C28 Manual 05.18.09 F English PDF

Sentinel C-28 Compact
Precision Leak Test

Instrument
Instruction Manual
IMPORTANT INFORMATION
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 purchasers 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.
!
CAUTION - When you see this warning symbol on the product, refer to the instruction manual for information before
proceeding.
CAUTION - To avoid personal injury due to electric shock, disconnect all power services before servicing.
If this instrument is not used according to the instructions of this manual, the protection provided by this equipment'
design may be compromised.
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION ...............................................................................1-1
QUICK START .....................................................................................................................1-1
INSTRUMENT FEATURES.................................................................................................1-4
UNPACKING ........................................................................................................................1-5
VERIFICATION OF PROPER INSTRUMENT SPECIFICATION ....................................1-6
INSTALLATION ..................................................................................................................1-7
MOUNTING CONSIDERATIONS ......................................................................................1-8
PLUMBING RECOMMENDATIONS ...............................................................................1-10
PNEUMATIC CONNECTIONS .........................................................................................1-11
ELECTRICAL CONNECTIONS ........................................................................................1-12
INPUT/OUTPUT TERMINAL TABLE .............................................................................1-16
ADDITIONAL ACCESSORIES .........................................................................................1-17
CHAPTER 2 INSTRUMENT OVERVIEW ...............................................................2-1
POWER ON ...........................................................................................................................2-1
OPERATOR DISPLAYS ......................................................................................................2-2
DISPLAY AND FUNCTION PANELS ................................................................................2-2
NAVIGATION KEYS ...........................................................................................................2-4
DISPLAY PANEL .................................................................................................................2-6
MONITOR .............................................................................................................................2-8
PART CONFIG ...................................................................................................................2-10
INSTR CONFIG ..................................................................................................................2-11
TEST DATA ........................................................................................................................2-12
SELF TEST ..........................................................................................................................2-12
HELP....................................................................................................................................2-13
FUNCTION PANEL ...........................................................................................................2-14
HOLD ..................................................................................................................................2-14
CHANGE PART ..................................................................................................................2-14
AUTO SETUP .....................................................................................................................2-14
AUTO CALIB .....................................................................................................................2-15
START .................................................................................................................................2-15
STOP ....................................................................................................................................2-15
CHAPTER 3 AUTO SETUP and AUTO CAL.........................................................3-1
TURN ON POWER ...............................................................................................................3-1
AUTO SETUP .......................................................................................................................3-2
AUTO CAL ...........................................................................................................................3-6
CHAPTER 4 INSTRUMENT CONFIGURATION AND COMMUNICATION............4-1
INSTRUMENT SETUP ROUTINE ......................................................................................4-1
MANIFOLD TYPE AND TRANSDUCER SELECT ..........................................................4-2
COMMUNICATIONS ..........................................................................................................4-4
SERIAL COMMUNICATION ..............................................................................................4-4
TCP/IP COMMUNICATIONS ...........................................................................................4-12
USB FLASH FIRMWARE UPDATE .................................................................................4-15
EMAIL COMMUNICATION .............................................................................................4-17
MISCELLANEOUS INSTRUMENT SETTINGS .............................................................4-18
VERSION ............................................................................................................................4-19
Rev 11/18/08
SECURITY ..........................................................................................................................4-19
CHAPTER 5 PART CONFIGURATION .................................................................5-1
REVIEW OR CHANGE PART TEST PARAMETERS.......................................................5-1
TEST TYPE ...........................................................................................................................5-3
TEST TIMERS ......................................................................................................................5-4
TEST PRESSURES ...............................................................................................................5-5
TEST PARAMETERS...........................................................................................................5-6
CALIBRATION PARAMETERS .........................................................................................5-9
MISCELLANEOUS ............................................................................................................5-10
COPY PART PROGRAMS ................................................................................... 5-11
AUTO RUN ........................................................................................................... 5-11
UNITS OF MEASUREMENT ............................................................................................5-12
DIGITAL INPUT AND OUTPUT CONFIGURATION ....................................................5-14
DIGITAL INPUT CONFIGURATION ...............................................................................5-15
PART PROGRAM LINKING ............................................................................... 5-17
DIGITAL OUTPUT CONFIGURATION ...........................................................................5-18
TIMING CHARTS ................................................................................................ 5-22
TOOLING CONFIGURATION ..........................................................................................5-23
CHAPTER 6 PRINCIPLES OF OPERATION .........................................................6-1
INSTRUMENT CONFIGURATIONS ..................................................................................6-1
PRESSURE DECAY TESTING ...........................................................................................6-1
CHAPTER 7 SELF TEST .......................................................................................7-1
VERIFY OR ADJUST PRESSURE TRANSDUCER CALIBRATION ..............................7-1
ADJUST MECHANICAL REGULATOR SETTING ..........................................................7-2
SELF TEST THE INSTRUMENT FOR LEAKS .................................................................7-4
CALIBRATION VERIFICATION (Open Leak Std) ............................................................7-6
CHAPTER 8 COMMUNICATIONS INTERFACE ...................................................8-1
COMMUNICATION SETUP AND EXECUTION ..............................................................8-1
SENDING INFORMATION ONE-WAY VIA COMMANDS THROUGH SENTINEL
C28 .........................................................................................................................................8-6
REQUESTING INFORMATION TO BE SENT USING TWO-WAY
COMMUNICATION .............................................................................................................8-6
CHAPTER 9 DOWNLOADED REPORTS ..............................................................9-1
INSTRUMENT CONFIGURATION ....................................................................................9-1
STATION CONFIGURATION.............................................................................................9-2
PRESSURE STREAMING ...................................................................................................9-2
TERMINAL TEST RESULTS OUTPUT AFTER EACH TEST .........................................9-5
FIXED WIDTH TEST RESULTS OUTPUT AFTER EACH TEST ....................................9-5
PART RESULTS ONLY AFTER EACH TEST ...................................................................9-6
FIRST 2 TEST RESULTS .....................................................................................................9-6
ALL RESULT INFORMATION ...........................................................................................9-7
STATION COUNTERS ........................................................................................................9-7
CHAPTER 10 TEST DATA .................................................................................... 10-1
COUNTER INFORMATION ..............................................................................................10-1
TEST RESULTS ..................................................................................................................10-2
STATISTICAL INFORMATION .......................................................................................10-3
Rev 11/18/08
CHAPTER 11 DIGITAL INPUTS AND OUTPUTS ................................................. 11-1
UNIVERSAL DIGITAL INPUT FUNCTIONS .................................................................11-1
PART PROGRAM SPECIFIC DIGITAL INPUTS ............................................................11-4
DIGITAL OUTPUT FUNCTIONS .....................................................................................11-6
CHAPTER 12 PREVENTIVE MAINTENANCE ...................................................... 12-1
PERIODIC MAINTENANCE .............................................................................................12-1
UPLOADING PROGRAM FIRMWARE ...........................................................................12-1
CALIBRATED LEAK STANDARD CERTIFICATION...................................................12-2
SPARE PARTS....................................................................................................................12-3
SERVICES ...........................................................................................................................12-4
CHAPTER 13 TEST MESSAGES .......................................................................... 13-1
CALIBRATION ROUTINE MESSAGES ..........................................................................13-1
SELF TEST MESSAGES ....................................................................................................13-2
TRANSDUCER ERRORS ..................................................................................................13-3
PART PROGRAM ERRORS ..............................................................................................13-3
PART PRESENCE ..............................................................................................................13-3
TOOLING ERRORS ...........................................................................................................13-4
TEST AND ERROR MESSAGES ......................................................................................13-5
CHAPTER 14 SPECIFICATIONS .......................................................................... 14-1
CHAPTER 15 OPTIMIZING THE TEST PERFORMANCE..................................... 15-1
CHAPTER 16 WARRANTY-SENTINEL INSTRUMENTS ...................................... 16-1
CHAPTER 17 GLOSSARY .................................................................................... 17-1
CHAPTER 18 INDEX ............................................................................................. 18-1
Rev 11/18/08
CHAPTER 1 INTRODUCTION
You made an excellent decision to buy this instrument! You now own the new Sentinel C28 high
performance, leak test instrument. This instrument incorporates the latest in high-resolution
analog-to-digital conversion, signal processing, Automatic Setup, 32-bit microprocessor
technology, Automatic Calibration, Quik fill-and-Test capability, easy-operator interface, and
comprehensive communication. The economics and compact packaging of these new instruments
make them ideal and affordable solutions to many assembly verification applications. The
convenient communication capabilities including TCP/IP (Ethernet) and RS232 make the
communication interface of these instruments into the factory information system easier with no
extra engineering time.
QUICK START
Step One:
Mount Instrument
Position the instrument above the part test fixture to minimize dirt and moisture
exhausting through the instrument.
Locate the instrument close to the test fixture to minimize test volume.
Mount the wall-mount instrument to framing or a panel using the four internal bolt
channels.(same bolt pattern as the Sentinel C-20 instrument). Allow sufficient clearance
to the enclosure for the supply connections and test ports and access to the inside for
maintenance.
Step Two:
Connect Supply Air (250-psig max for under 200 psi tests)
The air supply input connections are for test supply pressure (or vacuum) and pilot air
pressure. Connect an independent 65-110 psig supply to the pilot supply port.
Good leak tests and long instrument life depend on a clean, dry air supply. If you did not
purchase in-line air filters with your instrument, be sure to install 5.0 and 0.3-micron
filters at the input supply manifold. (See pages 1-10 and 1-11 for more information.)
Internal test regulators control the test pressure or vacuum, but it is also recommended to
regulate the air supply to the instrument at 10 psi greater than the highest test pressure for
optimal performance.
Step Three:
Power up Instrument
An electrical power cord is attached to the top, right side of the Sentinel C28 wall-
mounted enclosure.
Check the instrument label on the right side of the instrument to verify the Supply
Voltage for the instrument.
For 120 VAC, 50-60 Hz instruments plug the power cord into a standard 3-prong wall
socket (in the US and Canada). See pages 1-12 and 1-13 for more details.
For 220 VAC (50-60Hz) instruments this power cord has no three-prong plug on the end
so wire directly to power source using Line (black), neutral (white) and ground (green).
See page 11-12 for more details.
For 24VDC instruments this power cord has no three-prong plug on the end so wire
directly to power source using +V (white), V (black) and ground (green). See page 11-
13 for more details.
Rev 11/18/08 1-1

Operate the power switch on the top center of the wall-mounted enclosure to turn on the
Sentinel C28 instrument. (The power switch is a rocker style switch. The On and Off
markings on the power switch are marked as "I" and "O" respectively.)
Step Four:
Setup wiring via extension I/O cable from external I/O connector located on top of the enclosure
in the back left corner for 24 VDC or 120 VAC (50-60 Hz). Check the instrument label on the
right side of the instrument to verify the correct I/O Voltage. There is a resistor across the 24
VDC pins for 24 VDC I/O or a resistor across the 120 VAC pins for 120 VAC. Also there are
three capacitors on the circuit board above the output relays for 120VAC instruments. See Figure
150 for details.
Study the digital input and output requirements and assign to the available 6 inputs and 3
outputs. (See pages 1-14 through 1-16 for more details).
Step Five:
Auto Setup
Follow the operator prompted routine to set up the instrument to perform a basic leak test on the
test part. Auto Setup will automatically determine the best test sequence to meet the required
maximum cycle time for pressure decay leak rate tests only. Auto Setup does not function for
Pressure drop, Rate of change, or Occlusion tests. It does not establish the I/O functions.
Press AUTO SETUP on the Function panel
Press the EDIT key and use the up or down arrow keys to select the desired Test Type
to perform the desired test like 1P-Press Decay. Then press ENTER
Press the down arrow key, EDIT, and then enter the desired part number using the
up/down and left/right arrow keys for Apply to Part # (select part number 01-32).
Press ENTER and AUTO SETUP or right arrow to advance to the next screen.
Using the same method, edit the appropriate units of measurement for test pressure, leak
rate, pressure loss during test cycle, and timers. Press ENTER and AUTO SETUP or
right arrow key. (Take note of the differences for setting vacuum values when using psig
vs psiv pressure units see page 2-9.)
Edit the Desired Cycle Time (maximum total cycle time), Target Pressure (specified test
pressure), Leak Std Value (for leak standard mounted on test manifold), Leak Std
Pressure (Pressure at which leak standard was calibrated), Hi Lim Leak (high limit reject
point for test), and Cal method.
Edit Start AutoSetup for Yes and push ENTER.
Follow the instructions on the screen. The process will give you an opportunity to adjust
the manual regulator pressure to match the Target pressure by pressing ENTER to OK
this next step
Step Six:
Set Test Pressure
Connect the plug (Self Test Plug) attached to the chain on the bottom of the instrument
into the port on bottom right side. Adjust the regulator so the Instrument pressure
equals the desired Target test Pressure.
Step Seven:
Connect your test part
Use high quality tubing, swaged fittings, and the supplied Quick Connect fitting to
interconnect a Master (Non-leaking) part to the instrument.
Rev 11/18/08 1-2

Connect the Quick Connect fitting to Leak Test Port located on the bottom right side of
the wall mounted instrument.
Step Eight:
Proceed with the AutoSetup Routine:
The instrument will conduct an automatic tuning process on a master part for pressure
decay tests by performing a sequence of tests to determine the appropriate timer values
within the Desired Cycle Time.
The AUTO Setup will automatically set the optimal pre-fill, fill, stabilization, test,
exhaust, and relax times; Leak Std flow and pressure; and Target pressure and Min and
Max Test Pressure into the selected Part # to achieve the best possible test on the tested
part within the Desired Cycle Time.
At the completion of the Auto Setup routine the display will prompt for an Auto Calib
routine.
Step Nine:
AutoCal
The instrument will automatically determine the pressure loss to leak rate relationship for the test
part based on the timer values set by the Auto Setup routine.
Agree to perform the AUTO CALIB function.
At the completion of a successful Auto Cal routine, the instrument display will indicate a
calculated PF (Performance Factor). In general, values greater than 35 and up to 99
indicate an acceptable calibration for reasonably repeatable testing. What value results in
an acceptably repeatable test is very application dependent and does not apply to all parts.
Further testing is required to determine if these parameters will result in acceptable
repeatability. Higher values (which require longer Desired Cycle Time) will generally
predict more repeatable performance.
The instrument is ready for testing upon completion of AUTO CALIB routine.
Setup within Part Configuration any additional test parameters like Tooling Control,
Digital Input functions, and Digital Output functions.
Rev 11/18/08 1-3

INSTRUMENT FEATURES
Test status lights (In Test, accept, reject)
480 x 272 pixel graphic display
Display panel Power on-off switch
Functions panel
Source
air/vacuum and
pilot air ports
Exhaust muffler
Self Test plug
Regulator adjustment knob Test port quick connect fittings RS232 port (9 pin)
Figure 1 Overview of Sentinel C28 wall mounted instrument
Rev 11/18/08 1-4

INTERNAL INSTRUMENT LAYOUT
Digital Input/Output terminals Transducer terminals

Test valve terminals Pre-wired input/output connector
Main instrument circuit board TCP/IP connection Regulator Pressure Transducer

Leak Standard
Figure 2 Internal layout of the Sentinel C28 instrument
UNPACKING
Carefully remove the instrument from the shipping carton. Locate the quick connect fitting
supplied with the instrument. The fitting is provided for your test line connection. Open the
instrument and inspect for damage before progressing any further. Make certain that all cables
are securely attached to the appropriate connectors.
Figure 3 Quick connect test fitting
Rev 11/18/08 1-5

VERIFICATION OF PROPER INSTRUMENT SPECIFICATION
Before installing the instrument verify that the instrument supplied matches the application
specification. On the right side of the wall-mounted enclosure is an identification label with
the catalog number of the instrument. Below is a breakdown of the catalog number.
i.e. Sentinel C28-1W3BE-PA11A4-P02U10A1
Enclosure Construction
(i.e. 1 W 3 B E)
Pneumatic Connection
(1) NPTF
Instrument Mounting Option
(W) Wall
Power supply
(1) 120 VAC (2) 24 VDC (3) 240 VAC
Digital I/O
(A) Six Inputs/Three Outputs 120 VAC
(B) Six Inputs/Three Outputs 24 VDC
Keypad Language
(C) Chinese
(E) English
Pneumatic Test Manifold

i.e. -P A11 A4
Test Capability
(P) Pressure Decay, Pressure Drop, Rate of Change and
Occlusion Testing
Pneumatic Manifold Types
(A11) Standard Flow valves for Pressure testing (Std Cv)
(A31) Standard Flow valves for Vacuum testing (Std Cv)
(B11) High Flow valves for Pressure testing (Hi Cv)
(N11) Low Volume manifold (<100 psi)
Pressure Package
(A1) Vacuum
(A2) 0.5-2.0 psig
(A4) 2-30 psig
(A5) 2-100 psig
(A6) 2-200 psig
Rev 11/18/08 1-6

Transducers and Test Fittings

i.e. P02 U10 A1
Pressure Transducer
(P01) Absolute 20 psia
Second Transducer
(U10) No transducer
Test Port Fitting
(A1) 1/4 NPTF (for Manifold types A and B)
(A2) 1/8 NPTF (for Manifold type N)
INSTALLATION
The Sentinel C28 leak test instrument is a modular, flexible instrument designed to operate in a
factory environment or in a clean room. To operate trouble-free, it requires:
Clean, dry instrument air for test and pilot air

Vacuum for vacuum test applications
120 or 240 VAC electrical power or 24 VDC electrical power for the instrument
120 VAC or 24 VDC electrical power for the inputs and outputs
Because this is a precision instrument, it is preferable to locate this instrument at least 15 feet
away from high electromagnetic energy devices (induction heat treat equipment and welders)
whenever possible. In addition, plants having poor quality electrical power or ground systems
should consider using isolation transformers on the power drops.
In addition, the wiring for the digital inputs and outputs must be isolated and protected from
electrical noise.
Rev 11/18/08 1-7

MOUNTING CONSIDERATIONS
The Sentinel C28 instruments provide the best test results when located as close as possible to the
test parts. This will minimize the volume in the test pneumatics thereby reducing the total test
time requirements. Mount the Sentinel instrument above the test part to minimize the amount of
dirt and moisture that might migrate back into the instrument during the exhaust cycle.
Mount the wall-mounted, Nema 12 enclosure to a frame or panel. Insert the mounting bolts
through the four channels located on each interior corner of the enclosure. The bolt pattern for
the Sentinel C-28 enclosure matches the mounting bolt pattern of the Sentinel C-20 enclosure.
Select a mounting location that gives access to the bottom, top, left, and front of the enclosure.
Do not forget to allow room for the door swing. See Figures 5 for the mounting dimensions for
the unit supplied.
Mounting bolt channel
Figure 4 Sentinel C28 Mounting Bolt Channels
Rev 11/18/08 1-8

Power Entry (three conductor cable Top View

through strain relief)
Power Switch
I/O Connector
Pilot air source inlet
Exhaust muffler
Test air source inlet
Knock out for conduit
17 (435 mm) Lid opening

7.24 (183.9mm) 10.9 (277.3mm)
8.696 (220.9mm)
Test Port
Left Side View Test Port Fitting
Self Test Cap
and Holder Allow 4 (102 mm) clearance
for installation of test line and
7.087 (180.1mm) hand clearance
3.66 Mounting holes

(92.99mm) For or 6 mm
socket head cap
screws
Mechanical
Bottom view Regulator Knob
Rear View for Mounting Dimensions
Figure 5 Sentinel C28 Dimensional diagram
Rev 11/18/08 1-9

PLUMBING RECOMMENDATIONS
This leak test instrument needs clean, dry air in order to provide trouble-free operation. Good
plumbing practices will greatly enhance the quality of the test air.
Regulate the air supply for the test pressure circuits to at least 10 psi greater than the maximum
test pressure at all times while testing. For optimal test results, install an external regulator to
maintain a steady 10 psi greater pressure to the instrument.
For vacuum tests, connect a vacuum source to one of the inlet ports located on the left side of the
enclosure identified for vacuum. The vacuum source must be greater than the vacuum required
for the leak test.
A separate air supply to the pilot port must be between 65 to 110 psig at all times for the
instrument to operate properly.
See Figure 6 below for Plant plumbing recommendations.
Sentinel C28
Test Pressure/
Vacuum
Pilot
5.0 Micron 0.3 Micron Pressure
Coalescing Coalescing 65 psi
Shutoff
Filter Filter
Valve
Drip
Leg
Automatic
Drain SENTINEL-FILTER SET-SMALL
SENTINEL-FILTER SET-MEDIUM
SENTINEL-FILTER SET-LARGE
(Small<300cc Part, Large>3000 cc Part
Figure 6 Plant Plumbing Recommendations
Rev 11/18/08 1-10

PNEUMATIC CONNECTIONS
There is one test air (vacuum) supply inlet port (S1) and one pilot-air inlet port on the left side of
the Sentinel C28 enclosure. The supply inlet port is 1/4" FNPT and the pilot-air port is 1/8"
FNPT. After mounting or locating the instrument, connect the inlet air or vacuum supply to the
inlet port shown in Figure 7. To reduce future maintenance requirements use the recommended
plumbing detailed in Figure 6 Plant Plumbing Recommendations and utilize the 0.3 and 5.0-
micron coalescing filters. Be certain to replace the filter elements at least quarterly as preventive
maintenance.
The pneumatic test manifold connects to the exhaust manifold internally according on the
pressure/vacuum requirements. The pilot air uses 1/8" yellow tubing. The pressure supply line is
1/4" or 3/8" green tubing. Vacuum supply line is 1/4" or 3/8" green tubing. Exhaust line is 1/4"
or 3/8" clear tubing. Internal tubing between the test station regulator and the manifold
connection is either 1/4" or 3/8" red tubing. 3/8" tubing is used for the supply interconnection
and exhaust connection for the high flow manifold.
Supply Connections
Pilot
Supply port 1
Exhaust muffler
Self Test plug
Figure 7 Inlet Air supply connection
Interior Air Supply

Connections
Air supply (green tubing)

Pilot air (yellow tubing)
Exhaust air
Figure 8 View of air (vacuum) supply and exhaust pneumatic connections for Sentinel C28
instrument located on the left inside of the enclosure
Rev 11/18/08 1-11

