermal conductivity parts
Room temperature variation can affect the accuracy and repeatability of the system but are
usually minimal. This variable can be corrected by use of the dynamic compensation (zero
shift) feature within the Sentinel F-21 instruments or more frequent calibration.
A-8
The fill cycle helps to stabilize the rise and fall of pressure in the part by leaving the regulator
connected to the part through the fill valve until the end of the fill timer. Adequate time
should be put on the fill timer so that the pressure does not change more than 0.1% of test
pressure or drop below the minimum test pressure parameter before switching the makeup
air flow through the mass flow sensor. Minimizing the flow during the test cycle will
improve the test repeatability.
Gross Timer
The gross timer serves as an initial severe or gross leak check. It establishes the maximum
time allowed for the measured pressure in the part to reach the “Min Press” value. Once the
pressure reaches the “Min Press”, the instrument automatically moves onto the “Fill” timer.
This timer is usually set at twice the normal time it takes to reach “Min Press”. A “severe
leak” error message will occur if the pressure does not reach “Min Press” within the “Gross”
time.
The utility output can be programmed to go on during this timer.
Fill Timer
To begin establishing the amount of time required for fill, set the fill timer initially at 10
seconds for small parts (less than 15 cu. in. or 250 cc. internal volume), or 15 seconds for
larger parts. Set the test timers initially to 2 seconds.
When any change is made to the “Fill”, or “Test” timers, the instrument display
will indicate “Warning Cal Advised” after pushing the START button. The
message will remain on for 5 seconds and then begin the test cycle. During this
procedure for setting the timers, ignore the warning messages. After
determining the final settings, perform a calibration.
Enter all the test parameters and push EXIT. Push START to initiate a test on the master part.
Observe the pressure during the fill cycle and flow during the test cycle. The optimal fill
settings will minimize the flow for a good part during the test cycle. For flow testing the
residual flow in the test cycle should be less than 1% of the expected flow. For leak test
applications, the residual flow should be repeatable within + 3%. Test a non-flowing (non-
leaking) part and observe the pressure loss during the fill cycle and flow during the test cycle.
If there is pressure loss at end of the fill cycle (greater than 0.1 psi in 5 seconds) or drops
below minimum test pressure, increase the fill timer and possibly reduce the minimum test
pressure. If the fill pressure remains constant during the final stage of the fill cycle and the
flow during test is less than 1% of expected flow, you may decrease the fill timer by 10 to
25% to achieve a faster time cycle. Repeat the test on the master part and observe the fill
pressure and flow in test. Adjust the fill timer until optimal results for flow repeatability and
cycle time are achieved.
The duration of the fill timer effects the repeatability of the test cycle.
A-9
Test Timer
The recommended minimum time for the test timer is 1.0 second. After adjusting to the
optimal fill timer, set the test time to 1.0 second. Repeat the tests on a master part to assure
consistency to the previous tests. On very fast tests it is possible to reduce the test time to 0.5
second, but this is not recommended for general applications.
The utility output can be programmed to go on during this timer.
Exhaust timer
The purpose of the exhaust timer is to allow air to vent the part before retracting tooling. The
time required depends on the test pressure and part volume. The part starts exhausting
immediately after the “test” timer expires. Typical times are 1 to 3 seconds.
The Exhaust output which is activated during the exhaust timer only can be used to stamp a
part at the end of test. Depending on the setup parameters found on page 10-8, the output will
be activated after each test, for accept parts only, or reject parts only. In addition one of four
test result outputs (severe leak, below low limit, between limits, and above high limits) will
be activated during the exhaust timer to indicate the test results.
Relax timer
This timer is only used as the delay time between tests when operating the instrument using
“Auto Test” (see Chapter 10). It does not effect the normal testing cycle. A typical time
setting is 20 seconds
Master calibration part
To establish times, perform calibration, or optimization test procedures you must find a
master (leak free) part. If possible, this part should be marked and used as a reference
whenever calibration is required.
Verify integrity of test circuit and master part
Check that the test circuit and master part are leak free. To do this, place the master part in
the tooling fixture and run a test. As soon as the instrument enters the “Test” portion of the
leak cycle, push the HOLD button (the HOLD LED should light up.) Now watch the
displayed flow value. If the part and tooling are indeed leak free, the reading will eventually
stabilize around zero flow. If this doesn’t happen, use a water and soap solution to find the
leak. As an interesting experiment, grasp the brass test port with your hand. As the heat of
your hand warms the metal, the pressure in the test circuit increases (the flow will drop
toward zero.)
A-10
APPENDIX
OPTIMIZING THE TEST PERFORMANCE
Optimal test performance is a compromise between obtaining the best repeatability and
using the least amount of time. Improved repeatability usually requires longer time cycles.
There are several ways to optimize the repeatability of your leak or flow tests. The following
are techniques or “rules of thumb” that should be considered when you are fine tuning your
new instrument. It is important to utilize one or several master parts described earlier
(Master calibration part) for the optimization process. Parts can become “hardened” and