Located out the bottom of the enclosure is the quick-connect test port fitting. Use flexible tubing
to connect to the mating male quick connect fitting (supplied 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" or 1/8" 2000 lbs tubing with Parker CPI or
Swagelok fittings to provide rugged flexibility and eliminate any volumetric change within the
tubing during test. Properly tighten these fittings to assure leak-free connections. Typical push-
lock fittings are not appropriate for test lines because they can leak. They are acceptable
for use on the supply side of the test manifold only.
The quick connect SELF TEST plug attached to the bottom of the enclosure is supplied so the
operator can manually disconnect the test line and easily attach the quick connect plug for the
SELF TEST function. The SELF TEST function is a standard feature to make it easy to verify
the instrument's internal leak integrity.
Do not tighten the female quick connect fitting into the pneumatic block. Tightening
the fitting may crack the pneumatic block and void the warranty.
Regulator knob
Self test plug and holder
Test port
Figure 9 Bottom view of Sentinel C28 vacuum instrument
ELECTRICAL CONNECTIONS
WARNING: DISCONNECT POWER BEFORE OPENING ENCLOSURE TO WORK
ON ELECTRONICS.
The electrical supply connections for 120 VAC or 240 VAC (50-60 HZ) or 24 VDC are made
through a pre-wired electrical cable supplied with each instrument. The AC Line (black) or DC
V+(white) wire is terminated to the power switch. The AC Neutral (white) or DC V- (black)
wire is terminated to the power supply terminal or power terminal of circuit board. The ground
wire (green) is terminated to the grounding stud located in the upper left corner of the enclosure.
The separately powered digital input/outputs are pre-wired to a connector on the top of the
instrument enclosure. The external supplied 120 VAC or 24 VDC power for the inputs and
outputs are wired to ION (neutral or common) and IOH (hot) on the ST1 terminal of the main
circuit board. For the 120 VAC digital I/O circuit board, there are three red mobs located to the
right of the I/O fuse. See Figure 10 below. For the 24 VDC digital I/O circuit board, there are no
mobs in this position.
Rev 11/18/08 1-12

24V supply terminals

+24V (Clear) Digital input terminals
Common (Black) Digital output terminals
Ground (Shield) Test valve terminals
(3) red mobs for 120 VAC

I/O (the red mobs do not
exist for 24VDC I/O)
Figure 10 Power input 24VDC, digital input/output, and test valve terminals
Power On/Off Switch

Digital Input/Output connector
Power supply for 120/220 VAC models
Not used
Common (black)
24V+ (Clear)
Ground (Shield)
Neutral AC (White)
Line AC (Black)
Figure 11 120/220 VAC to 24VDC Power supply (AC powered instruments only)
There is a connector for the digital input/outputs and a power cord for the source power on the top
of the enclosure. The power On/Off switch is located in the center back on the top of the
enclosure.
Access hole
Source power cable
Power on-off switch
Digital Input and Output connector
Figure 12 Power supply cable, power switch, digital I/O connector and access hole
Rev 11/18/08 1-13

The input/output interface wiring connections for the Sentinel C28 are made via the connector on
the top of the instrument enclosure. This connector includes 6 inputs, 3 outputs, voltage source,
and common. An optional I/O cable interfaces this connector to the input/output devices and I/O
power supply. Before wiring this input and output cable, define and layout all the inputs and
outputs required by all the tests planned for this instrument. Make sure that there are sufficient
inputs (6) and outputs (3) for the test requirements. See definitions for the inputs and outputs in
Chapter 5, Part Configuration and Chapter 11, Digital Inputs and Outputs. The power supply for
the Inputs and Outputs is independent of the instrument power. A separate 120 VAC or 24
VDC supply needs to be wired to the I/O interface cable for the inputs and outputs. Check
the instrument label on the right side of the instrument to verify the voltage for the digital
I/O and instrument supply power. Also check the controller board to verify the presence
(for 120 VAC I/O) or absence (24 VDC I/O) for three red mobs (see Figure 10 above).
The available input functions are listed below. Review the list and check the inputs
required. Make sure that only 6 inputs are checked.
Digital Input function

____ Start station
____ Start Part
____ Stop/reset Station
____ Hold
____ Vent/Halt
____ AutoCal
____ Open Leak Std
____ Part Present
____ SPC Test Part
____ Part Select B1 (part programs 1)
____ Part Select B2 (part programs 2-3)
____ Ext. Pressure switch within fill sequence
The available output functions are listed below. Review the list and check the outputs
required. Make sure that only 3 outputs are checked.
Digital Output function

____ Test Lamp
____ Malfunction
____ Tooling Extend output motion 1
____ In relax
____ Auto Cal mode
____ Auto Cal master
____ Auto Cal LS
____ Press Select (In testing cycle)
____ In Prefill
____ In Fill
____ In Stabilize
____ In Test
____ In Exhaust
____ Test Passed
Rev 11/18/08 1-14

____ Test Failed

____ Below Lo Lim
____ Between Limits
____ Above Hi Lim
____ Part Accept
____ Part Reject
____ Severe Leak
____ Tooling Retract output motion 1
Input I/O power terminals (ST1)
ION (Black)
IOH (Red)
Digital inputs terminals (ST2)
IN6 (White)
IN5 (Orange)
IN4 (Yellow)
IN3 (Pink)
IN2 (Violet)
IN1 (Red/Blue)
Digital output terminals (ST3)
OT3 (Brown)
OT2 (Green)
OT1 (Tan)
I/O Fuse 2.5 amp
Figure 13 Pre-wired Input/Output terminations
Digital Input/Output wiring

Inputs (ST2) Instrument Connector Cable Connector Wire pigtail
Pin 1 IN1 Red/Blue-----------Pin C----- -------Pin C--------------Red/Blue
Pin 2 IN2 Violet---------------Pin O----- -------Pin O--------------Violet
Pin 3 IN3 Pink-----------------Pin G----- -------Pin G--------------Pink
Pin 4 IN4 Yellow--------------Pin T----- -------Pin T--------------Yellow
Pin 5 IN5 Orange--------------Pin M---- -------Pin M--------------Orange
Pin 6 IN6 White----------------Pin P----- -------Pin P--------------White
Outputs (ST3)
Pin1 OT1 Tan------------------Pin U---- -------Pin U--------------Tan
Pin 2 OT2 Green---------------Pin J----- --------Pin J---------------Green
Pin 3 OT3 Brown--------------Pin A---- -------Pin A--------------Brown
I/O Power (ST1)

Pin 1 IOH Red----------------Pin R---- --------Pin R-------------Red
Pin 2 ION Black--------------Pin E---- --------Pin E-------------Black
Pin N(gray/brown), Pin S (gray), and Pin L (blue) are not used.
Figure 14 Digital input/output wiring to instrument connector and I/O cable
Rev 11/18/08 1-15

The input and output terminals on the circuit board are pre-wired to the I/O connector mounted on
the top of the enclosure in the back right corner. See Figure 14 for pin designations for the 6
inputs, 3 outputs, common, and power. Use the diagram to wire the required inputs and outputs.
Note the terminal numbers and functions for each input and output. The use of these inputs and
outputs are programmed within each part program. This gives excellent flexibility to the use of
this instrument for a variety of applications. Within the Part Config menus (Tooling, Inputs, and
Outputs) individually select the functions of the pre-wired inputs and outputs required by each
part program. The inputs and outputs apply to either all or selected part programs based on their
functionality and how each part is programmed. See the setup procedure of the input and output
terminals in the Chapter 5, Part Configuration section, Inputs, Outputs, and Tooling screens. The
programming of the input and output functions in the Part Configuration menu must match the
wiring connections of the installation. For additional information about interfacing to remote
devices and/or a PLC, please refer to Chapter 5 and Chapter 11.
Refer to Part Configuration (see pages 5-14 to 5-23), digital input and output screens, to assign
the use of the input and output functions per the wiring terminations to the individual part
programs. Record the wiring of each terminal for reference when programming the inputs and
outputs in the Part Configuration section discussed in Chapter 5.
INPUT/OUTPUT TERMINAL TABLE
Terminal Inputs terminals There are six inputs and three outputs wired
to the multi-pin connector mounted on the top
1 ______________________________________
of the instrument. These I/O terminals are
2 ______________________________________
specified as either 24VDC or 120 VAC. On
3 _______________________________________
the lower right corner of the circuit board, a
4 resistor is soldered on either the 24 VDC or
_______________________________________
5 120 VAC pins. This defines the voltage of
_______________________________________
the source for the I/O. Refer to Part
6 _______________________________________
Configuration (Chapter 5) for the setup of the
input and output terminals. The power
Output terminals supply for the Inputs and Outputs is
1 independent of the instrument power.
_______________________________________
2 Wire a separate 120 VAC or 24 VDC
_______________________________________
supply via the power and common leads of
3 _______________________________________
the I/O connector.
Log the wiring for inputs and outputs for use during PART CONFIGURATION, Chapter
5, page 5-14 and 5-23.
Rev 11/18/08 1-16

ADDITIONAL ACCESSORIES
Helpful accessories that are available to provide additional capabilities to the instrument include:
* 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
pressure decay and mass flow instruments. Filtering dirt and water from the source air
eliminates many maintenance problems.
* Leak standard (spare or remote)
* External three-way test valve to test two parts
Pressure/vacuum gage
(calibrate or check
pressure readings)
USB Flash memory chip
Input/Output Cable 6 meters (14 pin connector)
14pin I/O Cable
Rev 11/18/08 1-17

CHAPTER 2 INSTRUMENT OVERVIEW

The Sentinel C28 instruments are compact, state-of-the-art leak test units, that will verify the
manufactured integrity of your products. The software is multi-tasking so it performs several
tasks at the same time. Therefore, the Display functions can be reviewed without interfering with
the testing functions. Part calibration and instrument setup functions directly associated with the
testing process are not editable during testing because they change the fundamental way the
system works. Attempting to use a conflicting function causes the Edit Not Allowed message
to appear. Non-test menus like communication can be edited while the instrument is testing.
POWER ON
After mounting the instrument, assuring proper electrical connections, and checking the air and/or
vacuum connections, you are ready to power up the instrument. The on-off switch is located on
the top of the instrument in the front center for the wall-mounted enclosure.
Figure 15 Power-on screen
After the Sentinel C28 instrument completes its internal checks and displays the Power-on screen
for about 3 seconds, the display advances to the Monitor screen. The contents of the Monitor
screen vary depending upon the configuration of the Sentinel instrument. The following display
is representative:
Rev 11/18/08 2-1

Figure 16 Initial Monitor screen
From the initial Monitor screen, view other screens by using the keys on the display panel.
For more information about setting up the Sentinel system, see CHAPTER 4, INSTRUMENT
CONFIGURATION, and CHAPTER 5, PART CONFIGURATION.
OPERATOR DISPLAYS
The Sentinel C28 Control Panel accesses the features of the firmware. For an example of a
typical test result display, see Figure 17 below.
Figure 17 Test Result Screen
NAVIGATING INSTRUMENT DISPLAYS

The display screens are organized for easy access and viewing of information. At the top is the
Screen Title. The center of the screen displays the body of information or parameters for editing.
In the lower right of the screen is the Part program number currently active for testing.
The Sentinel C28 user selects the information to display or functions to perform by pressing one
of the keys in the Display or Function panels located below the LCD Display.
DISPLAY AND FUNCTION PANELS

The DISPLAY and FUNCTION Panels give the operator convenient access to review or change
the test information stored in the instrument, perform various functions, and verify instrument
performance. (Access to change the stored information can be protected by a security password.
The selection of what information is protected by password is programmed within the "INSTR
CONFIG" function.)
Rev 11/18/08 2-2

Figure 18 Display and Function keypads
By pressing one of these keys, the following type of display appears.

Next screen within
Previous screen within Current
Display/Function Display/Function menu
Display/Function Active
menu name or Part accessed by pushing
menu accessed by screen of
name Key or the Display or
pushing Key variables
Function key.
Indicator
Settable
of screen
parameters
with arrow
position
indicating within
selected function
variable.
Indicator of
position
Potential system within
error messages available
Current active variables of
Open Leak Security lock part program current
Std Symbol or unlocked active
screen(s)
Figure 19 Typical display format
Editing Keys
Figure 20 Data entry keypad with Edit/Enter/Exit/Arrow keys
Rev 11/18/08 2-3

NAVIGATION KEYS
UP and DOWN arrow buttons move the display pointer up or down the screen to select a new
parameter for change. When in the edit mode, these keys scroll through available Yes or No
choices or option selections. When in the edit mode for a numeric character string like a timer,
pressure, or leak value, the up and down arrow keys sequence through the numeric character
library for each character.
1234567890
For an alphanumeric character string like a part name, email address, or instrument name, the
up and down arrow keys sequence through the alphanumeric character library for each character.
abcdefghijklmnopqrstuvwxyzABCDEFGHIJKLMNOPQRSTUVWXYZ @.;( )-+1234567890
After a momentary delay between keystrokes the curser automatically advances to the right for
the next new character in the numeric or alphanumeric variable being entered.
The Left and Right arrow buttons advance the selection of the functions within one of the
Display or Functions menus. When editing an alphanumeric display, these keys move the
position curser left or right within the line of characters being edited. Also when in the edit
mode, these keys scroll through available Yes or No choices or option selections.
EDIT
EDIT selects the information line indicated by the pointer on the display for change. After
pushing EDIT, the UP / DOWN and LEFT/RIGHT keys are used to choose new variables. Push
Edit key after making changes to save the highlighted variables and move down to the next row
where there are additional items to change or select.
(Pushing EDIT may initiate the password display if security is set and the value is editable.
Enter the correct password using the Up/Down and Left/Right keys and then push ENTER..)
Rev 11/18/08 2-4

ENTER
ENTER key stores the changes made to test parameters, Yes or No toggled choices, or
programmed choices into memory and escapes the edit mode. In order to leave a Display
screen and store the parameters as they appear on the screen, you must push ENTER.
You cannot escape a screen to another display function while in the edit mode.
EXIT
EXIT returns the highlighted line back to its original setting and escapes the edit mode. If
changes were made on the highlighted line, those changes are lost.
Moving from one display function to another and changing values or settings.
To sequence through the displays of information within each area, push the desired Display panel
key repeatedly. To change a parameter, push the EDIT key until the pointer is next to the item to
change. After making the change push EDIT to save the new information and advance to another
parameter on that screen or advance to the next screen within the function set. Push ENTER to
store the changed data on the edited line and exit the edit mode. The EXIT button will return the
edited line back to its original value and exit the edit mode. Push the Display panel key or left or
right arrow keys to go back or forward through the variable screens indicated on the top row of
the screen. If these keys are pushed while in the Edit mode, the instrument will not advance to
the next screen until Enter or Exit is pushed. If it does change screens, changes to the highlighted
line will not be saved.
To review parameters in another "Display" function, simply press the key for the display function
with the desired parameter. You must be out of the Edit mode to change Display screens. If in
the edit mode when the Display key is pushed, the highlighted line will return back to its original
setting and the instrument exits the edit mode. The Display key will need to be pushed again. To
exit any display function, push the MONITOR key.
Displays Are Part Program Specific
All functions or parameters for Part Configuration, Monitor, and Test Data are specific to the
selected part program. The selected part program number appears in the lower right corner of
each screen.
Rev 11/18/08 2-5

DISPLAY PANEL
The DISPLAY Panel is laid out to give the operator convenient access to review or change the
test information stored in the instrument or verify instrument performance. (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 INSTR CONFIG function, security.
Figure 21 Display Panel
The basic instrument software performs the following types of tasks:
Leak/Flow test operation (MONITOR) Automatic Test Setup (AUTO SETUP)

Display of the sequence of the test Input for initial max time cycle, leak
operation rates, test pressures
Display Real-time test data and bar graph Set regulator pressure for test
representation of active test Determine optimal timers within max
Display the operation of the digital inputs time cycle for the specified reject leak
and outputs including tooling motions if rate based by a series of controlled tests
programmed. on master part.
Test Data Information Display (TEST Part Calibration (AUTO CAL)
DATA)
Counters Automatic test calibration sequence
Historical Test Data determines pressure loss (or flow) to
Test Statistics leak rate relationship for test part and
Master part offset value.
Self test (SELF TEST) Help functions (HELP)
Station self leak test Explanation of screen variables in:
Set regulator pressure o Part Configuration
Transducer calibration o Instrument Configuration
Open orifice valve for calibration o Error messages
verification o Test data and Statistics
Rev 11/18/08 2-6

INSTRUMENT CONFIGURATION (INSTR CONFIG)

Instrument Configuration Communication with Ethernet and RS232
Test manifold, transducer, and Communicates the following
regulator setup information
Number of part programs to use Test results, each test
Communication setup and operation Test results, historical
for RS232 and TCP/IP Part setup configuration
Instrument name and serial number Instrument setup configuration
Date/Time Station setup configuration
Security Calibration information
Software configuration and versions Counter
Software update setup Statistics
Test data streaming (RS232 only)
Part Configuration (PART CONFIG)

Test type
Timers
Test Pressure settings
Test parameters for leak rate, pressure, Quik Test, and/or
performance factors for the specified test type
Calibration parameters
Part name, Part program copy, AutoRun
Units of time, pressure, and flow/leak rate
Digital Inputs for part program requirement
Digital outputs for part program requirement
Tooling control configuration
Figure 22 Display and Function Menu Functions
The instruments test manifold, transducers, and regulators are setup for general
operation at Cincinnati Test Systems before shipment. To change the setup, refer to the
appropriate chapters:
CHAPTER 3, AUTO SETUP AND AUTO CAL

CHAPTER 4, INSTRUMENT CONFIGURATION AND COMMUNICATION
CHAPTER 5, PART CONFIGURATION - change test parameters for individual parts
Rev 11/18/08 2-7

MONITOR
MONITOR key displays the active status of the part test or test results and the functioning of the
digital inputs and outputs.
Figure 23 Monitor display during stabilization segment of testing cycle
The monitor displays the following information during test and upon completion of test:
Part Name and part program number
Bar graph of pressure or pressure loss verses limits
Test sequence
Remaining test sequence time
Test pressure during fill and stabilization sequences
Test Pressure and Pressure Loss or Rate of loss values during test cycle
Calculated leak rate or rate of loss after test
Corrected Pressure loss after test
Pass/Fail test result and test type for each test
Accept/Reject part result at the completion of tests
Test Result Display
Figure 24 Test result screen
Rev 11/18/08 2-8

Pressure/Vacuum Settings and Displays
Vacuum pressure settings and values are entered and displayed as positive vacuum pressure
values (psiv) or negative pressure values (psig) measured from atmospheric pressure. Therefore,
2.0 psiv or 2.0 psig represents a vacuum setting of 12.7 psia (Atmospheric pressure is 14.7 psi
absolute so 14.7 psia minus 2.0 psiv is 12.7 psia). The bar display shown in Figure 23 Monitor
display will extend to the right as vacuum is applied to the part. If the part under test has a leak
or loses vacuum, the bar graph will retreat to the left.
Positive pressure tests (psig) will be displayed similarly. The bar display shown in Figure 23,
will extend to the right as the test pressure increases. If the part under test has a leak or losses
pressure, the bar graph will retreat to the left.
Both pressure and vacuum tests will display positive numbers for loss when the pressure units
during test are set for psig and the vacuum test units are set for psiv.
The bar graph displays the actual pressure (or vacuum) during the fill and stabilization cycle
verses the Min and Max pressure limits. This gives a quick visual indication of how the charge
and stabilization cycles are performing verses the pressure limits.
Min Max
During the test segment, the bar graph displays the pressure loss or pressure loss/time verses the
Lo Lim and Hi Lim set points. The Lo Lim set point is on the right side and the Hi Lim is on
the left side. This arrangement applies to pressure decay, Pressure loss, or Pressure loss/time
tests. For Occlusion tests, the Low Limit Pressure is also displayed on the right and High Limit
Pressure on the left. For Occlusion tests Low Limit Pressure represents low back pressure or
the high flow limit and the High Limit Pressure represents high back pressure or the low flow
limit. The test evaluation setting is always set as FPF as indicated below. Only the results
between the high and low limits are accepted or passed.
Hi Lim Lo Lim
F P F
Rev 11/18/08 2-9

View the Digital Inputs by pressing the MONITOR key twice. Pressing the Monitor key again
will access the Digital Output screen.
Figure 25 Digital Input, Monitor screen
Digital Input, Monitor screen is a typical display for the Digital Inputs and Digital Outputs.
The available 6 inputs or 3 outputs are displayed with terminal numbers only. The plus sign (+)
appears to the left of the terminal number when that digital output is activated or an input signal
goes high. These displays make it easy to view the function of the instrument for troubleshooting
purposes. When interfacing the instrument with a PLC or tooling control, the instrument can step
through the test sequence using the HOLD button to interrupt the sequence at various stages of
the test to verify that the digital inputs and outputs are activating appropriately.
PART CONFIG
Figure 26 Initial Part Configuration setup screen
Rev 11/18/08 2-10

PART CONFIG key accesses the following information on the selected part program:
Test type select from available test methods.
Timers set and review timers for test cycle
Pressure values set and review target pressure setting
Test Parameters set and review leak test and leak standard specifications
Part test calibration parameters review part calibration parameters
Miscellaneous functions set/ review part name, AutoCal method, and Auto Run feature
Units of measurement set/review measurement units of time, pressure, and leak rate for
part testing
Digital Input/Output terminal configuration set/review inputs and outputs used by part
program
Tooling Control set/review how tooling control operates for testing
See Chapter 5 for details about the Part Configuration functions
INSTR CONFIG
Figure 27 Initial Instrument Configuration Setup screen
INSTR CONFIG key provides access to instrument setup and communication functions.
Test Manifold factory set to indicate pneumatic manifold supplied

Number of part programs sets limit for number of part programs accessible for
programming and testing (max 32). Reduces the number of times the CHANGE PART key
needs to be pressed before scrolling back to part number one. (Select desired part number
directly by holding CHANGE PART key for 2 seconds and entering desired part number
via Up/Down and Left/Right arrow keys.)
Transducer ranges and regulator type factory set to indicate transducers and regulator
supplied
RS232 Communication set communication interface and request download of available
information
TCP/IP Communication function set IP, server, and gateway addresses
TCP/IP Communication control - request download of available information
Rev 11/18/08 2-11

USB Flash Update request firmware update with flash (thumb) drive
Miscellaneous set instrument name and review serial number, set and review instrument
time and date settings
Security set and review security configuration
Screen Saver setup set and review method for screen saver
Firmware version documentation review instrument firmware versions
For details of the Instrument Configuration function, see CHAPTER 4, INSTRUMENT

CONFIGURATION AND COMMUNICATION.
TEST DATA
TEST DATA key provides access to the following:

Counter information
Saved test result data
Statistics for a selected number of tests
See Chapter 10, TEST DATA, for the details about the Test Data information.
Figure 28 Test Data/Counter screen
SELF TEST
SELF TEST functions include:

Internal instrument leak check (SELF TEST) perform leak test on instruments internal
pneumatics
Transducer calibration determine transducers base signal and set span using an external
traceable gauge
Manual Regulator setting prompts manual setting of test pressure
Leak calibration verification - manual opening of Leak Standard Calibration Valve to check
instrument leak calibration.
Rev 11/18/08 2-12

See Chapter 7 about the SELF TEST functions.
Figure 29 Initial Self Test screen
HELP
HELP key displays definitions of the parameters on the screen. Push the HELP key while in
PART CONFIG, INST CONFIG, TEST DATA, SELF TEST, and AUTO SETUP screens to get
an explanation of the variables.
The following is a representative example of a Help screen. In this case, the INSTR CONFIG
key was pressed and then the HELP key. If more information is available, use the down arrow to
scroll down to the remaining information on the next screen. Press the EXIT or HELP key to
escape the Help screen.
INST CONFIG version <HARDWARE> re232 1
HELP
Manifold Type: Defines the hardware
pneumatic configurations and valve
arrangements installed within the
instrument.
6
Figure
P01
30 Help screen for Instrument Configuration
Rev 11/18/08 2-13