cause different results when tested repetitively or without sufficient relax time between tests.
Also check the test pneumatics to make sure that they are leak free per description earlier
(Verify integrity of test circuit and master part).
Volume
The laws of physics dictate that test volume and test response time are directly related. It is
always in your best interest, therefore, to reduce the volume of the test part, test lines, and
tooling that are in the test circuit. Some possibilities include:
- use filler blocks when possible to reduce the internal (test) volume of the part.
- mount the instrument as close to the test part as possible
- use the smallest diameter test line possible (so long as the gross or fill time
doesn’t have to increase).
Tooling and Processes
Unreliable fixtures and improper part sealing is by far the biggest cause of unconfirmed
rejects and poor repeatability. Seals should be made of cut resistant urethane. The
durometer value (typically 60 -70) of the urethane must be carefully selected for the
application. It should be as hard as possible while being able to reliably seal on the part seal
surface. The seal holder cannot allow the seal to creep (slowly move) during test. Tooling
cannot deform the part during test or artificially help seal the part.
The test line should be made of 2000 psi Parker tubing or similar with the shortest length and
smallest diameter (1/4" or 1/8") as possible. The instrument should be mounted above the
part to keep contamination away from the test pneumatics.
Isolate the test system from sources of warm or cold air (radiant heaters, air conditioning
ducts, loading docks, fans, etc.). They change the temperature of the part, causing the test
pressure to fluctuate. Test Parts should soak at room temperature before testing to assure
consistent test performance.
A-11
Cycle time
The easiest way to improve repeatability performance is to increase the total cycle time.
Total cycle time includes part of Gross + Fill + Test + Exhaust timers. Unfortunately, there
usually is a limit on allowed cycle time due to production thru-put requirements. In general,
since longer test cycle times almost always improve performance, you should extend the
total test cycle time to the maximum allowed to meet production.
Gross Timer
The value of this timer does not affect the overall time cycle for the test. The actual time it
takes to get to the “Min Press” does add to the overall time. Therefore there is little to
optimize here.
Exhaust Timer
This timer does add to the overall time cycle. Observe the time it takes for the part to exhaust
down to 3 psi. Set the exhaust timer as close to this time as possible. One shortcut to exhaust
large parts faster is to add a 120 volt, normally closed, larger orifice valve (0.25 inch or
greater) externally to the test line. Wire this valve to the “Exhaust” output. The part will now
exhaust through both the external valve and the internal fill/exhaust valve. This valve must
be leak tight because it is now a part of the test pneumatics and therefore will be leak tested
during each test.
Fill and Test Timers
Determine the total allowable test cycle time allowed for the test. Subtract the gross timer,
exhaust timer, and 1 second for the test timer from the total allowable test cycle time. Put the
remaining time in as fill time. When initially setting up the instrument it is desireable to
place the instrument in HOLD in order to observe the actual flow measured in the test cycle.
To allow time to push the HOLD button, set the TEST timer initially to 3 seconds. Push the
START button to initiate a test cycle. When the instrument finishes the FILL cycle and
starts TEST, push the HOLD button and watch the actual makeup air flow. If the flow is
stable or at zero, the FILL cycle could be reduced. If the flow is decreasing at a rapid rate,
the FILL timer should be extended. If the flow is decreasing slowly or is stable, the FILL
cycle can be reduced. Once an optimal FILL time is determined, set the TEST timer to 1
second. Only when trying to achieve a total cycle time of less than 2 seconds should the
TEST timer be reduced below 1.0 second. The absolute minimum TEST time is 0.5 second.
TEST times less than 1.0 seconds may introduce some repeatability errors.
A-12
WARRANTY-SENTINEL INSTRUMENTS
ACCEPTANCE: The furnishing of a product, to a customer shall constitute acceptance of
the product, unless notice of defect, nonconformity or disparity in quantity (as compared to
shipping manifest) is received by C.T.S., Inc. within thirty (30) days from delivery.
WARRANTY: C.T.S. Inc., the Seller, warrants that our standard instruments, under normal
and proper use, shall be free from defects in material and workmanship impairing its
usefulness, for a period of twelve (12) months from the date of shipment. Other
manufacturer’s component parts installed in or on our instruments are products of reputable
manufacturer’s sold to us under their respective brand or trade names. C.T.S., therefore,
makes no express or implied warranty other than the warranty offered to C.T.S., by the
supplier.
It is the buyers obligation to report any suspect defect as soon as possible. Immediate efforts
will be made to work with the buyer’s personnel to remedy the defect. If this support service
is not successful in correcting the problem, the instrument must be returned to C.T.S. at
buyers cost.
Warranty shall only be determined after receipt of instrument at our facility in Cleves, OH.
Equipment shall not be returned without first obtaining prior authorization by C.T.S.
personnel. All equipment returned for the warranty inspection must be securely packaged,
and returned prepaid. The equipment will be inspected upon receipt for obvious and
concealed shipping damages. If damage has occurred, it is the customers responsibility to
notify and file damage claims with the delivery company.
C.T.S.’s obligation under this warranty is limited to repairing or replacing, at C.T.S.’s