FUNCTION PANEL
Figure 31 Function Panel
HOLD
HOLD function manually pauses the test sequence at any step of the test process. Pressing the
key will pause the test sequence. Pressing the key again allows the test sequencing to continue.
(This function can be activated by a digital input.)
CHANGE PART
CHANGE PART key selects a stored part test program from the 32 available while in the
Monitor, Instrument Configuration, Part Configuration, and Test Data displays. There are several
ways to select the desired part program.
1. Push and hold Change Part key until prompt appears. Use up or down arrow keys to
sequence the ones digit and the left and right arrow keys to sequence the tens digit to the
desired part number and then push ENTER key.
2. Push the Change Part key repeatedly to sequence through the defined number of part
programs stored and available for selection (max 32).
Binary digital inputs or any of the communication options like RS232 or TCP/IP can also be used
to select the active part program.
AUTO SETUP
Auto Setup is a unique, fast, and easy way to perform the initial setup of a part program for a
new test part. Before using the Part Configuration menus, configure a new program using Auto
Setup. This routine will prompt the operator to input the very basic information needed to
initialize a part program (Test type, part number, desired cycle time, test pressure, reject rate, leak
standard flow rate and calibration pressure, and units of measurement). After prompting the
operator to manually set the mechanical regulator to the Target pressure, this setup routine will
Rev 11/18/08 2-14

start sequential tests to automatically determine the optimal timers to test the part within the
desired cycle time. At the completion of these tests the instrument sets up the specified part
number with the optimized test parameters (pre-fill, fill, stabilization, test, exhaust and relax
timers; min, max, and target test pressures; and hi lim, lo lim and leak standard values) that
provide the best possible test results within the desired cycle time limit. It then prompts for the
Auto Calib routine described briefly below. The Auto Setup routine is available for direct
pressure decay test types only. See Chapter 3 for details about the Auto Setup routine.
AUTO CALIB
AUTO CALIB automatically sequences through a calibration routine to establish the accept
and reject pressure (vacuum) loss values for the established part parameters. The tests are
conducted using a master test part in conjunction with the integral calibrated leak standard(s)
supplied in the instrument pneumatics or an external leak standard. (This function can be
activated by a digital input.)
See Chapter 3 about the Auto Calibration routine.
START
START initiates a test sequence. (This function can be activated by a digital input.)
STOP
STOP interrupts the test sequence and resets for a new test. (This function can be activated by a
digital input.)
Rev 11/18/08 2-15

CHAPTER 3 AUTO SETUP and AUTO CAL

After the instrument is mounted, plumbing connections completed, Digital I/O lines wired and
inlet power connections made, turn on power to the instrument.
TURN ON POWER
Use the power switch located on the top to turn on the power to the instrument.
The instrument software goes through a startup procedure that checks the RAM memory,
input/output modules, operator display, transducer zero, and calibration status. During this time
the Sentinel C28 initialization screen appears.
Figure 32 Sentinel C28 Initialization screen
When the Sentinel C28 system completes its self-check, it displays the Monitor screen.
Figure 33 Initial monitor screen
After verifying the instruments proper configuration with the correct pneumatic manifold as
described on pages 1-6 through 1-7, check the Hardware configuration for the instrument by
pushing the INSTR CONFIG key.
Rev 11/18/08 3-1

Figure: 34 Instrument Configuration, Hardware screen
The letters in the Test-Manifold Type (i.e. PA in the above example) should match the Pneumatic
Manifold code letters in the catalog number shown on page 1-6. Also check the Transducer Type
to assure that it matches the pressure transducer mounted on the manifold. If all agrees, exit the
Instrument Configuration screen.
AUTO SETUP
The easiest way to setup an instrument without considering digital input and output interface with
external devices is by using the Auto Setup routine. Auto Setup will only function for a single
test sequence of direct pressure decay. The Auto Setup routine resets the Input and Output
functions for a part program to the default. Therefore, Auto Setup must be performed with the
part manually sealed. After completing the Auto Setup routine, configure the instrument for
interface to external inputs and outputs reviewed in Chapter 5, Inputs and Outputs.
Push AUTO SETUP.
The Auto Setup routine is a unique process developed by Cincinnati Test Systems for the Sentinel
C28 instrument that makes the initial setup of the instrument to a new test part quick, easy and
efficient. The process will determine the best time sequence to test a part within the limits of a
desired maximum cycle time. If the desired maximum cycle time is set too short, the final test
will not produce repeatable results. Any leak test needs a certain amount of cycle time to achieve
sufficient resolution and repeatability that are dependent on the part volume, leak rate, test
pressure, and part characteristics. The Auto Setup routine will set the best possible test cycle
within the maximum cycle time specified for the test.
The Auto Setup routine is not functional for Pressure Loss (Drop), Pressure loss/time, or
Occlusion tests.
Rev 11/18/08 3-2

Figure 35 Auto Setup initial screen
Press the EDIT button and use the UP and DOWN arrow keys to edit the Test Type to the
desired method for testing the new part. The available test types are limited by the pneumatic
manifold supplied. Next press the EDIT key to save the Test Type selection and move down to
assign the new part program number (01 to 99) and press ENTER. Push the Auto Setup or right
arrow key to advance to the Units screen.
Figure 36 Auto Setup test units screen
Review and edit (using the EDIT, up and down arrows, and ENTER keys) the desired units of
measurement for test pressure, leak rate units, time, and pressure loss. Push the Auto Setup or
right arrow key to advance to the Test screen.
Figure 37 Auto Setup Test parameter screen
Rev 11/18/08 3-3

Enter the basic test information shown on the screen to setup the test.
Description
Desired This is the total desired time to complete the test on the part excluding tooling
Cycle Time motion. The Auto Setup will determine the best possible sequence of testing
within this maximum cycle time. But this optimized setup can not produce
acceptable resolution and repeatability if the total time is too short for the part
volume, leak rate, test pressure, and part construction. Utilize all the available
time in the manufacturing process to conduct this test. When acceptable
results are achieved, you may be able to repeat the process and reduce the total
cycle time.
Target This is the specified test pressure for the part. Auto Setup will preset the Min
Pressure pressure at 80% and Max pressure at 120%.
Leak Std This is leak rate value on the calibrated leak standard mounted on the
Value* pneumatic manifold or alternative standard used.
Leak Std This is the pressure value on the calibrated leak standard where it was
Pressure* calibrated.
High Limit This is the specified leak rate for the part. Auto Setup will preset the Low
Leak Limit Leak at 20% of the High Limit Leak. It will also set the Test
Evaluation to FPF. FPF means Fail > Hi Lim > Pass > Lo Lim > Fail.
These values and settings can be changed after completing the Auto Setup and
Auto Cal processes.
Cal This defines whether one or two parts are used in the calibration procedure. It
Method also specifies if the Leak Standard is located internally on the manifold where
the Calibration Valve will automatically activate in the calibration procedure
or located externally where it will be added to the process by the operator or
system control.
Start This starts the Auto Setup procedure
AutoSetup
Figure 38 Auto Setup test parameter inputs
*The Auto Setup routine will calculate an estimated flow value for the leak standard to
represent its flow at the Target Pressure if it is different than the Leak Std Pressure. For
optimal accuracy it is preferable to use a leak standard with a leak rate that is close to
the reject or high limit rate calibrated at the target pressure.
The first step is to set the mechanical regulator. Push ENTER key to confirm the interest to
SET REGULATOR Insert self test

Do you want to adjust regulator? cap into test port. Select OK to
continue, or Cancel to quit
No OK CANCEL OK
Figure 39 Auto Setup screens to adjust regulator and insert self test cap
Rev 11/18/08 3-4

Follow the screen instructions and replace the test line connection with the Self Test cap in the
test port and push the ENTER key. The instrument will display the current mechanical regulator
setting. Adjust the regulator so that the Instrument Pressure equals the Target Pressure for the
test.
Figure 40 Auto Setup Adjust Regulator screen
After setting the regulator, remove the self test cap and reconnect the test line and master part to
the test port. After acknowledging that the test line is connected by pushing the ENTER key in
the test line connected screen, the Auto Setup routine continues with a sequence of tests on a
master part to determine the optimal settings for pre-fill, fill, stabilization, test, exhaust, and relax
within the time constraint of the Desired Max Cycle Time. These tests include adding the
internal calibrated leak standard to one of the tests. At the completion of the testing cycles, the
optimized calculation screen below appears.
AUTO SETUP - Optimized calculations AUTOSETUP This action will overwrite

Complete. Actual total time will meet all previous data and settings
target. Calculated time may vary for associated with part program.
prefill.
OK CANCEL OK
Figure 41 Auto Setup Optimized calculation screen
To accept the optimized cycle values, push ENTER key. These new values will overwrite any
timer, pressure, and leak rate values previously stored for the selected part program number. To
overwrite the old values, push the ENTER key again. This completes the Auto Setup routine.
Auto Calibration is required. Would

you like to run AutoCal now?
YES NO
Figure 42 Transition screen from Auto Setup to Auto Cal routines
Rev 11/18/08 3-5

To finalize the setup of the part program to test parts, an Auto Calibration is required. Push the
ENTER key to confirm the initiation of the Auto Cal routine.
The Auto Setup routine enters the following parameters (depending on the Test Type selected) in
the target part program. Preview these parameters in the Part Configuration routine.
Part Program number* High Lim Leak* EDC Enabled Yes

Test Type* Low Lim Leak EDC Percentage 10%
Pre-fill Timer Max Mstr+Leak Loss EDC Quantity 30
Fill Timer Min Master Loss Test Pressure Units*
Stabilization Timer Leak Std Cal Flow* Timer Units*
Test Timer Leak Std Cal Press* Pressure Units*
Exhaust Timer Quik Test Enable No Flow Units*
Relax Timer Quik Test Timer 50% Cal Method*
Target Pressure* Quik Test LL Band
Quik Test HL Band
*Values input by operator at beginning of Auto Setup
Figure 43 Values set by Auto Setup routine into the designated part program
AUTO CAL
The Sentinel C28 instrument has a unique calibration procedure that simplifies calibration and
assures greater accuracy. Access this routine by one of three ways:
- Continuation of the Auto Setup routine discussed above

- Push AUTO CALIB key on keypad
As the default procedure Auto Cal uses the Standard Leak mounted on the internal pneumatics as
a known leak to determine the leak rate to pressure loss relationship for the test. This procedure
tests a master (no leak) part in the test fixture using the timers and pressures established for the
part program. The timers are set by one of several ways:
- Established by Auto Setup,

- Entered within Part Config menu (review Chapter 5)
- Input via one of the many communication channels - RS232 , TCP/IP (see
Chapter 4)
The procedure automatically tests the master (non-leaking) part twice with the Relax timer delay
between tests. Within each part program Auto Cal can be configured to use one of four methods:
Rev 11/18/08 3-6

Select Description Explanation

Parameter
One Part Automatic test Automatically tests same Master part twice using
Int. LS cycling using Leak calibrated leak standard mounted on the internal
Std in manifold pneumatic block.
One Part - Manual testing of Tests same Master part twice using calibrated leak
Ext LS same part using standard mounted externally from the instrument.
Leak Std outside
instrument
Two Parts Manual testing of Tests two different Master parts using the calibrated leak
Int. LS two parts using standard mounted on the internal pneumatic block. Any
Leak Std in tooling must retract between tests to change parts. A Start
manifold test input signal is required either via the keypad or
remotely using programmed start test logic to initiate the
second test after changing Master parts.
Ext LS two parts using standard mounted externally from the instrument. Any
Leak Std outside tooling must retract between tests to change parts. A
instrument Start test input signal is required either via the keypad or
second test after changing Master part with leak standard.
Figure 44 Auto Calibration methods
The Auto Cal procedure automatically determines:

Offset for a master part due to test dynamics associated with the type of test, part
configuration, test conditions, and fixture/tooling.
Corrected Leak Std Flow from the Leak Std Cal Flow based on differences between the
Leak Std Cal Pressure and Target Pressure
Final leak rate relationship to the measured pressure loss measurement. This relationship
involves the test pneumatics, part volumes, and method of testing.
AUTO CAL - Connect master part to test

port. Select START to run AutoCal, or
CANCEL to quit,
START CANCEL
Figure 45 Auto Cal Start screen
Rev 11/18/08 3-7

After loading the master no-leak part into the fixture and connecting the test part to the
instrument, push the START key to initiate the test procedure.
The system will make an initial test of the Master (no-leak) part to measure the pressure loss
associated with a non-leaking part. This should represent the typical offset associated with testing
parts within the environment of the test system. The pressure loss value is saved as the Master
Part Loss.
The system will conduct a second test on a Master part with a known calibrated leak standard
included in the test.
The system uses

Leak Std Cal Flow (LS) entered at the beginning of Auto Setup (or in Part Config)
Master Part Loss (dPM) measured in the first test
Master + Leak Loss measured in the second test with the Leak Std (dPM+LS)
to establish the Leak Rate relationship to Pressure Loss for the part program.
For pressure decay tests

Leak Rate = LS (dPmeas dPM)/(dPM+LS dPM)
dPmeas and Fmeas represent the measured pressure loss during each test. Leak Rate represents the
calculated test result displayed after each test.
Upon the successful completion of the Auto Calib routine, the display will show the calculated
Performance Factor for the calibration. The performance factor is an estimate of the quality of
the calibration. It combines the ratio of the Hi Lim result to the Master part result, the test
pressure, and difference between the Hi Lim result and the Master part result to scale its
anticipated performance. This value ranges from 0 to 99. It is generally desirable to have a
Performance Factor of 35 to 99. The actual acceptable Performance Factor can vary depending
on the desired Gage R&R performance of the test. Generally, longer timers will produce higher
Performance Factors. If the Performance Factor value is low, go back to Auto Setup and increase
the Desired Max Cycle time or go into Part Configuration and increase the timers for the test
(review Chapters 5).
Several conditions must be met during the Auto Calibration procedure for the instrument to
accept and store the calibration results. If the procedure does not meet these conditions, error
messages are displayed at the completion of tests.
If the Auto Cal routine is successfully completed, Auto-Cal Passed will be displayed.
Rev 11/18/08 3-8

Master Part Loss > Master +Leak Loss Test of Master Part with Leak Std included was
less than the Master Part. This generally
indicates that the part pressure is not stabilized
enough therefore requiring longer stabilization
time and there is not enough test time to create
a difference between accept and reject parts.
Also the relax timer should be longer.
Master + Leak Loss > Max Master +Leak One of the tests during Auto Cal had greater
Loss losses than the preset Max Master + Leak Loss
{This value is set by the operator}. This means
that there is leakage in the Master part or
fixture that is unacceptable, the Leak Std
Isolation valve did not open, or the Leak
Standard is clogged.
Performance Factor < Min Perf Factor Calculated Performance Factor is less than
preset Min Performance Factor {this value is
set by operator} indicating insufficient times in
Test and other timers or clogged leak standard.
Figure 46 Auto Cal Error messages
See a complete list of potential error messages in Chapter 13 Test Messages.
Correlation of multiple instrument calibrations for the same part

In order to obtain the optimum correlation of test results among several instruments testing the
same part type, it will be necessary to use a common calibrated leak standard and Master part to
calibrate each instrument. In this case, the instrument should be set for "One part Ext LS and a
common leak standard used with each instrument in the Auto Cal routine.
Rev 11/18/08 3-9

CHAPTER 4 INSTRUMENT CONFIGURATION AND
COMMUNICATION

COMMUNICATION
INSTRUMENT SETUP ROUTINE
The INSTR CONFIG key on the Display panel accesses the setup and operation of the universal
instrument functions. The universal instrument operations include Hardware and Firmware
Identification, Communication, Instrument Identification, and Security. The basic
configuration functions are:
Manifold Type, transducer range(s), and regulator type

Number of accessible part programs (max 32)
RS232 Communication
TCP/IP Communication setup
TCP/IP Communication
USB firmware update
Instrument name / serial number
Date / Time
Security
Firmware documentation
Instrument Configuration functions are reviewable at any time. The hardware parameters
within Instrument Configuration are not editable while the instrument is testing.
To change hardware parameters the instrument must not be testing.

Use the Up or Down arrow keys to position the pointer next to the item to be edited.
Press the EDIT key and the variable information for the selected field will be
highlighted.
For pre-set options use the Up and Down or Left and Right arrow keys to scroll
through the choices
For variable parameters like Instrument name, time, date, etc use the up and down
and left and right arrow keys to enter the desired numbers or letters. Each position
of the alphanumeric character string must be set by pushing the up and down arrow
keys repeatedly to scroll through the alphabet characters (small and capital letters),
symbols (space @ . ; ( ) - + ), and numbers (1,2,3,4,5,6,7,8,9,0). After a momentary
pause, the curser will automatically shift to the right for editing the next character.
Use the right and left arrow keys to move the cursor forward or back on a line.
.
After entering the desired value or selecting the desired option:
Press EDIT to save the setting and move to the next variable.
Press ENTER to save the setting and escape the edit mode,
Press EXIT to escape the edit mode without saving changes to the highlighted
variable.
Rev 11/18/08 4-1

COMMUNICATION
If a mistake is made, press EXIT before hitting the EDIT or ENTER keys. After
exiting the edit mode, press the EDIT key to return to the original data for editing.
Push INST CONFIG to advance to the next screen within a tab or the next tab indicated
across the top of the INST CONFIG screen.
Also use the right and left arrow keys to advance or retreat through the INST CONFIG
tabs identified across the top of the INST CONFIG screen.
Push MONITOR, PART CONFIG, TEST DATA, or any other key to escape INSTR
CONFIG.
You must exit the edit mode before switching to any other instrument function. Pressing
any Display or Function key while in the edit mode will not escape at edit mode. The
Exit or Enter key must be pushed first.
Push the HELP key while on any screen (not in Edit mode) to receive a brief
description of each variable. You must EXIT the edit mode to view the Help displays.
The stored instrument configuration settings are programmable remotely via RS232 or
TCP/IP by entering software access code commands via an internet connection.
MANIFOLD TYPE AND TRANSDUCER SELECT
Press the INSTR CONFIG key to see the INSTRUMENT SETUP Hardware items like Manifold
Types, Transducer Type and Regulator Type.
Figure 47 Hardware configuration screen for the manifold, transducer and regulator
Manifold Type
There are three manifold configurations available for the Sentinel C28 instrument. The
instrument will be configured for the manifold supplied at shipment. The available manifolds are
listed in Figure 48 on page 4-3. This Manifold Type is factory set and not editable in the field.
Number of Parts The Sentinel C28 can store up to 32 unique part programs. When using a
limited number of programs, the number of available programs can be limited by editing the
Number of Parts to the number of active programs. This limits the part programs available for
selection via the keypad or via remote selection. You can select a part program in a number of
ways.
Rev 11/18/08 4-2

COMMUNICATION
Change Part key in Functions part of keypad

- Repeatedly press the Change Part key until the desired program appears on the
LCD screen in lower right corner.
- Push and hold Change Part key until a prompt appears. Use up or down arrow
keys to sequence the ones digit and the left and right arrow keys to sequence the
tens digit to the desired part number and then push ENTER key.
Binary input
- Set up required number of digital inputs to select the part program numbers.
One input (part program 1)
Two inputs (up to 3 programs)
Three inputs (up to 7 programs)
Four inputs (up to 15 programs)
Five inputs (up to 31 programs)
Selection by RS232 communication inputs
Manifold Type
The configurations of the available manifolds for flow capacity, transducers, regulators, leak
standards, extra test features and available test types are listed below.
Manifold Manifold Absolute Second Regulators Leak Extra Test Types

Type or Flow Pressure Transducer Standard Features
Version capacity Transduc
ers
PA Standard One None Single One None Single Pressure decay,
Flow Ranges- mechanical Pressure drop, Pressure
Std Cv Vac up loss/time or Occlusion test.
1P to 100
psig
PB High One None Single One None Single Pressure decay,
Flow Ranges- mechanical Pressure drop, Pressure
High Cv (5 times Vac up loss/time or Occlusion test.
1P flow) to 200
psig
PN Low Flow One None Single One Low Single Pressure decay,
Low Ranges- mechanical Volume Pressure drop, Pressure
Volume 10 psiv in loss/time or Occlusion test.
1P to 100 Manifold
psig
Figure 48 Manifold types, components, and test types

The Manifold Type setting is not changeable. A new manifold type requires new firmware.
See Chapter 6 Principles of Operation for explanations of the different Pneumatic configurations
including diagrams, pictures, description, and timing charts of these manifold types.
The selection of Test Types (shown in Figure 48) is set within each part program using Part
Configuration or Auto Setup.
Rev 11/18/08 4-3

COMMUNICATION
Transducer Type 1 Defines the absolute pressure transducer supplied on each manifold
There are several different transducers available in the Sentinel C28 instrument
depending on the manifold defined above. The instrument will be configured for the
transducer supplied at shipment. The transducers available are:
Select Description Measurement range

Parameter
Druck 215 Absolute pressure transducer, range 0 to 215 psia 14.7 psig to 200 psig
Custom Custom range pressure transducer
Figure 49 Transducer type, description, and measurement range
Regulator Type 1 Defines the regulator supplied for test
The Sentinel C28 offers several choices for regulators depending on the options supplied. The
mechanical regulators are precision, relieving vacuum or pressure regulators selected with a range
that exceeds the maximum pressure range of the pressure transducer. It is not necessary to
program the range of the mechanical regulators because the operator manually adjusts them. The
Hardware set up for the regulator provides the following options. Check to assure that this setting
matches the equipment supplied.
Regulator Type Regulator Range

Mechanical Any mechanical regulator (ranges include vacuum, 2, 10, 30, 100,
200 psig)
Figure 50 Pressure Regulators
COMMUNICATIONS
SERIAL COMMUNICATION
The Sentinel C28 instrument has one port for serial communication located on the front OF THE
operator panel (external D connector).
Press the INSTR CONFIG key to see the INSTRUMENT SETUP Serial Communications
screens
Rev 11/18/08 4-4

COMMUNICATION
Figure 51 Serial RS232 Communication setup screen
The Sentinel C28 has one RS232 port. Port 1 is the nine-pin D connector located on the front
panel below the Display keypad. See Figure 52 below. This terminal needs an RS232 null cable
(crossover cable with the two send and receive wires crossed over) for direct connection to a
laptop or PDA.
RS232 connector
Figure 52 External RS232
RS232 Port 1 Interface

The RS232 serial output can be set up to communicate with a data Terminal (i.e. laptop
computer, PDA, or printer) or Fixed Width (for PLC interface, laptop computer).
Depending on the Interface selected, there are different screen options available for the
Configuration, Function, and Output functions. Use the INST CONFIG or left or right arrow
buttons to select the serial output for programming.
Rev 11/18/08 4-5

COMMUNICATION
Interface Configuration Function Output
Terminal Bit rate/Data Report output No output
bits/stopbits/Flow selection Stream only
(see Table 55 Stream and Test
below for Test only
availability)
Fixed width output Bit rate/Data bits/ Report output All result
Stopbits/Flow selection information
(See Table 55 First 2 test results
below) Part result only
Custom
Sentry Output Not available Not Available Not available
Figure 53 RS232 Interface Options

When selecting Terminal or Fixed Width Out interface, the independent serial interface port
can communicate selectable function reports such as test results data, counters, instrument and
station setup parameters, or part program parameters to a terminal like a computer, PDA, PLC, or
printer using a selectable array of communication configurations (or setups).
When selecting the Terminal interface, the RS232 output can stream pressure values every 0.01
seconds during a test (requires baud rate of 115200) and/or test results at completion of each test.
When selecting the Fixed Width Out for the RS232 port, the instrument will send a defined or
customized test result after each test.
RS232 Port 1 Config
The RS232 Port Config parameters independently select the data rate and the Flow Control
mechanism for the RS232 port. The allowed choices for the RS232 Config are:
Port Data Data Bits/Parity/Stop Bits Flow Control

Rate
RS232 9600 8/N/1 None
RS232 19200 8/N/1 None
RS232 33600 8/N/1 None
RS232 57600 8/N/1 None
RS232 115200* 8/N/1 None
* Required baud rate for pressure streaming output during test
Figure 54 RS232 Port Configuration
When selecting Sentry Output for Interface, there are no Configuration options.
RS232 Port 1 Function
There are sets of reports that are available via the RS232 serial ports to a PDA, PLC, computer or
printer.
Rev 11/18/08 4-6

COMMUNICATION
The choices of reports available on the RS232 serial port are:
Select Parameter Description

Instrument Config Setup Information for Hardware, Communication, Firmware,
Instrument name, Time, Date, and Security
Station Config Information about the manifold, transducer, and regulator
Part Config Part setup parameters for all available part programs,
Autosetup info Initial parameters provided in the AutoSetup routine
All part results All the test results for the active part program in the instrument memory
All results All the test results in the instrument memory
Last 1000 1000 most recent test results,
Station Counters Counters information,
Figure 55 RS232 Function Options
When selecting Sentry Output for Interface, there are no Function options.
RS232 Port 1 Output

When setting the RS232 Interface to Terminal, the RS232 Output function can send streaming
test pressure data and/or end of test result data. The streaming data contains complete
information about each segment of the test every 0.01 seconds. The each test result data includes
the part number, station number, time, date, pressure loss, leak rate, EDC correction, and test
pressure. The programmable selections for output are:
Output Option (For Terminal Interface)

No output No data streaming output or test result
Stream only* Test data stream every 0.01 sec.
Test only Test result data at the end of test
Stream and Test* Test data stream every 0.01 sec and Test result data at the end of test
* Requires baud rate of 115200 for pressure streaming during test cycle
Figure 56 RS232 Port Terminal Output Options
S01 P01 11/13/08 10:05:2.64 0000000046 PART ACCEPT

PLR P Leak Rate -0.000559 sccm Pressure Loss 0.000025 dpsig
Test Pressure 4.000154 psig EDC Offset 0.000000 sccm Predict
ed Leak 0.000823 sccm Quik Loss 0.000028 dpsig Quik Test Press
ure 4.000168 psig
Figure 57 Sample of Test Only output for a pressure decay leak rate test.
Streaming data
Every 0.01 seconds the Streaming Data option sends a string of hexcode that contains complete
data about the test at that time. The data includes station number, part number, phase of the test,
elapsed time, decrementing time within phase, pressure reading, and pressure loss values.
Rev 11/18/08 4-7

COMMUNICATION
S01P01G42,015D 4.89,025D 0.01,120C 4.000,1C29 0.00023
Figure 58 Sample of one reading from the Streaming test output
See page 9-2 through 9-4 for the coding of this data stream.
When selecting Sentry Output, there are no Output options.
Fixed Width output

When setting the RS232 Interface to Fixed Width Out, the Output Options are:
Output Selection (For Fixed Width Out Interface)

All result information Part and individual test results for multiple sequence tests
First 2 test results Test only results for first 2 tests of a multiple sequence test. Does
not include the part results
Part results only Part results only. Does not include individual test results.
Custom User choices the information and order of data to be sent out.
Figure 59 Fixed Width Output options
The test result outputs are pre-formatted or customize with Fixed Width and/or space delimited
text files. The following data is saved for each test result. Depending on the test type (pressure
drop, pressure rate of change, occlusion, or pressure decay leak rate,), the data saved will vary
somewhat. Below are examples of the three standard Fixed Width data outputs for a pressure
decay leak rate test
All result information

S01 P01 R-- 11/13/08 10:31:14.990 0000000053 A - PLR P LR -0.000559 sccm
PL 0.000158 dpsig Pt 2.000224 psig EDC 0.000000 sccm PQ 0.000458 sccm
QL 0.000098 dpsig QP 2.000233 psig
First 2 test reults
S01 P01 R-- 11/13/08 10:31:14.990 0000000052 A - PLR P LR -0.000559 sccm
PL 0.000035 dpsig
Part result only
S01 P02 R-- 07/03/08 14:45:38.080 0000005130 A
Rev 11/18/08 4-8

COMMUNICATION
S01 Station Number (only 01)
P01 Part Program number (01 to 32)
R-- Link Info (R-- stand alone program
11/13/08 Date (MM/DD/YY)
10:31:14.990 Time (HH:MM:SS.SSS) - 24 hour clock
0000000053 Unique test result number (sequentially assigned)
A Part result code A Accept R Reject
(See Figure 63 Part Result Evaluation Codes)
- SPC Flag ( - denotes no flag, * indicates data marked for SPC analysis)
PLR Test type: PLR - Pressure decay Leak Rate PLO Pressure loss or drop
DPT - Rate of pressure loss OCC - Occlusion
a q suffix attached to the above symbols indicates an abbreviated Quik Test
P Test Result P Passed F - Failed
(See Figure 64 Test Result Evaluation Codes)
LR Test Data Identifier: LR - Leak Rate
(See Figure 62 Test Data Identifiers Codes)
-0.000559 Test Result calculated value
sccm Test Result unit of measurement (flow unit or pressure loss unit)
PL Test Data Identifier (See Figure 62 Test Data Identifiers Codes)
0.000658 Actual measured variable
dpsig Actual measured unit of measurement
Pt Test Data Identifier (See Figure 62 Test Data Identifiers Codes)
2.000224 Test Pressure (at mid point of test cycle) value
psig Test Pressure unit of measurement
EDC Test Data Identifier (See Figure 62 Test Data Identifiers Codes)
0.0000000 Actual calculated offset
sccm Actual measured unit of measurement
PQ Test Data Identifier (See Figure 62 Test Data Identifiers Codes)
0.000458 Quik Test Result calculated value
sccm Quik Test Result unit of measurement (flow unit)
QL Test Data Identifier (See Figure 62 Test Data Identifiers Codes)
0.000098 Actual measured variable at Quik Test time
dpsig Actual measured unit of measurement
QP Test Data Identifier (See Figure 62 Test Data Identifiers Codes)
2.000233 Test Pressure (at Quik Test time of test cycle) value
psig Test Pressure unit of measurement
Figure 60 Test Result output
Custom Output option

The custom output option makes it possible to select the arrangement of the data that is output at
the end of each test. There are 8 initial Result Fields where the order and selection of data can be
made. If none is selected, that field is blank and no space is provided in the output. In addition
there are two final output formats for the actual test data. The initial order for the first 8 fields is
optional followed by one of the two actual test data formats. The choices of available data are:
Rev 11/18/08 4-9

COMMUNICATION
Field Field Field Field Field Field Field Field Field
1 2 3 4 5 6 7 8 9
None
Station #
Part #
Info Link
Time
Date
Unique ID
Part
Evaluation
SPC Flag
First 2 test
results
All result
information
Figure 61 Table of Variables for output to any of the initial 8 data fields
Actual test data options
First 2 test results

PLR P LR -0.000559 sccm PL 0.000000 dpsig
PLR P LR -0.000559 sccm PL 0.000000 dpsig Pt -0.000242 psig
EDC 0.000000 sccm PQ 0.000000 sccm QL 0.000000 dpsig QP -0.000210 psig
ALR Absolute Leak Rate MQ Master Part Quik Loss PMQ Master Part Quik
Pressure
EDC Environmental. Drift PF Performance Factor PQ Predicted Leak Rate
Correction Offset
LL Master+Leak Loss PL Pressure Loss Pt Test Pressure
LQ Master+Leak Quik Loss PLQ Master+Leak QuikPress QF Quik Test Flow
LQF Master+Leak Quik Flow PLR Pressure Loss Reading QL Quik Test Loss
LR Leak Rate PM Master Part Pressure QP Quik Test Pressure
ML Master Part Loss PML Master+Leak Pressure RL Loss Rate
Figure 62 Test Data Identifiers
Rev 11/18/08 4-10

COMMUNICATION
Part Result Evaluation Codes
Code Description Code Description Code Description
A Part Accept EP Part Error R Part Reject

AC Auto Setup Complete ID Invalid Calibration Data S1 Stop input received
AF Auto Cal Failed IF I/O Fault SB Stop button pushed
AM Auto Cal Master Part IO Invalid I/O Configuration SF Self Test Failed
Complete
AP Auto Cal Passed IP Invalid Part Selected SH Stop input high
PA Above Target Pressure SL Severe Leak
C1 Master+Leak Loss< PB Below Target Pressure SP Self Test Passed
Master Loss
C2 Master Loss>Max PC Part not changed TE Tooling not reset
Master+Leak Loss
Master + Leak PE Part Configuration Error TS Tooling reset
C3 Loss>Max
Master+Leaak Loss
CE Calculation Error PH Test Pressure High XH External switch did not
go high
CM Min Performance Factor PL Test Pressure Low XL External Switch did not
Error go low
CP Cal Required PM Master Part Pressure XO Transducer Over Range
Parameter Changed
PP Part not present XZ Transducer Zero Bad
QC Sequence Complete
Figure 63 Part Result Evaluation Codes
Code Description
P Test passed
F Test failed
E Test error
N Test skipped
L Test Completed AutoCal Leak Standard
M Test Completed AutoCal Master
Figure 64 Test Result Evaluation Codes
Rev 11/18/08 4-11

COMMUNICATION
TCP/IP COMMUNICATIONS
Press the INSTR CONFIG once more to see the TCP/IP Setup screen.
Figure 65 TCP/IP Communications setup screen
Obtain network settings (Manual or DHCP)

Manual the factory Information Management personnel within the company
assign a fixed IP address to the instrument.
DHCP - (Dynamic Host Configuration Protocol) - The instrument will communicate

with local network server, known as a DHCP server. The server will assign a temporary
IP addresses to the instrument.
Instrument IP Address
Instruments IP address on the factory network set manually or assigned by DHCP server.
Mail Server IP
Mail server IP address This information should be setup by Management Information Personnel
within company if there is an intent to use the email function of the instrument.
Gateway\Router
Set the Gateway/ router address. This information should be setup by Management Information
Personnel within company if default values do not apply to factory network.
Subnet Mask
Set the Subnet Mask address. This information should be setup by Management Information
Personnel within company if default values do not apply to factory network.
MAC Address (Media Access Control)

This is the Hexadecimal address of the network adapter. It should not be changed. It is like an
internet serial number for the instrument. (Factory set at CTS before shipment.)
Rev 11/18/08 4-12

COMMUNICATION
TCP/IP 1 Interface
Figure 66 Typical TCP/IP communication screen
There is one TCP/IP port that can be set up to communicate with a data Terminal (i.e. computer),
or Fixed Width Out device. Depending on the Interface selected, there are different screen
options available for the Function and Output options.
Interface Function Output

Terminal Data output selection No output
(See Table 68 below for available Test only
reports)
Fixed Width output Data output selection All Result Information
(See Table 68 below for available First 2 test results
reports) Part result only
Custom
Sentry output Not available Not available
Figure 67 TCP/IP Interface and Function Options
When selecting Terminal interface, the TCP/IP signal is programmable to communicate a

selectable set of test results data, counters, instrument and station setup parameters, or part
program parameters to a terminal and test results at the completion of each test.
When selecting the Fixed Width Output, the TCP/IP signals is programmable to communicate a
selectable set of test results data, counters, instrument and station setup parameters, or part
program parameters to a terminal and one of three types of outputs or a customized output as
outlined in Table 67 TCP/IP Interface and Function Options above.
The Sentry Output sets up direct communication to a computer with Sentry PCS software that
has the capability to request specific data for transfer. There are no output options.
Rev 11/18/08 4-13

COMMUNICATION
TCP/IP 1 Function
There are several reports available via the TCP/IP (Ethernet) port. Below is a list of the available
reports via the TCP/IP port. See Chapter 9 for samples of the different reports.

Instrument Config Setup Information for communication, Firmware, Instrument name,
time, date, and security
Part Config Part setup parameters for all part programs,
Figure 68 TCP/IP Function Reports
When selecting Sentry Output for Interface, there are no Function options.
TCP/IP 1 Output
Terminal
When selecting Terminal Interface, the Output options are No Output or Test Only.
Sample of a pressure decay leak rate test only output
S01 P01 11/13/08 14:13:47.45 0000000058 PART ACCEPT

PLR P Leak Rate -0.000559 sccm Pressure Loss 0.000035 dpsig
Test Pressure 2.000261 psig EDC Offset 0.000000 sccm Predicted Leak
0.000042 sccm Quik Loss 0.000021 dpsig Quik Test Pressure 2.000279 psig
.Fixed Width Output

When the TCP/IP Interface is set for Fixed Width Output, the output for each test can be set for
one of three pre-determined formats or a customize format to easily communicate test data to a
PLC. The output formats are defined below in Figure 69. See page 9-5 and 9-6 for examples of
each report.
Output Option Data transferred

All results Sends the test results and part results..
information
First 2 test results Sends just the first test result
Part result only Sends part results only.
Custom Information and order of information is selectable
Figure 69 Output Options
Rev 11/18/08 4-14

COMMUNICATION
Part Result only
S01 P01 R-- 11/13/08 14:21:41.370 0000000059 A
First 2 test results (for a single test)

S01 P01 R-- 11/13/08 14:21:57.880 0000000060 A - PLR P LR -0.000559 sccm
PL 0.000048 dpsig

S01 P01 R-- 11/13/08 14:22:10.370 0000000061 A - PLR P LR -0.000559 sccm
PL 0.000048 dpsig Pt 2.000312 psig EDC 0.000000 sccm PQ 0.000000 sccm
QL 0.000021 dpsig QP 2.000130 psig
Custom
See Figure 61 and the Actual test data options shown on page 4-10 for available formats for
custom outputs.
Sentry
When selecting Sentry for Interface, there are no Output options.
USB FLASH FIRMWARE UPDATE
Figure 70 USB screen
There is a USB mass storage connection inside of the Sentinel C28 instrument door. See Figure
71 below.
Rev 11/18/08 4-15

COMMUNICATION
USB port
Figure 71 USB connector inside the door of Sentinel C28 Instrument
Connect a USB flash drive to the receptacle inside the Sentinel C28 instrument. This flash drive
must be formatted to FAT32. DO NOT REMOVE THE FLASH CHIP WHEN THE LIGHT IS
BLINKING BECAUSE IT IS PROCESSING INFORMATION.
Update Firmware
When selecting Yes to update firmware, the instrument screen will display the firmware versions
stored on the USB drive. Move the cursor to the latest version and push the ENTER key.
INST CONFIG: tcp/ip 1 <USB> Emal
FILE
>C28 UPDATE 174.137
Figure 72 Firmware Update screen
The instrument will download the new firmware into the onboard memory of the instrument
automatically. For more complete instructions refer to pages 12-1 and 12-2 for how to format
the flash chip to FAT32 and download firmware files for instrument updates.
Drive Control
This function deactivates any writing to the flash drive for safe removal.
Rev 11/18/08 4-16

COMMUNICATION
EMAIL COMMUNICATION
Figure 73 Email communications
User id
When the operator wants to send an email of instrument information to an email address, a user
id must be entered. This can be up to a 19-character alphanumeric string. The user companys
IT department must establish a user id and password.
Email password
When the operator wants to send an email to an email address, the user must enter a password
in addition to the user id above. This can be up to a 19-character alphanumeric string.
From Addr: Instruments email address
Email address for the Instrument may be up to 39 characters long. The From Addr: is the
instruments email address.
Email Function:
There are several report outputs available to email. The available reports are:
Select Description
Parameter
Instrument Setup Information for communication, Firmware, Instrument name, time, date,
Config and security
Part Config Part setup parameters for all part programs
Last 1000 1000 most recent test results
Station Counters information
Counters
Figure 74 Email Function Reports
Rev 11/18/08 4-17

COMMUNICATION
Fnc Addr: Recipients email address for email function reports
Email address where function report is to be sent. It may be up to 39 characters long.
MISCELLANEOUS INSTRUMENT SETTINGS
Figure 75 Instrument name, serial number, security and time/date
Instrument Name
Enter up to 19 alphanumeric characters. The name appears on email messages from the
instrument.
Serial Number
Cincinnati Test Systems assigns this unique serial number to the instrument for reference and
service issues. The Serial Number is set before shipping the Sentinel C28 instrument. The user
can not change the Serial Number. Use this number as a reference for the instrument when
calling CTS for service or operations questions. This number should also appear on the
instrument label located on the right side of the instrument.
Edit \ View Security

To view the Security configuration of the instrument and potentially change the setup, edit the
Edit \ View Security line to ON in the MISC screen. This will advance you to the Security
Screen to review the current setup and password. See the security screen information on page 4-
19.
Time
The current time is stored with each test result as HH:MM:SS (24 hour clock). This instrument
does not recognize Daylight Savings Time so the time must be reset manually when this event
happens.
Date
The current date is stored with each test result as MM\DD\YY
Rev 11/18/08 4-18

COMMUNICATION
VERSION
Figure 76 Firmware serial numbers and software versions
Each major electronic component in the instrument has its serial number and software version
recorded for future reference for maintenance or service issues. If a service issue arises, record
these numbers when calling CTS for assistance.
SECURITY
Figure 77 Security Configuration screen
Record all changes to the original factory settings. It is important to know these values when
troubleshooting.
Rev 11/18/08 4-19

COMMUNICATION
Secure Calibration (No or Yes)
Yes prevents the operator from performing auto calibration without a password.
No allows operator to perform auto calibration without security protection.
Secure Change Part (No or Yes)

Yes prevents operator from changing test part parameters by pressing Change Part button
without a password.
No allows changing test part parameters by pressing Change Part button without security
protection.
Secure Part Config (No or Yes)

Yes prevents operator from changing test part parameters by pressing Part Config button and
Edit without a password.
No allows changing test part parameters by pressing Part Config button and Edit without
security protection.
Secure Instrument Setup (No or Yes)

Yes prevents operator from changing instrument and station parameters by pressing Instr
Config and Edit buttons without a password.
No allows changing instrument and station parameters by pressing Instr Config and Edit
buttons without security protection.
Secure Clear Data (No or Yes)

Yes prevents clearing test result data from instrument without a password.
No allows clearing test result data without security protection.
Secure Reset Cntrs (No or Yes)

Yes prevents clearing the counter registers from instrument without a password.
No allows clearing the counters registers without security protection
Change Password xxxxxxxxxxxxxxx

Edit allows the entry of a new password after entering old password
To initially enter a password the beginning password of 2424 must be used. After a new
password is entered, the beginning password is deleted. The password can be changed at any
point in the future. It requires the password to change it. Enter the new password value using
alphanumeric keys and press the ENTER button. Password can be upto 20 numeric characters.
BE SURE TO REMEMBER OR NOTE THE NEW PASSWORD.
Rev 11/18/08 4-20

CHAPTER 5 PART CONFIGURATION

REVIEW OR CHANGE PART TEST PARAMETERS
The part configuration function has the setup and test parameters that are part program specific.
These parameters include the test type, timers, pressure values and units, leak parameters and
units, test optimization settings, test evaluation criteria, calibration method, and tooling control
functions. There are 32 part programs available. Each part program is independent of the others
except for some universal input and output functions. These parameters are accessible via several
sequentially addressed screens. Below is a summary of the variables on each screen. Chapter 6
has a complete description for most of the parameters and methods to optimize the test.
Reviewing or editing Part configuration parameters is easy.
Use the Up or Down arrow keys to position the pointer next to the item to be edited.
Push the EDIT key and the variable information for the selected field will be
highlighted for editing.
For pre-set options use the Up and Down or Left and Right arrow keys to scroll
through the choices
For variable parameters like Part name, timers, pressures, etc. use the Up/Down and
Left/Right arrow keys to sequence through letters and numbers to select the desired
number or letter for each character. After a slight delay between pushing keys the
curser will automatically move to the right for the next character. Use the right and
left arrow keys to move the cursor forward or back on a line.
After entering the desired value or selecting the desired option:

Press EDIT to save the setting and move to the next variable.
Press ENTER to save the setting and escape the edit mode,
Press EXIT to escape the edit mode without saving changes to the highlighted
variable.
If a mistake is made, press EXIT before hitting the EDIT or ENTER keys. Press the
EDIT key to return to the original data for editing.
If PART CONFIG or any other Function or Display key is pushed while in the edit
mode, the instrument will not escape the edit mode. The edit mode must be ended
by Exit or Enter before moving to a different field. If the instrument does escape the
Edit mode without using Enter or Exit, changes on the highlighted line will not be
saved.
Press PART CONFIG to advance to the next screen within a tab or the next tab
indicated across the top of the PART CONFIG screen.
Also use the right and left arrow keys to advance or retreat through the PART CONFIG
tabs identified across the top of the PART CONFIG screen.
Push MONITOR, INST CONFIG, TEST DATA, or any other key to escape PART
CONFIG.
Rev 11/18/08 5-1