option, any defective non consumable parts. Consumable parts are specifically excluded
from this warranty; these include but are not limited to lamps, elastomers, seals, valve seats,
and other wear surfaces. All liability under this warranty shall be voided if there has been any
unauthorized repair or modification made, or the equipment is not operated in compliance
with its operating instructions, or used in any process beyond the purpose for which it was
intended. The installation of this instrument should include proper filter and moisture
separation on the incoming air supply. Repairs required to remove foreign material from the
valves or test circuit will not be covered under the terms of this warranty.
This warranty being expressly in lieu of all other warranties expressed or implied and all
other obligations on our part, C.T.S. shall not be held liable for any special, indirect, or
consequential damages arising out of this warranty or any breach thereof, any defect in or
failure or malfunction of the equipment and/or apparatus furnished hereunder.
INSTALLATION, SERVICE, AND IN-FIELD WARRANTY SERVICE: If C.T.S.,

Inc. personnel are required to supervise, check installation, make adjustments, inspect or
repair equipment in the field, there will be charges based on the then current hourly rate for
in-plant time plus travel time and travel and living expenses. Extra charges at a rate of 1.5
times the straight time rate will be made for overtime, Saturday, Sunday, and Holidays.
Travel time and expenses are charged to and from the CTS., Inc. plant in Cleves, Ohio. The
A-13
repair or replacement of parts will be charged in addition to services performed, unless parts
are covered under the CTS.Inc, warranty agreement. There will be no charges for in-plant
labor time for warranty repairs covered under CTS, Inc. warranty agreement. The customer
is responsible for the travel time and expenses.
STATE, MUNICIPAL OR INSURANCE REGULATIONS: Where equipment to be

supplied is of the design or manufacture which may be subject to state or municipal
ordinances or insurance company regulations, such equipment will be designed and
manufactured in accordance with generally accepted practices and will be adequately tested.
However, unless specifically stated in our proposal, such equipment will not necessarily be
designed or manufactured to conform to any particular ordinance or regulation. The Seller
will assume no liability for difficulties experienced by the buyer should such equipment fail
to comply with any particular ordinance or regulation unless our proposal specifically states
that the equipment would conform to said ordinances or regulation.
DRAWINGS, SCHEMATICS AND OPERATING INSTRUCTIONS: This instrument

is supplied with only this one copy of the “Instruction Manual” and the standard electrical
and pneumatic schematic prints included within it. Additional copies can be purchased. A
certified “Calibration Report” will be included for each orifice supplied.
ERRORS AND
OMISSIONS: Stenographic and clerical errors are subject to correction.
A-14
INDEX
Accessories ........................................... 1-3