Press the HELP key while on any screen (not in Edit mode) to receive a brief description of
each variable. You must EXIT the edit mode to view the Help displays
The stored part parameters are programmable remotely via RS232 or TCP/IP by entering
software access code commands via an internet connection. There is memory for up to 32 part
programs.
Select programmed part parameters via the Functions keypads CHANGE PART key, binary
coded digital inputs, or RS232.
Review or change any test parameter by pressing the PART CONFIG button. A password may
be required to change the parameters. All of the unique part program parameters for each part
program are displayed via several screens. The table below summarizes the location of the
parameters, which are organized by test timers, test pressure values, test parameters, calibration
parameters, Misc settings, units of measurement, digital inputs and outputs, and tooling control.
Test type Cal. Parameters (for pressure decay leak rate only)
Select Test Type Performance Factor
Timers Master Part Press
Pre-fill Timer Master+Leak Press
Fill Timer Master Part Loss
Stabilize Timer Master+Leak Loss
Test Timer Corr. Leak Std Flow
Exhaust Timer Miscellaneous
Relax Timer Part Name
Pressures Cal Method
Target Pressure Copy to Target Part
Copy Part Program
Test parameters TST:PDC Autorun Method
Low Limit Leak (or Loss or Rate) Autorun Cycle Count
High Limit Leak (or Loss or Rate) Autorun Enable
Low Limit Pressure Units
High Limit Pressure Time Unit
Max Master(+Leak) Loss Pressure Unit
Min Master Loss Pressure Unit
Min Perform Factor P/T Unit
Leak Std Cal Flow Flow Unit
Leak Std Cal Press Digital Inputs
Quik Test Enable Assign input terminals
Quik Test Timer Digital Outputs
Quik Test LL Band Assign output terminals
Quik Test HL Band
EDC Enabled
EDC Percentage Not all parameters are available for each test
EDC Quantity type.
Figure 78 Part Configuration menus
Rev 11/18/08 5-2

TEST TYPE
Press the PART CONFIG button in the Display section of the keypad. The Test Type parameter
is the first parameter displayed for review and edit.
Figure 79 Test type screen
Each part program can be independently setup to perform any of the Test Types available within
the Manifold-Firmware supplied. Press the INST CONFIG key to review the Manifold Type
supplied. Review the table below to see the Test Types available.
Manifold Type Test types (Single Pressure) Tests Types (Multiple

Mechanical Regulator sequential single pressure tests
using Start Part input)
PA Std Cv 1P Single Pressure Decay Pressure Decay
PB High Cv 1P Single Pressure Drop Pressure Drop
PN Low Volume 1P Single Pressure Rate of Change Rate of Change
Single Occlusion Occlusion
Figure 80 Test type verses pneumatic manifold

Chapter 6 Principles of Operation describes the basic Test Types with pictures, pneumatic
diagrams, and timing charts for each. How to link part programs for multiple sequential single
pressure tests using Start Part input is described later in this chapter.
Rev 11/18/08 5-3

TEST TIMERS
Press the PART CONFIG or right arrow key. The timer parameters will display for review or
edit.
Figure 81 Timers Screen
Test Type Code Test Type Test Type Code Test Type
PLO Pressure Loss or Drop DPT Pressure Rate of Change
PLR Pressure Decay Leak Rate OCC Occlusion
Figure 82 Test Type Codes
The Sentinel C28 displays the Test Type codes in Figure 82 after each test in the Monitor display
and stores them with each test result.
The different test type setups and tooling control configurations have different timer
requirements. Table 83 below describes the timer functions and the test types that use them.
TIMERS DESCRIPTION TEST TYPE/TIMER USE

PLR Plo DPT OCC
Tooling When tooling control is specified, there can be one extend timer O O O O
Extend for one tooling motion.
Timer
Prefill Maximum time to reach the MIN PRESSURE. A not-to-exceed A S S
timer. Checks for excessively leaking parts or lack of pressure
(min. time is 0.2 seconds)
Fill Time to continue filling the part with regulated air after reaching A S S
MIN PRESSURE. Time to stabilize part pressure with additional
air.
Stabilize Time to stabilize part pressure while isolated from the pressure A S S
regulator. This time directly affects the repeatability of the test.
Test The precise time over which to measure pressure drop or decay or A S S S
the precise end time to measure pressure rise.
Rev 11/18/08 5-4

Exhaust Time to relieve or vent part pressure before signaling the end of A S S S
test. Need time to prevent blowing out debris or fixture seals.
May be set to zero when part program used within Parent Program
to allow program linking without relieving part pressure.
Relax Timer used during Auto Cal, Auto Setup, and Auto Run routines A S S S
as a precise delay between tests to allow the part to recover to
repeatable virgin state. Usually short relax times result in
decreasing pressure losses (flows) in successive tests.
Tooling When tooling control is specified, there can be one tooling retract O O O O
Retract timer for tooling motion.
A Timers calculated and set by Auto Setup routine.
O Timers used if tooling control activated
S Timers set by operator (Auto Setup not available for these test types.)
Blank Not applicable to the test
Figure 83 Timers used by different Test Types
There are digital outputs, selectable within the Output tab (discussed later in this chapter) that go
high during the pre-fill, fill, stabilize, test, exhaust, and relax timers.
TEST PRESSURES
Figure 84 Pressure screen
Target Pressure Target Pressure is the specified test pressure for the part. For vacuum test
pressures enter as positive values if psiv was selected as the pressure unit. Enter as a negative
if psig was selected as the pressure unit. (i.e. A test pressure 9.7 psia would entered as 5 psiv
or -5 psig.)
All pressure loss, leak standard values, and calculated leak rates are corrected to the
Target Pressure.
Enter vacuum test pressures same as discussed above.
This value is entered during Auto Setup.
Rev 11/18/08 5-5

Minimum Test Pressure Minimum test pressure is not a displayed value. It is automatically
set at 90% of Target pressure or Target pressure 0.5 psig, whichever is a greater deviation
from the Target Pressure. This pressure value must be reached before the pre-fill timer elapses
and must be maintained through fill and stabilization timers or the testing cycle will end as a
severe leak. The Auto Setup routine will also set the Minimum Test Pressure at 90% of the
Target Pressure or -0.5 psig. This pressure value is not editable.
Maximum Test Pressure Maximum test pressure is not a displayed value. It is automatically
set to 110% of Target pressure or Target pressure + 0.5 psig, whichever is greater deviation
from the Target Pressure. Actual pressures during fill and stabilize must remain less than the
Maximum Test Pressure to successfully complete the test. If the pressure goes above the
Maximum Test Pressure, the testing cycle will end as a Malfunction. Auto Setup routine will
set the Maximum Test Pressure at 110% of Target Pressure or +0.5 psig. This pressure value
is not editable.
Target Pressure Window Target Pressure Window is not a displayed value. This is a
plus/minus 50% window set about the Target Pressure that must be maintained during the Test
segment of the testing cycle. It generates a Malfunction output if the actual pressure falls
outside this window during test. This percentage value is not editable.
TEST PARAMETERS
Figure 85 Test Parameters screen
Test parameters are values specifying limits or set points for the test as well as the leak
standard value to calibrate the instrument, Quik Test options, limits to validate the calibration,
and Environmental Drift correction options. There are different Test Parameters depending the
Test Type. The instrument will only display the parameters that are appropriate for the Test
Type. The table below describes the parameters and Test Types in which they are active.
Parameters with an M denote values that are entered as part of Auto Setup. Parameters with
an A denote values that Auto Setup automatically sets. O denotes parameters that are
optional for the test and are setup after completing Auto Setup and Auto Cal if this function is
used. These values can be changed, after Auto Cal routine is completed, without having to re-
calibrate the instrument. S denotes values entered by the operator because Auto Setup is not
an option. F denotes fixed values that are not editable.
Rev 11/18/08 5-6

Parameter Description PLO PLR DPT OCC

Low Lim Low set point value used to evaluate test results. Auto A
Leak Setup sets at 20% of preset Hi Lim Leak
Hi Lim High limit value or specified leak or flow rate to evaluate M
Leak parts. (Setting must be nonzero.)
Low Lim Low limit pressure loss (or loss per second) value to S S
Loss (Rate) evaluate parts for pressure drop (or rate) test.
Hi Lim Loss Specified maximum pressure loss (or loss per second) over S S
(Rate) a set time period for pressure drop (or rate) test
Low Limit Low limit of back pressure at the end of the test timer for S
Pressure occlusion test indicating high flow
High Limit High limit of back pressure at the end of the test timer for S
Pressure occlusion test indicating low flow
Test* Test results are compared to two set points for pass or fail F F F F
Evaluation status. There are three areas for evaluation of results: above
high limit, between limits, and below low limit. This
parameter is fixed and not editable as F/P/F.
Max Maximum pressure loss allowed during either test in the A
Mstr+Leak Auto Cal routine. Prevents the acceptance of a calibration
Loss* with excessive pressure loss due to part or fixture leaks. Set
slightly higher than max loss during Auto Cal. AutoSetup
sets value at 2x Master+Leak Loss
Min Master Minimum pressure loss or flow allowed during either test A
Loss * in Auto Cal routine. Prevents the acceptance of a
calibration of a blocked part or test line.
Min Minimum value for Performance Factor calculated at O
Perform completion of Auto Cal routine. Resultant evaluation of
Factor ratio of Master Part Loss (Flow) to Master+Leak Loss
(Flow), Test Pressure, and loss (flow) due to Leak Std.
Leak Std Certified flow value of Leak Standard used to calibrate M
Cal Flow instrument.
Leak Std Certified pressure at which Leak Standard Flow was M
Cal Press calibrated.
Quik Test Should Quik Test be activated? Auto Setup sets to No. O
Enable
Quik Test Defines the time as a percent of the Test Timer when the O
Timer Quik Test function decides to stop the test or continue.
Quik Test The leak (flow) rate +/ band around the Lo Lim within O
LL Band which the tests will continue to completion
Quik Test The leak (flow) rate +/ band around the Hi Lim within O
HL Band which the tests will continue to completion
EDC Enable Should Environmental Drift Compensation be activated? O A O
Auto Setup sets to Yes
EDC Defines the band about the master part curve where test O A O
Percentage values are saved to calculate EDC drift. Auto Setup sets to
10%.
EDC Defines the number of test results within the EDC band O A O
Quantity used to calculate drift. Auto Setup set to 30.
M Represents variables manually entered by the operator in AutoSetup
A Variables calculated and set by Auto Setup routine.
O Optional variables entered by operator after setup to meet application requirements
S Represents variables manually entered by the operator (Auto Setup- not available for this test type)
Blank Not applicable to the test
Figure 86 Test Parameters screen
Rev 11/18/08 5-7

EDC (Environmental Drift Correction) adjustment or offset is the allowed band around the
Master Part curve due to fluctuations in process temperature or test volume. This compensation
band is calculated as a percentage of the difference between "Master Part Loss and "Hi Limit"
parameters. The function calculates the environment drift based on a moving average of the EDC
Quantity of test results that are within the percent band around the "Master Part " pressure curve.
The test result must be an accept that is above the Lo Lim value. EDC Percentage value can be
set at: Off, 10%, 25%, 50%, 90%. The Auto Setup routine sets the EDC On with a 10% band
for a quantity of 30 units. EDC resets to zero when power is cycled on, there is no activity for
one hour, an Auto Cal is performed, or the Lo Limit or Hi Limit values are changed.
Test Evaluation
Test results are compared against two set points for pass or fail status. There are three areas for
evaluation of results: above high limit, between limits, and below low limit. This parameter is
not editable. This fixed evaluation criteria is:
Test Evaluation Code Description

Above Hi Lim>Betw>Below Lo Lim Three zones of evaluation for Pass and Fail
F P F* Pass if between high and low limits
*Default setting for Auto Setup routine and instrument
Figure 87 Test Evaluation
F > Hi Lim > P > Lo Lim > F
High limit reflects a big loss or fall

back in pressure or vacuum
Figure 88 Test Evaluation options as displayed on bar graph display
For typical leak test applications, the high limit value is the reject leak rate. Therefore, the
flow rates (pressure drop or pressure loss rates) above the high limit are designated as Fail. The
low limit value is typically set at zero or at a negative value that is 10 to 30% of the high limit
value (or reject rate) below zero. (i.e. If the high limit or reject rate is 10 sccm, then the low
limit value would typically be set at -1 to -3 sccm.). The area between the limits is designated
as Pass. The low limit value can alarm the operator by failing tests if the measured pressure
loss or 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, environment,
or fill air or if the part volume changes significantly due to tubing or part blockage. The area
below the low limit is set as Fail to fail tests with significantly low or negative leak rate values.
The fixed set up for the Sentinel C28 is FPF.
FAIL>high>PASS>low>FAIL (FPF - Pass if between high and low limits)
For the Occlusion (blockage) test, the High Limit Pressure value represents the high limit for
back pressure resulting from a restrictive flow path allowing a minimum flow rate through the
part. The Low Limit Pressure represents the low limit for back pressure resulting from a less
restrictive flow path allowing a maximum flow rate through the part. The set up is
FAIL>high>PASS>low>FAIL.(FPF Pass if flow greater than Low Limit Pressure but less
than Hi Limit Pressure).
Rev 11/18/08 5-8

For typical flow applications, the test verifies that acceptable flow occurs between a low and
high flow limit. The typical set up would be FAIL>high>PASS>low>FAIL (FPF Pass if
between limits).
CALIBRATION PARAMETERS
Figure 89 Calibration Parameter screen

Calibration Parameters are values that are measured or calculated as a result of the Auto Cal
routine for a pressure decay leak rate test. This screen only appears for pressure decay leak
rate tests. The table below describes the parameters. The Calibration Parameters are not
editable. There are no Calibration Parameters for Pressure drop, Pressure Rate of
Change, or Occlusion tests because there is no Auto Cal routine for these tests.
Parameter Description PLR

Performance Resultant evaluation of ratio of Master Part Loss (Flow) to A
Factor Master+Leak loss (Flow), Test Pressure, and loss (flow) due
to Leak Std
Master Part Measured pressure at the midpoint of the test cycle during A
Press Auto Cal process for Master no-leak part.
Master+Leak Measured pressure at the midpoint of the test cycle of second A
Press test during Auto Cal on master part with Leak Std.
Master Part Measured pressure loss for Master no-leak part by absolute A
Loss transducer during first test of Auto Cal process
Master+Leak Measured pressure loss by absolute transducer during second A
Loss test of Auto Cal for Master part with Leak
Corr. Leak Leak Std Cal Flow adjusted from the Leak Std.Cal Press to the A
Std Flow Target Pressure.
A represents variables determined automatically by Auto Cal routine.
Blank - not applicable to the test.
Figure 90 Calibration Parameters screen
Rev 11/18/08 5-9

MISCELLANEOUS
Figure 91 Miscellaneous Part Configuration screen
Part Name:
Enter user desired 12-digit alphanumeric name of part. This part name is displayed in the upper
right corner of each screen in Monitor and Part Configuration.
Cal method
The Sentinel C28 instruments can perform the auto calibration routine in one of four ways. The
method depends on where the leak standard is located and whether one or two parts will be tested
during the calibration sequence. The choices are:
Select Description Explanation
Parameter
One Part Automatic test Automatically tests same Master part twice using calibrated
Int. LS cycling using Leak leak standard mounted on the internal pneumatic block.
Std in manifold With integral tooling control, tooling does not retract
between tests.
One Part - Manual testing of Tests same Master part twice using calibrated leak standard
Ext LS same part using mounted externally from the instrument. With integral
Leak Std outside tooling control, tooling does not retract between tests. A
instrument start input is required to start second test.
Int. LS two parts using standard mounted on the internal pneumatic block. With
Leak Std in integral tooling control, tooling retracts between tests. A
manifold Start test input signal is required either via the keypad or
second test after changing the Master part.
Ext LS two parts using standard mounted externally from the instrument. With
Leak Std outside integral tooling control, tooling retracts between tests. A
instrument Start test input signal is required either via the keypad or
second test after changing Master part with leak standard.
*Leak std. value must be pre-set in Part Config, Test parameters, under Leak Std Value.
Figure 92 Calibration Method options
Rev 11/18/08 5-10

COPY PART PROGRAMS

The current active part program can be copied to a new part program number by using this copy
program. All parameters including timers, pressures, leak values, calibration data, units, part
name, tooling, inputs, and outputs are copied to the new part program number.
Copy to Target Part 1 (desired Part Number)

Edit the desired or target part number where all the Part Configuration information for the current
active part program is to be copied.
Copy Part Program No/Yes

If the target part program is empty the parameters will be copied while the line on the display
shows Please Wait. If the target part program is already setup with part parameters, a message
will appear with a warning and request, Target Part is not empty, are you sure you want to
overwrite? Answer yes, if appropriate, and all the parameters will be copied over.
AUTO RUN
The Auto Run function performs repetitive tests to verify the instrument's functionality or conduct
repeatability tests on one part. The system uses the Relax timer (set within PART CONFIG,
TIMERS function for each part program) as the delay timer between tests. If the system is using
the tooling functions, the tooling will not release between tests.
Auto Run Method (Standard or LS on 3rd)

The Auto Run function will perform test repeatedly using one of two methods. The first method
conducts the same test repeatedly without any changes to the part setup. The second method
conducts the test repeatedly but the instrument will open the Leak Std Isolation valve every third
test to add the Leak Standard to the tests. It will provide test data for both the Master Part and a
part at the Leak Standard leak rate.
Autorun Cycle Count 010

Before initiating the AutoRun routine, edit the desired number of tests. The maximum number of
tests that can be set is 2147483647
Autorun Enable (No or Yes)

Edit "Autorun Enable" to Yes
Press the MONITOR key to observe the tests and press START.
After sequencing through each test while in the MONITOR mode, the instrument will briefly
display the measured pressure loss and then calculated leak rate. It will then briefly show the
remaining cycles in Autorun followed by the decrementing relax timer until the next test starts.
To determine how many tests remain within the AutoRun routine, either observe the test
remaining at the end of the next test or press the PART CONFIG key and tab to the MISC screen
to observe the number remaining next to "Autorun Cycle Count". If the display is left on the
MISC tab in PART CONFIGURATION while running AutoRun, the number of remaining tests
will be displayed after each test on the bottom line of the display. The Autorun Cycle Count
display will not decrement. You must press a left and then right arrow key to refresh the screen.
Also after completing the tests, the "Autorun Enable" will remain as Yes after the test is
completed. To reactivate AutoRun, you must edit the "Autorun Cycle Count" to indicate the
number of additional tests desired and edit "Autorun Enable" to Yes and the press START to
begin the cycling.
Rev 11/18/08 5-11

To stop the AUTO RUN routine, press the STOP button at any time. To reactivate AutoRun after
it is stopped (by STOP), you must edit "Autorun Enable", to Yes and press START. If "Autorun
Cycle Count" is set at zero, the instrument will run one test.
UNITS OF MEASUREMENT
Figure 93 Units of measurement for part program (time, pressure, and leak rate)
Time Units
Establishes the resolution and length of the timer settings for the part programs. Each program
can operate with different units of time.
Display setting Description

hour Hours (displayed to xx.xx)
min Minutes (displayed to xx.xx)
sec Seconds (displayed to xx.xx)
msec Milliseconds (displayed to xx.xx)
Figure 94 Units of Measurement for Time
Pressure Units
Select the units of measurement for pressure readings by the part program. (Each program can
operate with different units of pressure.) Changing the units of reading re-scales all the pressure
readings to the new units of measurement. The available units are:
Rev 11/18/08 5-12


Psig pounds per square inch gage
psiv Pounds per square inch below Atm
iWC inches of water column
cmWC Centimeters of water column
mmWC Millimeters of water column
Ksc Kg/cm2
atm Atmospheres
Bar million dynes per square centimeter
cmHg Centimeters of Mercury
inHg inches of mercury
kPa kilo pascals
MPa Mega Pascals
mbar millibar
mmHg millimeters of Mercury
pa pascels
Torr Torr
Figure 95 Units of pressure
Leak Rate units
Establishes the units of measurement for pressure decay leak rate (flow) calculations on the
display. The numeric values entered for high and low limits and leak standard values must be in
the units of measurement set here. Units available are:

sccm Standard cubic centimeters per minute
sccs Standard cubic centimeters per second
scch Standard cubic centimeters per hour
slpm Standard liters per minute
slps Standard liters per second
slph Standard liters per hour
scfm Standard cubic feet per minute
scfs Standard cubic feet per second
scfh Standard cubic feet per hour
Figure 96 Units of Flow Rate or Leak Rate
Units of measurement for the pressure loss readings
Select the units of measurement for pressure loss or pressure loss per second readings during the
test cycle by the part program. (Each program can operate with different units of pressure.)
Changing the units of reading re-scales all the pressure loss readings to the new units of
measurement. The available units are:
Rev 11/18/08 5-13


Pressure Loss Pressure Loss/Second (/second)
psig psi/s pounds per square inch gage
psiv Pounds per square inch below Atm
iWC iWC/s inches of water column
cmWC cWC/s Centimeters of water column
mmWC mWC/s Millimeters of water column
atm Atm/s Atmospheres
Bar Bar/s million dynes per square centimeter
cmHg cHg/s Centimeters of Mercury
inHG iHg/s inches of mercury
kPa kPa/s kilo pascals
MPa MPa/s Mega Pascals
mbar Mb/s millibar
mmHg mHg/s millimeters of Mercury
pa Pa/s pascels
Torr Torr
Ksc Ksc/s Kg/cm2
Figure 97 Units of pressure change or change rate during Test cycle
DIGITAL INPUT AND OUTPUT CONFIGURATION
The Sentinel C28 can communicate with external hardware using digital inputs and outputs.
There are 6 input and 3 output terminals prewired to a terminal connector on the top of the
enclosure. The 3 sourcing outputs are solid state relays. As a group they are fused for 2.5 amps.
The 6 inputs are sinking. They can be wired to pushbuttons, prox switches, lights, relays,
solenoid valves, etc. or to a PLC for the interface or control of the process that the instrument is
monitoring. See Chapter 10 Digital Inputs/Outputs for more explanation.
Because of the variety of functions that these inputs and outputs perform, they are divided into
two general types: Universal and Part Program Specific. Universal inputs or outputs are
functions shared by all part programs so when selected within a part program their function is
automatically assigned to that terminal for all other part programs. These inputs and outputs are
usually connected to a Start button or Part Result light that serves the same function for every part
programmed in the instrument. The remaining inputs and outputs are selected specifically for the
part program in which they are picked. There are groups of outputs that can share a terminal and
have different functions depending on the part program. This provides the flexibility to have
defined inputs and outputs only operate within certain part programs. For instance, there may be
a tooling valve that operates an air actuated connector for sealing parts. Within each part
program this valve-connector can be used or not to seal different test parts. See pages 11-10
through 11-10 for an example.
Rev 11/18/08 5-14

DIGITAL INPUT CONFIGURATION
Figure 98 Digital Inputs programming screen
The standard Sentinel C28 has six digital inputs wired to the I/O Connector on top of the
instrument. Define each terminal for wiring purposes before completing this program. Select the
use of these inputs within each part program. If an input is not used within the program, select
Unassigned. If the input was assigned to a Universal input within another program, it will be
automatically assigned within all other part programs. If the input terminal is assigned to one of
the Part Program Specific functions within one of the other part programs, Constrained will
appear on the Input terminal and only inputs within its part program specific group can be
selectable for that terminal in other programs. The complete list of available inputs follows.
Universal Inputs (Automatically set within all part program when defined in any one program.)
Test Cycle Inputs Test Result Binary Part Program

Inputs Selection Inputs
Start Station SPC Test Part Part Select B1
Stop/Reset Station Part Select B2
Hold Part Select B3
Vent/Halt Part Select B4
Part Select B5
Figure 99 Universal Digital Input Options
Rev 11/18/08 5-15

Part Program Specific Inputs Individually set within each part program. Each part program
can select whether to use one of these Part Program Specific Inputs in the test or not.
Start Auto Part Test Leak

Test Cal Control Control Std
Group Group Group Group
Start Auto Part Ext Open
Part Cal Present Press Leak Std
Sw
Figure 100 Part Program Specific Programmable Inputs
Binary Part Program Select Inputs
Binary inputs are Universal inputs that remotely select the new part program. The number of
Binary Input terminals required depends on the highest part number that is to be accessed. Part
program number 1 (1 terminal), programs 2 and 3 (2 terminals), programs 4-7 (3 terminals),
programs 8-15 (4 terminals), and programs 16-31 (5 terminals). The inputs must be appropriately
set before the start signal is sent. If all binary part program select inputs are low, the instrument
tests using the last part program selected.
See the programming option under the Tooling tab where tooling motion inputs are defined for
each part program.
Digital Input Description

Test Input Functions
Universal Inputs
Start Station Initiates the testing function for the active part program.
Stop/Reset Stn Advances the test immediately to the exhaust cycle and then releases
tooling (if selected). Required as input when tooling is not released for
reject test results. See more description in Chapter 12.
Hold Pauses the test cycle within any phase of test sequencing. When the Hold
input is released, the test resumes.
Vent/Halt Advances the test immediately to the exhaust cycle but does not release any
tooling motion. A separate Stop/Reset Stn input is required to release the
tooling motions to the home position. See more description in Chapter 12.
SPC Test Part If this input is high when the Start Test input is received, the test results
will be identified as an SPC part by an * in the test result data and on the
TEST DATA screen. Used to sort test results and identify special SPC part.
Part Program Specific Inputs
Ext Press Sw Digital input (can only define one) must be received before the end of the
fill cycle in order to continue the test cycle. This could be an external
pressure verification signal or some poki-yoki test.
Start Part This part specific input starts the test of the part program in which it is
programmed. This input can link the test result of another part program to
automatically start a specific test program based on the result of that test.
This input facilitates part linking. Care must be taken when tooling control
is involved between tests because the tooling of each test is independent.
See further information about programming linking below.
Rev 11/18/08 5-16

Part Present This input (only one will be monitored) must be high when the start test
input is received. It must go low between part tests. Indicates the presence
of the part or component before receiving a Start input signal. This can
verify that a part is in the test fixture or provide one poki-yoki input signal.
AutoCal Remotely initiates the Auto Cal routine. Also requires the Start input(s)
when the master part is positioned in the fixture and ready for testing.
Open Leak Std. Opens the Leak Std Calibration valve during complete test cycle to add the
Leak Std to the test circuit.
Binary Part Selection Inputs
Universal Inputs (Number of required inputs depends on highest
part number to be selected.)
Part Select B1 One binary input for part program 1
Part Select B2 Two binary inputs for programs 2-3
Part Select B3 Three binary inputs for programs 4-7
Part Select B4 Four binary inputs for programs 8-15
Part Select B5 Five binary inputs for programs 16-31
Figure 101 Universal and Part Program Specific Inputs
PART PROGRAM LINKING
The Sentinel C28 can sequence through two or three tests by wiring the part specific input Start
Part to part specific outputs like Test Passed and Test Failed. This is a hard wire approach to
multiple test sequencing. The part-specific test result output like Test Passed or Test Failed
is wired from one part program to the part specific Start Part input of a follow-up test program.
Each part program is independently executed including programmed digital inputs and outputs.
This method makes it possible to select a unique sequence of more than two different Test types
like a pressure decay test followed by an Occlusion test followed by a rate of change test. The
tooling control and all the digital I/O functions, test parameters, and test results for each part
program are performed in sequence and independently stored by each individual part program.
To use this method for performing more than one test requires individually programming and
calibrating each desired part program. The part programs are joined or linked by wiring the Test
Passed or Test Failed digital output programmed within a test program to the programmed
Start Part digital input of the succeeding test program. The number of available digital
I/O.limits the number of test programs that can be linked. It does not provide total part tooling
control continuity through the sequencing of the multiple tests. The test results are individually
identified by their independent test program numbers. Auto Setup and Auto Cal would be
performed for each part program independently.
Editing the Inputs
Unassigned and Constrained Inputs

Within Part Config, Inputs, the inputs will either be Unassigned, Constrained, or
assigned to one of the Universal or Part Program Specific Inputs.
Unassigned - No input within any part program has been assigned to this terminal. There is
the full range of inputs available for selection.
Rev 11/18/08 5-17

Constrained - A Part Program Specific input has been assigned to this input within another
part program. When attempting to edit the assignment of this terminal, only other input types
within the same input group will be displayed for selection. In most cases no other option is
available except Unassigned.
Programmed Universal Inputs Within a program, if a terminal is already assigned to an

input signal that is universal, it is common to all part programs. The choices are leave as is or
Unassign all parts. If Unassign all parts is selected, press ENTER and EDIT to re-assign the
input to a different input function. This will also Unassign that terminal in all of the other part
programs.
Programmed Part Program Specific Inputs Within a part program, if a terminal is already
assigned to a Part Program Specific input, only other Part Program Specific inputs within its
group can be selected for that terminal. When trying to change an assigned input from a
programmed condition, press the EDIT key and use the arrow keys to sequence through the
possible alternatives. To deactivate the use of this input terminal within this part program, select
Unassign. To change the input to a different function outside the previously selected group,
first select Unassign all part and press ENTER. Then press EDIT key and use the arrow keys
to sequence through the input choices to find the desired input function. But be aware that by
selecting Unassign all part, the input function is unassigned for all the other part programs until
they are reassigned.
DIGITAL OUTPUT CONFIGURATION
Figure 102 Digital Output programming screen
Within each part program select the desired digital outputs for the assigned terminals as needed
for the part program. If an output is not used within the program, leave Unassigned. If the
output was assigned to a Universal output within another program, it will be already assigned
within all the part programs. If the output terminal is assigned to one of the Part Program
Specific functions within one of the other part programs, Constrained appears on the Output
terminal and only similar outputs will be selectable on that terminal in other programs. This
provides the flexibility to have defined outputs only operate within certain part programs. As an
example there may be a tooling valve that operates a cylinder for sealing parts. Within each part
Rev 11/18/08 5-18

program this tooling valve may or may not be required so some programs may use the tooling
motion and others not.
The standard Sentinel C28 has three digital output terminals. Define each terminal before
completing the wiring and programming. See the Output Timing chart below for information
about when the outputs occur. The outputs are Universal or Part Program Specific. Within
the Part Program Specific outputs, there are Groups of outputs that can share the same digital
output terminal between part programs. When programming the same terminal for different
outputs the device receiving the output must be capable of interpreting the signal differently for
different part programs. The available outputs are:
Universal Outputs (Automatically set within all part programs when defined in any one
program.)
Test Cycle Results

AutoCal Mode Severe Leak
Malfunction
Part Accept
Part Reject
Figure 103 Universal Output Signals
Part Program Specific Output Groups (Individually set within each part program. Different
outputs within a group can be assigned to the same output terminals within other part programs. )
Test Cycle Results Test Control

Calibration Group Test Indication Group Tooling Control Outputs
AutoCal Master Press Select Tooling Extend 1
AutoCal LS Tooling Retract 1
Test Cycle Timer Group Test Result Group
In Relax Test Passed
(In test) Test Failed
In Pre-fill Below low limit
In Fill Between limits
In Stab Above high limit
In Test
In Exhaust
Figure 104 Programmable Outputs
These outputs are programmed to go on during certain events of a typical test cycle for external
use. The chart shows the outputs for single pressure test configuration. Review the chart and
decide which outputs perform the functions desired for your tests. These sourcing solid-state relay
outputs are fused as a group for 2.5 amps and can handle either 120 volts AC or 24 volts DC
depending on I/O power configuration supplied (three soldered red mobs across terminals below
and to the right of the output terminals in upper right portion of the circuit board are for 120 VAC
I/O). See circuit board diagrams on 5-24 and page 11-13 for location of these mobs. The
Input/Outputs are powered independent of the instrument power supply so that safety interlocks
with emergency stop and light curtains will not shutdown instrument power.
Rev 11/18/08 5-19

Output Selections
Test Cycle Outputs

AutoCal Mode Goes high during entire Auto Cal routine from start of first test until end
of exhaust of second test. This output could be used to prevent normal
machine cycling while AUTO CAL is being performed.
AutoCal Master Goes high during first test of Auto Cal routine while testing the Master
part.
AutoCal LS Goes high during second test of Auto Cal routine while testing the
Master part with the Leak Std included.
In Relax Goes high during the Relax timer in the Auto Setup, Auto Cal, or Auto
Run routines.
Press Select Goes high during the entire test sequence from start of Pre-fill timer 1 to
the end of Exhaust timer.
In Pre-fill Goes high during the Pre-fill cycle only. Could be used to activate an
external fill valve to fill large volume parts quickly.
In Fill Goes high during the Fill timer only
In Stab Goes high during the Stabilization timer only
In Test Goes high during the Test or detect timer only
In Exhaust Goes high during the Exhaust timer only. Could be used to activate an
external exhaust valve to prevent exhausting dirt or moisture from the
part back through the instrument pneumatics.
Figure 105 Test cycle outputs
Test Result outputs
Part Results
Part Accept Signals the completion of an accepted part test after the last tooling
motion. For dual-test stations, this indicates that both tests passed. The
output stays on until the start of next part test.
Part Reject Signals the completion of a rejected part test after the last tooling motion.
For dual-test stations, this indicates that either of the dual tests failed. The
output stays on until the start of next part test.
Severe Leak Goes high after the last tooling motion for part tests that fail to reach
Minimum Pressure within the Pre-fill timer or remain above minimum
Pressure during Fill and Stabilization timers. It stays high until the start
of the next test. The reject output also goes high for a severe leak.
Malfunction Goes high after the last tooling motion for part tests that fault out due
tooling problems; start test, part presence, or ext press sw faults;
transducer faults; invalid calibration, leak standard, or flow sensor data; or
outside target window during test cycle. It stays high until the start of the
next test.
Test Results
Test Passed Signals the completion of a test that passed at the start of the exhaust
cycle. This output stays on until the start of a new part test.
Test Failed Signals the completion of a failed test at the start of the exhaust cycle.
This output stays on until the start of a new part test.
Below low limit Goes high at the start of exhaust cycle when test results are below the
Low Limit set point and stays high until the start of the next test.
Rev 11/18/08 5-20

Between limits Goes high at the start of exhaust cycle when test results are between the
Low Limit and High Limit set points and stays high until the start of the
next test.
Above high limit Goes high at the start of exhaust cycle when test results are above the
High Limit set point and stays high until the start of the next test.
Figure 106 Test Result Outputs
Editing the Outputs
Unassigned and Constrained Outputs

With Part Config, Outputs, the outputs will either be Unassigned, Constrained, or
assigned to one of the Universal or Part Program Specific Outputs.
Unassigned - No output within any part program has been assigned to this terminal. There
is the full range of outputs available for selection.
Constrained - A Part Program Specific output has been assigned to this output within
another part program. When attempting to edit the assignment of this terminal, only other
selected output types within the same output group will be displayed for selection.
Programmed Universal Outputs Within a program, if a terminal is already assigned to an

output signal that is Universal, it is common to all part program. The choices are leave as is or
Unassign all parts. If Unassign all parts is selected, press ENTER and EDIT to re-assign the
output to a different output function. This will also Unassign that terminal in all of the other
part programs. If another Universal output is selected, it will apply to all of the other part
programs. If a Part Program Specific output is selected, then that group of outputs will be
available for that terminal in all of the other part programs.
Programmed Part Program Specific Outputs Within a part program, if a terminal is

assigned to a Part Program Specific output, it will display Constrained. An example is a
tooling extend or tooling retract output. When trying to change an assigned output from a
programmed condition, press the EDIT key and use the arrow keys to sequence through the
possible alternatives. To deactivate the use of this output terminal within this part program, select
Unassign. To change an output to a different function outside the previously selected group,
first select Unassign all part and press ENTER. Then press EDIT key and use the arrow keys
to sequence through the output choices to find the desired output function. But be aware that by
selecting Unassign all part, the output function is unassigned for all the other part programs
until they are reassigned.
Rev 11/18/08 5-21

TIMING CHARTS
Auto Calibration Cycle
AutoCal Mode
AutoCal Master
AutoCal LS
In Relax
First Test of Master Relax Second test of Master +LS
Figure 107 Auto Calibration Digital Output Timing Chart
Pre-
Fill Fill Stabilize Test Exh.
Tool Extend 1
Press Select
In Prefill
In Fill
In Stab
In Test
In Exhaust
Tool Retract 1
Test Passed
Test Failed
Below Lim
Between Lim
Above Lim
Part Accept
Part Reject
Severe Leak
Malfunction
Figure 108 Single Test Digital Output Timing Chart
Rev 11/18/08 5-22

TOOLING CONFIGURATION
Figure 109 Tooling setup screen
The Sentinel C28 will support one tooling motion, part present, and start test options. There are 6
digital inputs and 3 digital outputs to program within the Input and Output screens to interface
these control functions with each part program. The option for a tooling motion is set for each
part program within the Tooling screens. Selection made on this screen defines some of the
outputs selections found on the Outputs screen.
Tooling Option (Disabled, Off, On)
Tooling Option provides progressive steps into implementing tooling control.

On - Implements all the tooling options selected on the Tooling Control, Timers, Input
and Output screens into the test sequence.
Disabled - Prevents any tooling control settings from being implemented into the test
sequence. Allows for the set up of all the variables on the Tooling Control screens and the Timer
and Outputs screens
Off - Prevents any tooling control settings from being implemented into the test
sequence. Allows for the set up of the Tooling Control screens only. Does not allow the tooling
variables selected on Tooling Control screens to appear in Timer, Input, or Output screens. If the
Tooling Option is changed to Off from Disabled or On, it will eliminate the output tooling
motions signal programming for the outputs.
Number of Motions (0 or 1)
There are 0 or 1 tooling motions or control outputs available for each part program. Each part
program can have a different tool output. The selection of a tooling motion here will define if a
tooling output will appear in the Outputs screens. After defining if a tooling motion output or
part presence is required, go to the Input and Output screens to program the sequence of inputs
and outputs to the wired to the I/O terminals.
The Extend and Retract motions have Extend and Retract timers without Extend and/or Retract
digital inputs to control the sequence to the test cycle. There is no feedback, but there is a timer
delay for the tooling motion before the start of a test or display of the test result.
Rev 11/18/08 5-23

All the Digital Inputs and Outputs must be wired to the 6 input and 3 output terminals I/O pins of
the connector on top of the enclosure. The source power for the I/O should be independent of
instrument power. Do not use the internal 24 volt power supply as the source for the 24 volt
I/O board because it is not sufficient.
24VDC instrument power terminals 6 Digital Input terminals

Digital I/O power terminals 3 Digital output terminals
ST1 ST2 ST3 Three red mobs on 120

VAC I/O circuit
boards. There are no
mobs on a 24 VDC I/O
circuit board.
Ethernet port USB port
Figure 110 Instrument Circuit Board
Pre-wired I/O
To simplify the wiring of the digital inputs and outputs, the input and output terminals of the
instrument are wired to an external 14 pin connector mounted on the top on the enclosure. An
interface cable is offered as an option. The diagram below indicates the internal termination, wire
color code, and function of each pin for the internal 14 pin I/O cable and connector.
Rev 11/18/08 5-24

Turck Wire Color Function ST3 on board ST2 on board ST1 on board
Internal and External digital outputs digital inputs DC power
Pin # Cables
A Brown Output 3 OT3 output 3
C Red/Blue Input 1 IN1 Input 1
E Black Neutral ION Neutral
G Pink Input 3 IN3 Input 3
J Green Output 2 OT2 output 2
L Blue
M Orange Input 5 IN5 Input 5
N Gray/Brown
O Violet Input 2 IN2 Input 2
P White Input 6 IN6 Input 6
R Red Hot IOH Hot
S Gray
T Yellow Input 4 IN4 Input 4
U Tan Output 1 OT1 output 1
Figure 111 Internal Input/Output Connector Cable and Pinouts to Internal Connectors
Rev 11/18/08 5-25

CHAPTER 6 PRINCIPLES OF OPERATION

INSTRUMENT CONFIGURATIONS
Depending on the types of tests required and resolution and repeatability desired, the Sentinel
C28 instruments are assembled with one of the following pneumatic packages. See pages 1-6
through 1-7 for the catalog breakdown for this instrument.
Manifold Test Types Pressure ranges

Version
PA Single Pressure/ vacuum decay leak rate, loss, rate of Vacuum to 100 psig
Std Cv loss, or occlusion tests with standard Cv valves.
1P
PB Single Pressure/ vacuum decay leak rate, loss, rate of Vacuum to 200 psig
High Cv loss, or occlusion tests with high Cv valves (5X greater
1P flow than standard Cv valves)
PN Single Pressure/ vacuum decay leak rate, loss, rate of 10 psiv to 100 psig
Low Vol. loss, or occlusion tests with low Cv valves and small
1P manifold volume (<1 cc)
Figure 112 Pneumatic Manifold configurations
The pneumatic module is mounted in the bottom of the enclosure. It interfaces to the circuit
board, operator keypad and display. The enclosure limits the number of total regulators to one.
The following details descriptions of the tests, pneumatic circuits, and timing diagrams.
PRESSURE DECAY TESTING
Leak Testing Using Absolute Pressure Decay Test Systems
The basic principle of operation of a pressure decay leak test instrument is to fill the test part to a
specified target test pressure, isolate the test part from the source air and allow the pressure to
stabilize, and then measure the pressure loss due to a leak over a defined time. The leak test
instrument translates the pressure loss value measured over the fixed test time to a leak or flow
rate. To achieve the greatest accuracy and repeatability in this test the Sentinel C28 corrects all
pressure loss values and leak standard flow rates for deviations in pressure from the Target
pressure of the test using the formula below.
dPloss = Actual dPloss x (Ptarget/Ppart)
dPloss is the corrected pressure value for the test

Actual dPloss is the measured pressure loss in test
Ptarget is the specified Target Pressure for the test
Ppart is the measured test pressure at the mid point of the test cycle
With these corrected values the instrument calculates the leak or flow rate basically using the
following relationship. The instrument measures and corrects the parameters of dPM and dPM+LS
during the Auto Cal function and stores these parameters for the calculations.
Rev 11/18/08 6-1

dPPart - dPM
Leak Rate = ---------------- x LRLkStd + EDC
dPM+LS - dPM
Leak Rate = Calculated Leak Rate (sccm)

*dPpart = corrected pressure loss of the test part (psi)
*dPM = corrected pressure loss for non-leaking master part during Auto Cal cycle (psi)
*dPM+LS = corrected pressure loss for the master part with the leak standard during Auto Cal
(psi)
*LRLkStd = Corrected leak value on certified leak standard used to calibrate the system (sccm)
EDC = Environmental drift correction is the correction factor for drifts in ambient
temperature, part temperature, part elasticity, and part absorption characteristics from original
calibration parameters in sccm.
*Pressure loss and leak rate values are adjusted for pressure variations from target pressure per
the formula shown above.
The settings for the Pre-fill, Fill, Stab, and Test timers influence the resolution and
repeatability of the instrument under test conditions. Calibrating the instrument to each part type
using the timer settings establishes the pressure loss to leak rate relationship for that part under
the conditions of the defined test cycle and that particular part volume.
Pressure Decay, Pressure Loss, Pressure Rate of Change, and Occlusion Testing with
Absolute Pressure Transducer
Version PA, PB, and PN Single Regulator/Single Transducer Test Pneumatics
Part
Isolation Pressure
Fill/Exhaust Valve Transducer
Valve
Test
Part
Regulator Leak
Standard
Calibration Valve
Figure 113 Version PA, PB, and PN Pneumatic diagram for pressure decay, pressure loss,
pressure rate of loss, and occlusion tests
Rev 11/18/08 6-2

Fill/Exhaust Pilot Valve Part Isolation Pilot Valve Fill/Exhaust Pilot Valve
Part Isolation Pilot Valve Fill/Exhaust Pilot Valve Calibration Pilot Valve
Calibration Pilot Valve Calibration PilotValve Part Isolation Pilot Valve
Figure 116 Test

Type/Manifold PN
Figure 114 Test Figure 115 Test Low internal test volume
Type/Manifold PA Type/Manifold PB for single pressure or
One regulator for a High Flow manifold vacuum decay test.
pressure or vacuum with one regulator for a Limited to 10 psiv and
decay test instrument. pressure or vacuum 100 psig.
Limited to 100 psi tests decay test instrument.
Limited to 200 psi tests.
A precision mechanical regulator controls the fill (evacuation) pressure for the test through a
normally vented fill/exhaust valve and a normally open part isolation valve. After the fill cycle,
the part isolation valve closes and then the fill/exhaust valve changes to vent the closed part
isolation valve to atmosphere during the test cycle. This prevents leakage from the air source into
the test pneumatics, which might hide a leak condition. At the end of the test cycle, the part
isolation valve opens to exhaust the part. The normally closed calibration valve opens
automatically only during the second test of the Auto Calibration routine and during Auto Setup
routine in order to connect the calibrated leak standard to the test volume. There is also a manual
control of the calibration valve within the SELF TEST, Open Orifice routine for calibration
verification. There is a programmable digital input option to activate this isolation valve to the
Leak Standard as an automated way of verify the system calibration. In AutoRun there is an
option to open the Calibration Valve to add the Leak Standard for every third test.
Some applications require a fast fill capability because of the large volume of the test part. The
purpose of the high flow pneumatics is to quickly get air into (or evacuate) the part for testing and
exhaust (or vent) the part at the conclusion of the test. The high flow valves minimize the pre-fill
and exhaust times, therefore minimizing the total cycle time. The high flow pneumatics valves
have a Cv factor or flow coefficient that is approximately 5 times greater than the standard valve
package.
Rev 11/18/08 6-3

Pre-fill Fill Stabilization Test Exhaust

Fill/Exhaust
Valve
Part Isolation
Valve
Calibration*
Valve
*only activated during second test of Auto Cal, third test of Auto Setup or manually via Self
Test or digital input.
Figure 117 Timing sequence for Version PA PB, and PN pressure decay, pressure loss, and
pressure rate of change tests
Occlusion (Back Pressure)

The occlusion test is a back pressure test. The part is pressurized by activating the Fill/Exhaust
Valve. At the end of the Test timer the actual test pressure is compared to the Low Limit
Pressure and High Limit Pressure settings. Low Limit Pressure indicates high flow or minimum
blockage or low back pressure. High Limit Pressure indicates low flow or maximum blockage or
high back pressure. At the end of test, the part exhausts when the Fill/Exhaust valve deactivates.
Test Exhaust
Fill/Exhaust
Valve
Figure 118 Timing for occlusion tests in all manifold types that offer Occlusion testing
ESTABLISHING TEST PARAMETERS