Anti-tie-down logic .............................. 4-4, 10-6, 10-7, 11-7, A-3
AUTO CAL (Automatic part calibration)
Use ...................................................... 3-4, 6-1
Setup ................................................... 4-4, 10-4, 11-3, 11-14
AUTO TEST ........................................ 4-4, 10-1, 10-2
Blockage test (test evaluation) .............. 4-4, 10-4, 10-5, A-3, A-6
Burst test (Integrity test) ....................... 1-2, 4-4, 5-1, 5-3 thru 5-7, 10-3
Calibr'n ................................................. 5-1, 5-4, 5-7, 10-4, A-4, A-6, A-7
Cal Req’d Alarm .................................. 9-1, 9-2, 10-11, 13-1
Cal Req’d Warning ............................... 9-1, 9-2, 10-11, 13-1
Change part program (CHG PART) ..... 3-4, 4-1, 4-4, 5-1, 6-1, 7-1, 10-3,
.............................................................. 10-11, 11-3, 11-13, A-3
Change test parameters ......................... 3-5, 3-6, Ch. 5, A-4
Change part name ................................. 5-1, 5-5
CHG PART button ............................... 3-4
Clamp output ........................................ 10-6, 10-7, 11-1, 11-2, 11-6 thru 11-9,
.............................................................. 13-2, 13-3
Clamp timer .......................................... 5-1,5-2,5-6,10-6, 11-6, 11-8, 11-9,A-4
Clock frequency ................................... 2-8, 11-21
Clock verification terminals ................. 2-8, 11-20, 11-21
COMM (Communication to printer or computer)
.............................................................. 3-5, 3-6, 8-1, 8-2
Control logic ......................................... 4-4, 10-6 thru 10-9, Ch. 11,A-1 thru ,A-3
Control logic timing sequence .............. 5-1, 5-2, 5-6, 11-6, A-4
Counters (COUNT) .............................. 3-5, 3-6, 9-1, 9-2
CTS Talk .............................................. 1-3, 8-1, A-2
Cycle time ............................................. A-8 thru A-10
Date/time .............................................. 4-4, 10-1
Dimensions ........................................... A-2
Dual pressure test ................................. 1-2, 4-4, 5-3 thru 5-8, 10-4, 10--5,11-6
Dynamic compensation (Zero shift) ..... 5-1, 5-4,5-5, 5-7,5-8, 10-3, A-4, A-7
Electrical connections ........................... 2-6, 2-7, 2-8, 11-7 thru 11-25
ENTER button ...................................... 3-5, 3-6
Error messages ..................................... Ch. 13
Exhaust function (Part stamp) .............. 4-5, 5-2, 5-6, 10-8, 11-2, 11-6, A-3
Exhaust time ......................................... 5-1, 5-2, 5-3, 5-6, 11-2, 11-6, A-4, A-10,
.............................................................. A-12
EXIT button .......................................... 3-5, 3-6
Fill time ................................................ 5-1, 5-2, 5-3, 5-6, 11-6, A-4, A-9, A-12
I-1
FLOW (review or change flow values) ........ 3-5, 3-6, 5-1, 5-4, 5-5, 5-7, 5-8, A-4 thru A-7
Lo lim, Hi lim, calibr'n, zero shift pct.,
zero shift quant., zero shift value,
Change part name
Flow rate units of measurement ........... 4-5, 10-12, A-3
Fuses ..................................................... 2-7, 12-3
Gross time ............................................. 5-1, 5-2, 5-3, 5-6, 10-8, 11-6, A-4, A-9, A-12
Gross timer output ................................ 4-4, 10-8, 11-6, A-1, A-3, A-9
High limit ............................................. 5-1,5-4,5-7,5-8,10-4,10-5,A-1,A-4 thru A-7
HOLD function ..................................... 3-4, 4-3, 4-4, 10-8, A-2, A-3
IEEE 485 interface ............................... 3-6, 4-5, 8-1, 10-9, 11-20,11-21,A-2, A-3
In calibration output ............................. 4-4, 10-8, 11-2, A-1, A-3
Inlet air filter ......................................... 1-4, 2-3, 12-1
Input/output termination board ............. 2-7, 11-7, 11-18, 11-21 thru 11-25
Input terminals ...................................... 2-7, 11-7, 11-18, 11-21 thru 11-23, 11-25
Installation concerns ............................. Ch. 2
Instrument configuration ...................... 1-1, 1-2, Ch. 10
Instrument overview ............................. Ch. 3
Integrity test (Burst test) ....................... 1-2, 4-4, 5-1, 5-3, 5-6, 5-7, 10-3
Internal filter ......................................... 1-1, 1-2, 3-3, 12-1, 12-3
Internal instrument overview ................ 3-3
Leak/FLOW
(review or change flow values)...3-5, 3-6, 5-1, 5-4, 5-5, 5-7, 5-8, A-4 thru A-7
Lo lim, Hi lim, calibr'n, zero shift pct.,
zero shift quant., zero shift value,
Change part name
Leak rate
(Flow rate) units of measurement ....... 4-5, 10-12, A-3
Limit counters ....................................... 9-1
Limits output ........................................ 4-5,10-9, 11-3, A-1, A-3
Low limit .............................................. 5-1,5-4,,5-7,10-4, 10-5,A-4 thru A-6
Machine controls .................................. 4-4, 10-6 thru 10-8, Ch. 11
Machine setup ....................................... 4-4, 4-5, Ch. 10, Ch. 11
Master part ............................................ 6-1, A-10
Max Cal Flow........................................ 5-1, 5-4, 5-7, 5-8, 13-4, A-4, A-6