Leak Values Within LEAK routine
Low Limit High Limit

The Sentinel C28 instruments have two set points, low and high limits, with which to compare
test results. These limit values define three regions (above high limit, between limits, and below
low limit) in which to qualify the results of each test. There are five optional outputs, which are
activated starting at the beginning of the exhaust cycle to indicate in which area (test passed, test
failed, above high limit, between limits, and below low limit) the test results fell.
The instrument evaluation criteria are defined FPF (Fail below Lo Lim, Pass between limits, and
Fail above Hi Lim). The Fail/Pass/Fail criteria matches the appearance of the bar graph on the
display. When the part is pressurized, the bar graph goes up or to the right on the display. As
pressure is lost the bar graph falls or moves to the left on the display. Small leaks cause a small
loss. High Leakers have a large drop in pressure. Therefore, the bar graph moves to the right as
the part is charged with pressure or evacuated for a vacuum test. If the part has a small or no
leak, the bar graph will move very slowly back to the left. If the part has a large leak, it will
move quickly to the left. Therefore, the Lo Lim threshold is on the right side of the graph and the
Hi Lim threshold is on the left side of the graph for both pressure decay and vacuum decay
testing.
Rev 11/18/08 6-4

Hi Lo
Lim Lim
p/f p/f p/f
Accept/ Reject>Hi Lim> Accept/Reject>Lo Lim>Accept/Reject

Above Hi Lim Between Limits Below Lo Lim
Figure 119 Bar Graph illustration

For pressure decay leak test, pressure loss, and pressure rate of change 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, loss, or rate of
change 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 Part Configuration, Chapter 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 is also set to fail. It is usually
desirable to alert the process when parts test significantly better than when initially calibrated so
it is set to fail any value that is below the low limit.
For occlusion (blockage or back pressure) applications, it would be desirable to check that the
effective pressure when pressurizing a part is within limits of back pressure that is controlled by
the flow going through a part. High flow will cause low back pressure while low flow will cause
high back pressure. The Low Limit Pressure set point will be on the right side of the display and
High Limit Pressure will be on the left side of the display. This is consistent with Low Lim and
High Lim display for the all the other tests.
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. The Low
Limit flow set point is on the right while the high lim flow is on the left side.
Leak Standard (orifice)

This is the value of the leak standard located on the internal pneumatic manifold or of the
calibration device located externally in the test station pneumatics or in the part. This value is
used when calibrating the instrument. It must be entered before starting the Auto Cal process.
The internal leak standard has a calibrated leak value printed on the stainless steel housing. There
is also a printed calibration report for the leak standard included with the instrument or located in
the component documentation binder if an entire machine is supplied by CTS. The flow value of
the leak standard was determined at a specified pressure, which should be the test pressure for the
application. If the test pressure is different, the flow value for the leak standard will be different.
The calibration date is provided on the flow standard and certificate. .
Environmental Drift Correction (EDC)
The environmental drift correction routine helps to maintain the calibration of the system by
continuously monitoring and calculating a correction factor for 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, part absorption characteristics, etc. These factors influence the dynamics of how the test
Rev 11/18/08 6-5

part reacts to the testing process and the determination of the relationship of pressure changes to
leak rate. "Environmental Drift Correction defines how wide of a band around the Master Part
Loss value will be considered as normal variations in flow rate for a non-leaking part. The
"Environmental Drift Correction (+EDC %) is based on reject rate. The instrument continuously
calculates a running average of test results that fall within the band (+EDC %) about the original
Master or No-Leak part curve. It corrects each future result by the calculated drift determined
from previous test results. The drift value is calculated as shown.
n Flow
Environmental Drift Correction = ------------- - Master Part Flow
n
Typical settings for Environmental Drift Correction are 10, 25, 50, and 90%. The sample size
is set as EDC quantity (3 or greater). Flexible parts require a greater Environmental drift
correction than rigid parts.
The Environmental Drift Correction effectively defines how much shift can occur. This limits
the routine from continuing to compensate for possible growing leaks in the seal or test
pneumatics.
Pressure Values Within Test Parameters settings
Minimum Pressure, Target Pressure, Maximum Pressure, and Target Press Window
The Target Pressure is the specified test pressure. Set the regulator to match the specified
Target Pressure by using the "Set regulator" routine within the SELF TEST display function.
Adjust the regulator to display the desired Target pressure.
The Minimum Pressure (automatically set at 90% of Target Pressure or Target pressure
minus 0.5 psig, whichever is the lowest pressure) must be met initially within the Pre-fill
timer to start the fill cycle. The test pressure must remain within Minimum and
Maximum Pressure limits about the Target Pressure to assure that the part is charged to
the proper pressure or vacuum during the fill (and stabilization) timers. Failure to
maintain pressure within these limits will stop the test as a Severe Leak. The Minimum
and Maximum Pressures are automatically set at +/-10% or +/-0.5 psi, whichever is the
greater band about the specified Target pressure.
During the Test timer the pressure in the part must remain within the Target Press
Window percentage about the Target Pressure (set at 50%). Failure to stay within this
window during the Test timer results in a Malfunction and a test result error message of
Test Pressure Low or Test Pressure High.
Minimum Pressure, Maximum Pressure, and Target Press Window value are not
displayed and are not editable.
Master Press and Master+Leak Press

The Master Press and Master+Leak Press are the pressures measured at the mid point of
the test cycle during the AutoCal routine. These pressures are used to correct the
pressure loss values measured in the calibration routine to the Target Pressure using the
formula.
Rev 11/18/08 6-6

Target Pressure
Master Part Loss = -------------------- x Measured Master Loss
Master Press
Master Part Loss and Master+Leak Loss

The Master Part Loss value is measured during the first test of the AutoCal routine. It
represents the pressure loss associated with testing a Master (leak free) or zero leak part. The
The Master+Leak Loss value is the measured pressure loss in the second test of the AutoCal
routine. Master+Leak Loss represents the pressure drop associated with a Master part that has
a leak equal to the Leak Standard. The Master Part Loss and Master+Leak Loss values
cannot be modified after calibration. These values are adjusted for the variation of the
actual pressure in test verses the Target Pressure.
For pressure decay tests,
[dPPart Master Part Loss ]

Leak Rate = --------------------------------------------------- x (Leak Standard)
[Master+Leak Loss Master Part Loss]
Max Mstr+Leak Loss

This parameter is a safety-check value used during the calibration process to make sure that the
system is not calibrated with a leaking master part or fixture. Its final value should be set 2 times
or less higher than Master+Leak Loss value determined in the initial part calibration. The
AutoSetup routine will automatically set this value at two times the Master+LS Loss after
optimizing the timers to conduct the leak test within the Desired Cycle Time. If you are manually
determining the timers for the test, initially set this value high like 0.4 psi in order to allow error-
free testing while adjusting the timers.
Min Master Loss

This parameter is a safety-check value used during the calibration process to make sure that the
system is not calibrated to Master part with a different volume or characteristic than an actual test
part. Its final value should be set to 50% or lower than the Master Part Loss determined in the
initial part calibration. This value will initially be set at zero in order to allow testing for the first
time.
Low Limit Loss and High Limit Loss

These parameters are set as the test limits for Pressure Loss (Drop) or Pressure Rate of Change
tests. The High Limit Loss or Rate is the set point that represents the test specification of xx
Pressure Loss in yy seconds or zz loss/sec.
Low Limit Pressure and High Limit Pressure

These parameters are the back-pressure limits for the Occlusion test. Low Limit Pressure
represents a high flowing part where the opening is on the high side of the tolerance band. High
Limit Pressure represents a low flowing part where the opening is restrictive or on the low side of
the tolerance band.
Rev 11/18/08 6-7

Timer Values within Part Configuration function - Timers
The purposes of the pre-fill, fill, and stabilization times are to increase the internal air pressure
from atmospheric to test pressure and allow adequate time for the pressure inside the part and test
pneumatics to stabilize. The effect of the fill time upon the stabilization time is discussed below.
When filling the part, the incoming air compresses the atmospheric air inside the part. This
causes heat generation due to the initial air in the part being compressed suddenly (adiabatic
compression). The pressure in the part will match the regulator pressure during the fill cycle
using the relieving characteristics of the regulator to bleed excess pressure or supplying additional
air. When the stabilization cycle begins (for pressure decay tests), the test part is isolated from
the regulator and the part pressure continues to seek equilibrium in an exponential fashion. The
part pressure quickly decreases at first but then slowly decays through the remaining stabilization
time and into the test cycle. The amount of decay in the stabilization cycle is moderated by the
amount of time spent in the fill cycle.
The pressure loss during stabilization and test 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 temperature of the incoming fill air
- The ambient temperature conditions
- The elasticity of the part and fixturing
- The absorption characteristics of part construction
The following factors will require a longer stabilization time:
- Larger part air volumes

- Higher test pressures
- Lower thermal conductivity parts
- Greater differences in temperature between the part and ambient air
- Flexible part walls
- Low leak rate requirements
Room temperature variation can affect the repeatability of the system but are usually minimal.
This variable can be corrected by more frequent calibration or use of the Environmental Drift
Correction feature in the Sentinel C28 instruments.
The fill cycle helps to stabilize the initial rise and fall of pressure in the part by leaving the
regulator connected to the part until the end of the fill timer. Adequate time should be put on the
fill timer so that the pressure does not drop below the minimum test pressure parameter. Because
all pressure loss or flow readings are corrected for deviations from the Target Pressure, it is
usually beneficial to get into stabilization quickly as long as the pressure remains above the
Minimum Pressure.
The stabilization timer is the time allowed for the temperature and volume of the part to stabilize
before the test starts. Enough stabilization time is required by the system so that when calibrating
a good part there is not more than 0.1% loss of test pressure during the test timer cycle.
Minimizing the pressure loss for a good part during calibration will improve the test repeatability.
Rev 11/18/08 6-8

The Sentinel C28 instrument has a pressure-streaming feature via the RS232 ports. This feature
outputs the test pressure every 0.01 seconds from the start signal through the exhaust cycle.
These pressure values can be recorded and plotted via HyperTerminal on most computers using a
data program like MS Excel. The plotted curve may assist in setting the timers if you are
manually trying to set the timers. More information about the pressure streaming values can be
found on page 9-2.
The Auto Setup routine in the Sentinel C28 instrument automatically performs a series of tests to
determine the optimal timer settings for Pre-fill, Fill, Stabilization, Test, Exhaust, and Relax to
achieve the optimal test within Desired Cycle Time. The Auto Setup routine is addressed on the
Function panel of the display keypad.
.
Pre-fill Timer
The pre-fill timer serves as an initial check on the tooling and part. It establishes the maximum
time allowed for the measured pressure in the part to reach the Minimum Pressure value. Once
the pressure reaches the Minimum Pressure, the instrument automatically moves onto the Fill
timer. This timer is usually set at twice the normal time it takes to reach Minimum Pressure. A
Severe leak error message will occur if the pressure does not reach Minimum Pressure within
the Pre-fill time. There are test failed, severe leak, and part reject outputs at the end of the test
cycle and the reject lights go on. Any tooling will retract at the end of the test cycle without
using STOP/RESET unless the Retract on Reject is set for NO.
There is a selectable digital output that goes high during this timer.
Fill Timer
To begin establishing the amount of time required for fill, set the fill timer initially at 2 seconds
for small parts (less than 15 cu. in. or 250 cc. internal volume), or 5 seconds for larger parts. Set
the stabilization and test timers initially to 10 seconds each.
When any change is made to the Fill, Stab, or Test timers, the instrument display will
indicate Calibration required after pushing the START key. An Auto Cal routine must be
successfully performed before another test can be run.
Enter all the test parameters and push MONITOR. Push START to initiate a test on the master
part. Observe the pressure during the fill cycle. If the fill pressure remains above the minimum
test pressure for the duration of the test, reduce the fill timer by 10 to 25%. If the fill pressure
dropped below the minimum test pressure, increase the fill timer. Repeat the test on the master
part and observe the fill pressure to be sure it remains above the minimum test pressure. Repeat
the above to determine an optimal fill time. Once the optimal fill time is set, increase the pressure
regulator setting by 1/2%.
When the pressures drops below Minimum Pressure during the stabilization timer, a Severe
Leak error message will occur. The severe leak and reject outputs will go high until the
start of the next test. If the pressure goes above the Maximum Pressure during stabilization,
Test Pressure High error messages will occur at the end of test and the Malfunction output will
go high but no test lights go on. Any tooling will retract at the end of the test cycle without using
STOP/RESET unless Retract on Reject is set No.
There is a selectable digital output that goes high during this timer.
Rev 11/18/08 6-9

Stab Timer
Before setting the stabilization timer, the fill timer should be set. The optimal settings will
minimize the pressure drop for a good part during test. For small parts, initially set the
stabilization timer to 5 seconds and the test timer to 3 seconds. For larger parts, set the
stabilization and test timers to 10 seconds. Start the test cycle on the master part and watch the
pressure during stabilization and pressure loss during test. If the pressure during stabilization
drops below the minimum test pressure, increase the fill timer. If the pressure loss during the test
cycle is excessive (greater than 0.1% of test pressure), increase the stabilization timer. If the
losses during stabilization and test are within acceptable limits, go to the next section, Test timer.
When the pressure drops below Minimum Pressure during the stabilization timer, a Severe
Leak error message will occur. The severe leak and reject outputs will go high until the
start of the next test. If the pressure goes above the Maximum Pressure during stabilization,
Test Pressure High error messages will occur at the end of test and the Malfunction output will
go high but no test lights go on. Any tooling will retract at the end of the test cycle without using
STOP/RESET unless Retract on Reject is set No. There is a selectable digital output that goes
high during this timer.
Test Timer
With the leak standard value and pressure set in the Test Parameter routine and all parameters
set for a test, activate the Auto Cal routine using the AUTO CAL button. At the completion of
the Auto Cal test routine, review the Master Part Loss and "Master+Leak Loss" values stored
in the PART CONFIG, Calib Parameter screen. The objective for setting the stabilization and
test timers is to achieve at least a minimum difference between the Master Loss and the
Master+Leak Loss values of 0.050 psi for small parts (<250 cc), 0.020 psi for medium parts,
and 0.005 psi for large parts (>15,000 cc) and have the Master+Leak Loss value be at least
twice the Master Loss value. The fill and stabilization timers affect the Master Loss value.
The test timer affects the difference between the Master Loss and Master+Leak Loss values.
Adjust the timers to provide the optimal overall time cycle. There is a selectable digital output
that goes high 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, can be used to open an extra exhaust valve to speed
up the exhaust process or divert possible dirty part air through an external valve.
Relax timer
The relax timer is primarily used as a delay time between the first and second test within the
automatic calibration routine and AutoRun routine. Sufficient delay is required so that the part
can return to a virgin state before the second test. It does not affect the normal testing cycle time.
It needs to be long enough to assure repeatable calibrations. Typical times range from 15 seconds
to 8 minutes depending the test pressure and size/material of the part. This timer is also used as
the delay time between tests when operating the instrument using Auto Run.
Quik Test
During calibration the Sentinel C28 stores the master part calibration test data and calculated
High limit and Low Limit parameters. At the Quik Test Percent of the Test Timer the instrument
measures the pressure loss and compares the projected leak rate from this reading against the
specified Quik Test Low Limit and High Limit bands. If the Projected Leak Rate is within either
Rev 11/18/08 6-10

of these two bands, the test continues to the end of the test timer. If the instruments projected
leak rate is outside of these bands, it will stop the test, output the results according to the Test
Evaluation criteria, and display the projected leak rate. Quik Test is only available for test types
that have an Auto Cal procedure that requires two tests (PLR Pressure decay).
Low Limit Band

-LL Quik Test Limit
Low Limit
+LL Quik Test Limit
Master Part
High Limit Band

-HL Quik Test Limit
Pre-fill, High Limit

Fill &
Stabilize +HL Quik Test Limit
QT% of Test Timer
Timers
Test timer
Figure 120 Graphical illustration of Quik Test
The chart above shows the Master Part curve, the Low Limit with its LL Quik Test band limit,
and the High Limit with its HL Quik Test band limit. If the pressure loss is within either the LL
Quik Test band or HL Quik test band at the QT% of Test Timer, the test will continue and
complete the entire test cycle. If the results are outside the limit bands at the QT% of Test Timer,
the test will stop and the test result will reflect the Test Evaluation criteria (i.e. F/P/F for Fail
>HL>Pass>LL>Fail). Setting narrow bands about the Low Limit and High Limit is a very
aggressive approach that will greatly limit the number of tests that run to the end of the test timer.
Set wider bands as a more conservative approach to Quik Test.
An initial analysis of Quik Test should be performed before actually implementing this feature by
establishing the QT% of Test Timer at 10, 25, 50, 75, or 90% and setting Quik Test to OFF.
An Auto Cal must be performed after setting the "Quik Test Timer %" to measure the typical leak
response curve for the test and determine the response at the Quik Test Timer%. Test production
parts over a reasonable time (up to 1000 parts in various production conditions). The instrument
projects a leak rate at the Quik Test Timer% and then completes the full test cycle and calculates
the leak rate for the complete test. The Sentinel C28 stores up to 5000 test results that include
both the actual complete test result and a projected test result based on the Quik Test
measurement. By comparing the two leak rate results, a percent of error for the Quik Test feature
can be calculated. If the results are satisfactory, the Quik Test feature can be implemented by
setting appropriate High Limit and Low Limit Bands based on the test comparison and Enabling
Quik Test. This feature will save the time difference between a full test time and the Quik Test
Time for almost all of the accepted parts and most of the rejected parts. If the results are not
consistent to each other, test further by increasing the Quik Test Timer %, re-calibrate the
instrument, and compare the results again.
Rev 11/18/08 6-11

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, press the HOLD key (the display will indicate that the instrument is in HOLD.) Now
watch the displayed pressure loss (flow) value. If the part and tooling are indeed leak free, the
reading will eventually stabilize around a fixed value. If this does not 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 (flow) in the test circuit increases
(the pressure loss on the display decreases).
Rev 11/18/08 6-12

CHAPTER 7 SELF TEST
CHAPTER 7 SELF TEST
Push the SELF TEST button on the Display panel.
The Self Test key accesses several functions that check or verify the proper test operation of the
Sentinel C28 instrument. The functions include:
Verify or calibrate the pressure transducer
Verify or adjust the pressure regulator setting
Self Test the instrument pneumatic manifold for leaks
Verify leak rate calibration by opening the leak standard calibration valve
Figure 121 Initial Self-Test Functions screen
VERIFY OR ADJUST PRESSURE TRANSDUCER CALIBRATION
Transducer Cal 1 (No or Yes)
Make sure to supply air to the Sentinel C28 system. After editing to Yes, follow the display
instructions. Connect a Master Pressure Gauge to the test port and press ENTER.
The instrument takes a minute or so to monitor the signal level of the transducer to measure the
base atmospheric pressure reading and the transducers signal stability. The instrument displays
the pressure readings as gage pressure relative to the current atmospheric pressure. Every test
pressure reading is displayed as gage pressure relative to an atmospheric pressure reading made
immediately before the start of the test cycle.
Rev 11/18/08 7-1

CHAPTER 7 SELF TEST
TRANSDUCER CAL Connect Master

Pressure Guage to test port. Select
OK to continue, or CANCEL to quit.
CANCEL OK
Figure 122 Transducer Calibration screen for Master Gauge Input

6 P57
It is best to perform this Transducer Calibration at the typical test pressure. This will assure the
greatest accuracy where the tests are performed. Otherwise, check it near the high end of the
transducer span.
Follow the instructions on the screen. If the Master Pressure Gauge reading is different then the
Instrument reading, press EDIT and enter the Master Pressure Gauge reading.
The purpose of checking the span of the pressure transducer is to allow the instrument to recheck
the noise level of the transducer signal and correlate the pressure readings to a traceable pressure
gage. This assures that the test pressure readings are accurate.
ADJUST MECHANICAL REGULATOR SETTING
Mechanical Regulator
Tests conducted with a mechanical regulator depend on the setting of the regulator prior to testing
to provide consist part-to-part pressures for a leak or pressure loss tests. The Sentinel C28
corrects each pressure loss readings for variations of the actual test pressure during the test cycle
verses the tests Target Pressure to achieve greater part-to-part accuracy and repeatability.
To initially set the regulator for testing, perform the Set Regulator routine below.
Set Regulator 1 (No or Yes)

Select the line, Set Regulator 1 and edit to Yes.
Rev 11/18/08 7-2

CHAPTER 7 SELF TEST
SET REGULATOR Insert self

test cap into port. Select OK to
continue or CANCEL to quit.
OK CANCEL
Figure 123 Set Regulator screen
Follow the instructions on the screen by connecting the Self Test plug into the test port in place of
the quick connect test line. Select OK by pressing ENTER, as instructed on screen to proceed.
(To exit the Set Regulator routine, push the left arrow key to select CANCEL and press ENTER.)
The current air pressure setting for the regulator displays on the line next to Instrument
pressure.
Regulator Knob
Self Test Plug
Test Port
Figure 124 Regulator Knob and Self Test Plug in Test Port
Adjust the regulator knob, shown in Figure 124. The regulator knob is the black wheel (or gray
knob). Adjust the regulator knob until the required air pressure value is indicated on the display
screen.
Figure 125 Set Regulator pressure screen
Rev 11/18/08 7-3

CHAPTER 7 SELF TEST
Press SELF TEST or ENTER to return to the screen shown below.
Figure 121 Initial Self-Test Functions screen
SELF TEST THE INSTRUMENT FOR LEAKS
The SELF TEST function provides a way to check the integrity of the Sentinel C28 pneumatic
circuit. By isolating the instrument from the test part and the external tooling and plumbing, this
special test will verify that the instrument is performing a valid test free of possible internal leaks
in the instruments pneumatics. If there is a question about where a leak might exist in a
complete test setup or why an unacceptable test result is occurring in a general test, performing a
Self Test on the instrument will clarify if the instrument is contributing to the problem.
Conduct a Self Test.
Self Test Pressure (Target Pressure or pressure setting of the regulator)

Press EDIT to enter the pressure setting of the mechanical regulator or the Target Pressure of the
current active part program. Press EDIT.
The pressure units are defined by the pressure units selected in Auto Setup. Press the Auto Setup
key twice and edit the desired pressure units. Then return to Self Test.
Self Test Level (Level 1 or Level 2)

The instrument performs two levels of Self Test. Level 1 is a general integrity test of the
pneumatic circuit. Level 2 is more stringent and should be used when testing for low leak or flow
rates. Select the desired Self Test Level and press EDIT.
Start Self Test (No or Yes)

Edit to Yes. Follow the instructions on the screen to conduct Self Test.
Rev 11/18/08 7-4

CHAPTER 7 SELF TEST
SELF TEST Insert self test cap into

test port. Select OK to continue, or
CANCEL to quit.
CANCEL OK
Figure 127 Self Test function screen
If the Self Test plug is not already connected to the test port, remove the test line quick connect
fitting and connect the Self Test plug for the Self Test function. See Figure 128 below to identify
the Self Test plug and Test port fitting.
Regulator adjustment knob