Maximum test pressure ........................ 4-1,4-3, 5-1, 5-3, 5-4, 5-7, 13-3, A-4, A-8
Min Cal Flow......................................... 5-1, 5-4, 5-7, 5-8, 13-4, A-4, A-6
Minimum test pressure ......................... 4-1,4-3, 5-1, 5-3, 5-4, 5-7,13-3, A-4, A-8
MISC (Miscellaneous or setup menus) ..... 3-1, 3-5, 3-6, 4-4, 4-5 Ch. 10
Mounting instrument ............................ 2-1, 2-2
Operation panel .................................... 3-2, 3-4
Output limits ......................................... 11-3, A-1, A-3
Output terminals ................................... 2-7, 11-7, 11-18, 11-21 thru 11-24
Part name (change) ............................... 5-1, 5-5, 5-8, A-4
Part present input .................................. 4-4, 10-8, 11-1, 11-17
Part test parameter storage .................... Ch. 5
Password ............................................... 3-5, 4-4, 4-5, 5-1, 5-2, 10-3, 10-11
I-2
Plumbing recommendations ................. 2-3
Pneumatic connections ......................... 2-4
Pneumatic manifold .............................. 1-1, 1-2, 3-3, 12-2
Power connections. ............................... 2-6, 2-7, 11-7, 11-21
Pre-fill cycle ......................................... 1-2, 4-4, 5-1 thru 5-3, 5-6 thru 5-8
PRESS (review or change pressure values).. 3-5, 3-6, 5-1, 5-3, 5-7,
Min. pressure, max. pressure,target pressure A-4 , A-8
Pressure units of measurement ............. 4-5, 10-12, 10-13, A-3
PREV button ......................................... 3-5, 3-6
Preventive maintenance ........................ 12-1
Printouts ................................................ 8-1
Programming panel .............................. 3-2, 3-5, 3-6
Regulator setting ................................... 4-3
Reject rate (high limit, low limit) ......... 5-1, 5-4, 5-7, 5-8, 10-4, 10-5,
.............................................................. A-5 thru A-12
Relax time ............................................. 5-1, 5-3, 5-6, A-4, A-10
Review test parameters ......................... Ch. 5, A-3
RS232 interface .................................... 3-2, 3-6, 8-1, 8-2, 11-21
RS485 interface .................................... 3-6, 4-5, 8-1, 10-9, 11-20, 11-21
Seal timer .............................................. 5-1, 5-2, 5-6, 11-1, 11-2, 11-6, 11-10,
.............................................................. 11-11, A-4
Security codes ....................................... 3-5, 4-4, 4-5, 5-1, 5-2, 10-3, 10-11
Security setup ....................................... 4-5, 10-9, 10-10, 10-11, A-3
Auto calibration process ..................... 4-5, 10-10, A-3
Change calibration parameters ........... 4-5, 10-10, A-3
Reset counters ..................................... 4-5, 10-10, A-3
SELF TEST parameters ...................... 4-5, 10-10, A-3
Change transducer value ..................... 4-5, 10-10, A-3
Change “Total tests for Cal REQ’d” values...... 4-5, 10-11, A-3
Access to CHG PART function .......... 4-5, 10-11, A-3
SELF TEST .......................................... 3-4, 4-1, 4-2, 7-1, 10-10, 11-3
Single pressure test ............................... 1-1
Spare parts ............................................ 12-2, 12-3
START button ...................................... 3-4
Start up of instrument ........................... 4-1 thru 4-3
STOP button ......................................... 3-4
Target Pressure ..................................... 4-1 thru 4-3, 5-1,5-3,5-7,7-1,11-3,
.............................................................. 13-3,13-4,A-7
Test evaluation limits ........................... 4-4, 5-1,5-4,5-7,5-8,10-4, 10-5,
.............................................................. A-4 thru A-6
Test parameters ..................................... Ch. 5, A-4 thru A-12
Test time ............................................... 5-1 thru 5-3, 5-6, 11-6, A-4, A-5,
.............................................................. A-8 thru A-10, A-12
Test timer output .................................. 4-4, 10-8, 11-2, 11-6, A-1, A-3, A-10
Time/Date ............................................. 4-4, 10-1
TIMERS (review or change timers values) 3-5, 3-6, 5-1 thru 5-3, 5-6, 11-6, A-4
Clamp, seal, gross, fill,
test, exhaust, relax .............................. A-8 thru A-10, A-12
I-3
Toggle Clamp ....................................... 11-4, 11-7, 11-14, 11-21
Transducer calibration. ......................... 0-12 thru 10-16
Transducer verification terminals ......... 2-8, 11-20, 11-21
Utility inputs ......................................... 4-4, 10-7, 10-8, 11-7, 11-17, 11-18,
.............................................................. 11-21, 11-25, A-2, A-3
Utility outputs ....................................... 4-4, 10-8, 11-2, 11-6, 11-7, 11-12,
.............................................................. 11-21, 11-22, 11-24, A-1, A-3
Volume (part) ....................................... A-11
Zero shift value. .................................... 5-1, 5-4, 5-5, 5-7, 5-8, A-4, A-7,
Zero shift percent .................................. 5-1, 5-4, 5-7, 5-8, A-4, A-7
Zero shift quantity ................................ 5-1, 5-5, 5-8, A-4, A-7
I-4

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SENTINEL F-21

MASS FLOW TEST INSTRUMENTS

CINCINNATI TEST SYSTEMS, INC.

Figure 1 Version S Pneumatic diagram and manifold layout

Figure 3 Version D Pneumatic diagram and manifold layout

* Portable, battery-powered printer

* Inlet air filter set (0.3 and 5.0 micron filters)

* clean, dry instrument air

Because it is a precision instrument, it is preferable to locate the instrument at least 15 feet

Figure 4 Quick connect fitting and door keys

Recommendations on plant plumbing

Figure 6 Plant plumbing recommendations

Figure 8 Areas on Sentinel F-21 enclosure for electrical inputs

Figure 9 Input/Output and power terminations for Sentinel F-21

Figure 9A Input/Output and power terminations for 24 volt model

Figure 10 Clock and transducer output terminals for Sentinel F-21

The basic instrument software performs different types of tasks.

Leak/flow test operation including tooling control

Chapter 10 INSTRUMENT CONFIGURATION (MISC)

The default setup is summarized on the “INSTRUMENT CONFIGURATION (MISC)”

Figure 11 Overview of Sentinel F-21 instrument

Figure 12 Internal layout of the Sentinel F-21 instrument

LED for HOLD indicates that the test sequence is paused.

Figure 13 Operations Panel

Figure 14 Programming Panel

COUNT button accesses stored counter information.

PREV button steps back to the previous display within a function.

Figure 15 Self test connections for the Sentinel F-21

* If there is no internal leak:

“.0x ccm No Leaks

* If there is an internal leak:

XX ccm: INT LEAK

- CHG PART Configuration

* Make pneumatic connections to instrument (see Chapter 2).

Set regulator to desired test pressure

* Reconnect the test line to the quick connect test port.

Setup function Factory setting Changes

Date (current year, month,

Auto Test routine (skip for setup) 0 ________

Modify instrument setup options? ............(Change to Y to access ________

Record all changes to the original factory settings. It is important to know

PART 5: BRASS VALVE2

“Gross 2” Time to reach Minimum Test Pressure in second test.

PART 5: BRASS VALVE2

PART 5: BRASS VALVE2

“Low Limit”* Specified low limit flow used to evaluate parts.

The last menu under FLOW is :

Part name setup

PART 5: BRASS VALVE2

Test Parameters Factory settings Changes

(For test style - leak only) _____

Part Name - up to 12 alpha/numeric characters

Calibration routine for a part:

Multiple Part Calibrations

SELF TEST: (Cap Test

.xx ccm -No Leaks (max. allowed flow is preset.)

for an acceptable non-leaking test pneumatics, or

for a leaking test pneumatic panel.

“XFER DATA EACH TEST”