Self Test plug
Self Test plug holder
Test port
Figure 128 Self Test connections for the Sentinel
The instrument conducts a pre-programmed extended leak test on the instrument. If there is no
internal leak, the following message will appear, "Self Test Passed". Reconnect the test line to
the quick-connect test port and return the self-test cap (plug) to the self-test holder.
If there is an internal leak, the following message appears: Self Test Failed"
Verify that there is an inlet air supply to the instrument and confirm that the regulator is
set to the correct pressure.
Check the oring on the Self Test plug for cuts or knicks.
Check all the plumbing connections on the pneumatic manifold for possible leaks using a
soaping agent. If it is difficult to see all the fittings, you can remove the pneumatic
manifold block and reconnect the supply air to another air source. This should make it
easier to check for leaks with a soaping agent.
If no leak is found, there may be an internal leak across the part isolation valve or leak
standard isolation valve.
After fixing the leak, perform another Self Test to verify the pneumatics integrity.
Reconnect the test line to the quick connect at the test port.
Do not tighten the male quick connect fitting of the Sentinel C28 into the pneumatic block.
Tightening the fitting may crack the pneumatic block and void the warranty.
Rev 11/18/08 7-5

CHAPTER 7 SELF TEST
CALIBRATION VERIFICATION (OPEN LEAK STD)
Manual control of the Leak Standard Isolation Valve
It is important to periodically verify the leak rate calibration of the instrument. It is desirable to
do this without re-calibrating the instrument because of the time involved and the benefits of
having Environmental Drift Correction adjust the calibration to the process. Testing a Master
(No Leak) part with the internal leak standard added to the test circuit is a quick and effective
way to verify the instrument's calibration without changing anything. By simply testing the
master part with the calibration valve energized, the instrument should measure a leak rate very
close (+10%) to the Leak Standard value (displayed in PART CONFIG, Calibration Parameters
screen for the part program).
To execute this simple calibration verification routine, mount a Master part into the test fixture.
Open Leak Std (No or Yes)
Edit the "Open Leak Std" item to Yes. Push the MONITOR key to monitor the test. Start the test
on the Master part. When the pre-fill cycle begins the Leak Standard Calibration valve opens and
stays open until the end of exhaust. During the time when the Leak Standard Isolation valve is
open a symbol appears on the bottom line of the display next to the password lock symbol.
Upon completion of a test cycle, the leak rate test result will be displayed. Compare the leak rate
test result to the stored Leak Standard value Corr. Leak Std Flow for the selected part program,
found in PART CONFIG, CAL:PLR. If the two values are reasonably close (+10%), the
instrument's calibration is satisfactory.
Be sure to close the Leak Standard Calibration valve before proceeding with your normal
leak testing operation. Push the SELF TEST key twice and edit the Open Leak Std line to read
No. The Leak Standard symbol will stop appearing during each test.
Rev 11/18/08 7-6

CHAPTER 8 COMMUNICATIONS INTERFACE

The setup and operation of the Sentinel C28 communication options are explained in CHAPTER
4, INSTRUMENT CONFIGURATION AND COMMUNICATION. The Sentinel C28
communicates via RS232 and TCP/IP. This chapter will explain some of the communication
considerations for these different methods.
There is one RS232 termination, (9 pin connector) on the operator panel on the front of the
instrument. The USB port is located inside the instrument at the bottom center of the door. The
TCP/IP jack is located near to the USB port on the inside of the instrument. See Figure 129
below for the location of the internal terminals.
TCP/IP USB
Figure 129 TCP/IP and USB terminals
The standard RS232 interface cable for a portable printer is a nine-pin female to nine pin male
serial null (leads for transmit and receive are crossed between pin connections) cable. The RS232
interface cable for a computer is a nine-pin female to nine-pin female serial null cable.
COMMUNICATION WITH OTHER SERIAL DEVICES

The Sentinel C28 instruments have the ability to communicate with other printers or compatible
devices (such as computers or PLCs). Communication can be either with the instrument sending
information on command using the menus under the instrument's INSTR CONFIG key or with an
external device programmed to request specific information.
COMMUNICATION SETUP AND EXECUTION

The Sentinel C28 instrument communicates via TCP/IP (Ethernet) and RS232. This
communication is two-way with each method. The USB flash drive is only available to download
firmware updates. There are common interface commands established to communicate with the
instrument via RS232 or TCP/IP methods. These commands can remotely request selected data,
send new setup parameters for storage, and change some instrument functions. Instrument setup
parameters, station setup parameters, part program parameters, calibration data, counter data, test
result data, and security setup are all available for communication.
Rev 11/18/08 8-1

Figure 130 RS-232 connector

The setup and operation commands for communications to and from the Sentinel C28 are
accessed via the INSTR CONFIG key. For serial communication, the operator must use RS232.
For communication via TCP/IP, the operator or computer must select the TCP/IP connection
available through the one port.
For TCP/IP communication, the instrument must have an IP address. Enter the information
regarding the Gateway/Router, Subnet Mask, and instrument IP address or obtain an IP address
by setting the Obtain network address to DHCP within INSTR CONFIG, TCP/IP
communications. The instrument power must be cycled if an IP address is changed.
Figure 131 Front panel Display keys
There are several communication and terminal parameters that must be setup within your
computer to enable communication with the Sentinel C28 instrument. Computers with Microsoft
Windows 98, XP, etc. usually have standard communication software called Hyper-Terminal
found under START/ Accessories/ Communications.
The Sentinel C28 communicates in two ways. It can output a number of standard reports via the
RS232 or TCP/IP. See Figure 132 below for a list of available reports. Review Chapter 4 on how
to select these reports.
Rev 11/18/08 8-2

Report Selection Description

Instrument Config Setup Information for Hardware, Communication, Firmware,
Instrument name, Time, Date, and Security
Part Config Part setup parameters for all part programs,
All part results* All the test results for the active part program in the instrument memory
All results* All the test results in the instrument memory
Last 1000* 1000 most recent test results,
Figure 132 Communication Reports or Functions
The test report output format for Last 20, 100, 1000, All Part Results, and All Results are set for
either Space delimited or Fixed Width output.
Setup for HyperTerminal within Microsoft Windows 98 or higher
Transferring data from the Sentinel C28 instrument to a computer with Windows 98 or higher
1. Connect null-modem cable to the com port of the computer from external RS232 connection
or connect an ethernet cable via a hub
2. Start Windows 98 or higher.
3. Choose START, PROGRAMS, Accessories, Communications, and HyperTerminal.
4. Choose HyperTerminal icon
5. Enter a connection name such as "
RS232" or Ethernet and choose
desired icon, OK.
6. Within Connect to window, set
"Connect using" to the com port for
your computer, like "com 3" or
select TCP/IP for Ethernet
connection. For TCP/IP
connections enter instruments IP
address and Port Number 23.
7. When communicating with the

instrument via RS 232, HyperTerminal
can be configured to work with the
following options. After setting the
instrument configuration, set up Hyper-
Terminal to communicate with the
same parameters found under
Configure below the Connect using
window on the screen similar to Figure
135 when Com 2 or Com 3 is Figure 133 Connect to screen
selected.
Rev 11/18/08 8-3

Data input field RS232

Connect Using COM3 (or other COM)
Bits per second 9600 or 115200 baud
Parity No parity
Data bits 8 bits
Stop bits 1 stop bit
Flow control none
Figure 134 RS232 Configuration settings
Configuration settings for serial communication (example of Windows XP). These settings
should match the Configuration setting within INST CONFIG for the serial device (RS232).
Figure 135 Com Port Serial Communication Properties
Rev 11/18/08 8-4

8. For RS-232 or TCP/IP, choose File, Properties, Settings
Figure 136 HyperTerminal Controller Properties screen
9. Click on the button "ASCII Setup"
Figure 137 ASCII Settings Screen
Rev 11/18/08 8-5

When using HyperTerminal as an ASCII terminal, the following settings need to be set in
HyperTerminal or the communication software as properties to receive and display data
10. Choose File, Save As, Save.

11. The HyperTerminal is ready to receive data from the Sentinel C28 instrument now and in the
future.
12. For future data transfers, the computer will have a dedicated icon on HyperTerminal setup to
receive data.
13. On the Sentinel , press INSTR CONFIG, select "RS232" or TCP/IP 1 as the port option,
and select the desired output by the adjusting the settings for Interface, Function and Output for
either RS232 or TCP/IP outputs. Press ENTER. Make sure that the Sentinel C28 and receiving
device are set the same. The data transfer is initiated when ENTER is pressed.
14. The data can be transferred directly to a file that can be opened in a spreadsheet program like
EXCEL. Click on Transfer in the upper tool bar of HyperTerminal. Chose Capture Text and
define a file name where the data should be sent. Click on Start in the transfer window.
15. When the data transfer is complete, click on Transfer and Stop.
16. Open the spreadsheet program. Open the txt.file where the data was stored and saved using
spreadsheet software like Excel.
16. While opening the txt file into Excel, check Delimited. Check Space,comma and
tab and then Next and Finish..
17. Most data can also be copied from HyperTerminal and pasted into Excel. After pasting into
Excel, highlight the data and select Data, Text to Columns, Delimited, Space, comma, NEXT,
and FINISH. There is a limitation on width of the data line in HyperTerminal that may cause the
data to wrap to another line and get sorted to the wrong columns.
18. Remember the test result files have the most recent results at the top or first.
SENDING INFORMATION ONE-WAY VIA COMMANDS THROUGH SENTINEL C28
Communication screens within INSTR CONFIG functions.
When the instrument is setup to communicate with RS232 or TCP/IP, the operator can
command the instrument to send out any desired information via the INSTR CONFIG
key. The operator chooses the desired report from the communication options defined by
the combined settings of Interface, Function, and Output within the RS232 or
TCP/IP. After entering the desired choice, the information is sent to the computer that
is connected for the transfer. Full details about requesting the reports through the keypad
for these communication options are described in pages 4-4 through 4-15.
REQUESTING INFORMATION TO BE SENT USING TWO-WAY COMMUNICATION

via remote commands using one of the communication options.
A remote computer can request information from the Sentinel C28 via the two-way
communication capabilities. Sending the desired alpha-numeric character string outlined
below will either:
Request test results, part or instrument setup information, or counter information.

Download changes to stored part or instrument setup information. .
Rev 11/18/08 8-6

Enter HyperTerminal and connect with the Sentinel C28 instrument via TCP/IP. The
display will indicate that a connection is made.
Type help (return) and the following will display on the computer screen when the proper
connection is made with the Sentinel C28 instrument.
help
*************************************************************************
* TREE ROOT CONTROLLER *
*************************************************************************
* : Instrument config *
* <P#>: Part config menu (please select a part number) *
* <T#>: Test data (please select a part number) *
* <S#>: Self test (please select a part number) *
* <A#>: Autosetup *
* <M>: Module menu *
* : Update Firmware *
* VER: Display Version Number *
* Dir: Display Current Branch *
* Help: Help *
Figure 138 TREE ROOT menu for the Sentinel
To address a particular menu, type the letter within < >, and Return or Enter. The
submenu for that letter will be sent.For instance, to find out about the Part Configuration
for part 01, type p01, Enter.
p01
* Part Configuration
**************************************************************************
* <X>: Tst type, Test description for this part. *
* <R>: Timers, Test timer settings for this part. *
* : Pressure, Pressure settings for this part *
* <S1>: tst *
* <C1>: cal *
* <M>: misc *
* : units *
* : inputs *
* <O>: outputs *
* <T>: tooling *
* Help: Help *
*************************************************************************
Figure 139 Part Configuration menu output.
Rev 11/18/08 8-7

To find out the settings for the Timers, type R, Enter.
R
*************************************************************************
* Timers, Test timer settings for this part. *
*************************************************************************
* <1B0>: Prefill 0.15 sec *
* <230>: Fill 0.60 sec *
* <320>: Stabilize 6.55 sec *
* <420>: Test 1.45 sec *
* <5F0>: Exhaust 0.15 sec *
* <8D0>: Relax 11.85 sec *
* Help: Help *
*************************************************************************
Figure 140 Part configuration, Timers menu output
If you have entered into the Part Configure menu via the commands just discussed, you can
change a timer by using the following command. The command involves entering the variable
character found within < > and the new value for the variable. For instance:
1B0 = 0.5 would change the pre-fill timer to 0.5 seconds
The direct way to change that one variable while in the original screen after entering the
connection would be:
P01R1B0=0.5
This directs the change to Part Program 01 (P01), Timer value (R), Pre-fill timer (1B0).
To determine the correct variable code, you should enter into HyperTerminal and determine the
correct codes for the variables desired. The main TREE ROOT codes are:
TREE ROOT
TREE ROOT Description
Code
I Instrument Configuration
P# Part Configuration menu (specify with part number)
T# Test data (specify with part number)
S# Self Test (specify with part number)
A# Auto Setup (specify with part number)
Module menu
Update Firmware
VER Display Version Number
Dir Display Current Branch
Help Help
Figure 141 TREE ROOT code identification
Rev 11/18/08 8-8

See the list of configuration and menu codes for Instrument Configuration below.
Instrument Configuration
TREE Config Menu Description
ROOT Code Code
I Instrument Configuration
H Hardware, Instrument Hardware Settings
530 Manifold Type
7B0 Number of Parts
541 Transducer Type 1
671 Regulator type 1
S RS232 Port 1 Front door
I RS232 Port 1 Interface
C RS232 Port 1 Configuration
F RS232 Port 1 Function
S RS232 Port 1 Output
T Instrument Networking Settings
4 Obtain network settings
IP Instrument IP address
M Mail Server IP address
G Gateway IP address
S Subnet Mask
C MAC address
1 TCP/IP 1
I TCP/IP 1 Interface
F TCP/IP 1 Function
P TCP/IP 1 Output
U USB Universal Serial Bus Settings
P Update firmware
M Drive control
E Email, Instrument email settings
I User id
P Email Password
R From Address
F Email Function
AF Email Function address
M Misc, General instrument settings
IN Instrument name
S Serial number
C Edit/View security
T Time
D Date
Figure 142 Instrument Configuration menu codes
To request a download of test data independent of what is requested through the keypad of the
instrument, enter codes as though you were going through the keypad to request the output. For
Rev 11/18/08 8-9

instance to output the last 1000 test results via TCP/IP 1, you would enter a string of characters
going from the TREE ROOT through the menu code.
Type I, Enter for Instrument Configure

Type 1, Enter for TCP/IP 1
Type F> Enter to determine the code for Sta Last 100
The instrument will feed back all the codes for Function (F). From this list it will be determined
that the code for Sta Last 100 is 3.
Type F=3, Enter
The instrument will output 100 test results via TCP/IP 1.
The configuration codes for Part Configuration are listed below.

.
TREE Conf Menu Part Configuration
ROOT Code Code
P# Part Configuration information for part number #
X Test type, Test description for this part
R Timers, test timer settings for this part
P Pressures, Pressure settings for this part
S1 Test Parameters, 1st test
C1 Calibration Parameters, 1st test
M Miscellaneous
U Units of measurement
I Inputs
O Outputs
T Tooling configuration
Figure 143 Part Configuration codes
The menu codes vary by test type within Part Configuration. If you want to change or define the
part configuration values via an RS232 or TCP/IP, input P# and enter and the Configuration code
and enter. The menu codes within the Configuration code will output with their identification.
Use these menu codes to enter new values using the format described above.
To back out from a menu, Type exit to escape back to the TREE ROOT menu.
To determine the available choices within a Menu, type the menu code and >. For instance to
determine the available choices for Manifold type within Hardware:
Exit, return
I, return
H, return
530>, return
Or type IH530>, return
and the list of manifold options will appear.
To request reports from the Sentinel C28 via RS232 or a TCP/IP connection using Hyper-
Terminal, the path to the reports is similar to using the keypad to find the menu where the desired
output is selected. So to output the Last 20 test results (Function selection) in Fixed Width format
Rev 11/18/08 8-10

(Interface selection) with All the Test Results (Output selection), you need to find the INSTR
CONFIG functions on TCP/IP or RS232 communication.
So from the TREE ROOT menu, type I, return.
*************************************************************************
* Instrument Configuration *
*************************************************************************
* <H>: Hardware, Instrument hardware settings. *
* <S>: Rs232 1, Front door comm port interface. *
* <T>: TCP/IP, Instrument networking settings *
* <1>: TCP/IP 1, User defined TCP/IP interface. *
* : USB, Universal Serial Bus settings. *
* <E>: Email, Instrument email settings. *
* <M>: Misc, General instrument settings. *
* <V>: Version, Detailed instrument version settings. *
* Help: Help *
*************************************************************************
Figure 144 Instrument Configuration menu on HyperTerminal
To communicate with TCP/IP 1, type 1, return.
*************************************************************************
* TCP/IP 1, User defined TCP/IP interface. *
*************************************************************************
* : TCP/IP 1 Interface Fixed width out *
* <F>: TCP/IP 1 Function Sta Last 20 *
* : Fixed width out Part result only *
* Help: Help *
*************************************************************************
Figure 145 TCP/IP 1 menu displayed on Hyper-Terminal
To get the right format output make sure that INTERFACE is set for Fixed width out,
Function is set for Sta Last 20, and Fixed Width out is set for All result information. The
above display showing the current settings for our desired output is not quite right. We need to
change the Fixed width out. If we do not know the code for the desired output, we can enter an
inquiry command to list the available code and outputs.
Type the letter code in the < > follow by an >. Therefore to find the options for the Fixed
Width out output options,
Rev 11/18/08 8-11

type P> and Enter
L01: 1,3 A> All result information :01:AD

L01: 2,3 2> First 2 test results :02:82
L01: 3,3 P> Part result only :03:06
L01: 4,4 C> Custom :08:1F
Figure 146 Output options for Fixed Width Interface
To change the Output option to All result information which is selection A for the options
above.
Type P=A
V01: I1P=All result information :04:7C
Figure 147 Response to Output change
Now test results will be sent after each test by the instrument in the All result Information
format. To download the last 20 results, find the code for sta Last 20.
Type F>, enter
L01: 1,10 C> Station Cntrs :07:AD

L01: 2,10 1> Sta Last 20 :08:9C
L01: 3,10 2> Sta Last 100 :09:69
L01: 4,10 3> Sta Last 1000 :0A:22
L01: 5,10 4> All results :0B:A4
L01: 6,10 5> All part res :0C:A0
L01: 7,10 I> Instr Config :0D:25
L01: 8,10 S> Station Config :0E:2E
L01: 9,10 P> Part Config :0F:00
L01: 10,10 A> Autosetup info :10:93
Figure 148 Response to request for Function selections.
To request the Sta Last 20 results of All result information,
Type F=1, enter.
Rev 11/18/08 8-12

S01 P01 R-- 01/10/08 04:23:59.020 0000387755 A - No barcode

PLR P LR 0.000000 sccm PL 0.000000 dpsig PT 0.132648 psig EDC 0.
000000 sccm PQ 0.000000 sccm QL 0.000000 dpsig QP 0.136364 psig
S01 P01 R-- 01/10/08 04:23:58.230 0000387754 A - No barcode
S01 P01 R-- 01/10/08 04:23:57.440 0000387753 A - No barcode
S01 P01 R-- 01/10/08 04:23:56.650 0000387752 A - No barcode
S01 P01 R-- 01/10/08 04:23:55.880 0000387751 A - No barcode
S01 P01 R-- 01/10/08 04:23:55.090 0000387750 A - No barcode
S01 P01 R-- 01/10/08 04:23:54.290 0000387749 A - No barcode
Figure 149 Portion of the Sta Last 20 Test Result All Result Information output on
Hyper-terminal.
Rev 11/18/08 8-13

CHAPTER 9 DOWNLOADED REPORTS

The following reports may be downloaded from the Sentinel C28 instrument to a PLC or
computer using the RS-232 or TCP/IP communications ports.
INSTRUMENT CONFIGURATION
The Instrument Configuration report displays the setup parameters from the INSTR CONFIG
setup screens: This includes the current settings for the communication options (RS232 and
TCP/IP), firmware versions, and other miscellaneous instrument settings.
RS232 1
===============================================================
RS232 Port 1 Interface Fixed width out
RS232 Port 1 Config 115200/8N1/none
RS232 Port 1 Function Station Cntrs
Fixed width out First 2 test results
TCP/IP
===============================================================
Obtain network settings DHCP
Instrument IP address 172.16.0.97
Mail Server IP address 170.16.0.4
Gateway IP address 172.16.0.1
Subnet Mask 255.255.0.0
MAC address 001127041214
TCP/IP 1
===============================================================
TCP/IP 1 Interface Fixed width out
TCP/IP 1 Function Instr Config
Fixed width out First 2 test results
USB
===============================================================
Update firmware No
Drive control Unmount
EMAIL
===============================================================
User id I24
Email password password
From Addr: I24@cincinnati-test.com
Email Function Station Cntrs
Fnc Addr: ggrebe@cincinnati.com
Rev 11/18/08 9-1

MISC
===============================================================
Instrument name I24 STATION 1
Serial Number 1029384756 I24 CONTROLLER
Edit / View Security ON
Time 11:17:16
Date 11/14/08
VERSION
===============================================================
System Version 104
Build number 081113164839
Sram 0.37
SECURITY
===============================================================
Secure Calibration No
Secure Change Part No
Secure Part Config No
Secure Instrument Setup No
Secure Clear Data No
Secure Reset Cntrs No
Change Password (11534336) 0.01
Figure 150 Instrument Config report
STATION CONFIGURATION
This report indicates the setup of the instrument hardware for the test station. Parameters include
the manifold type that will define the type of tests available for selection within the part
configuration section. The remaining parameters define the established pressure transducer and
regulator type and range. Also displayed is the number of part programs that are accessible.
HARDWARE
===============================================================
Manifold Type PA - Std Cv 1P
Number of Parts 32
Transducer Type 1 Druck 20PSIA
Regulator Type 1 Mechanical
Figure 151 Station configuration report
PRESSURE STREAMING
The pressure streaming output is a string of information identifying the significant information
about a test every 0.01 seconds. This data output is only available via the RS232 port when the
RS232 Interface is set for Terminal. The RS232 Ouput must be set for Streaming or Streaming
and Test. To make the information output as short and concise as possible for each data point, the
data identifiers are output in hex code. The data provided changes depending on the test type and
phase or segment of the test. The data string consists of a station number, part number, segment
or phase of the test process, elapsed time, time within each segment, pressure measurement,
Rev 11/18/08 9-2

pressure loss or flow measurement, and potentially EDC correction. Each set of variable data
consists of a variable identifier, variable unit of measurement, and the measured variable.
Stream of typical test data associated with a reading every 0.01 seconds
S01P01G42,015D 5.13,025D 3.00,120C 60.196,1C29 0.01356
Data Value
Data value
Data value
Data value
Segment of the test
Part Program number
Station Number
Station no., part no., and test segment identification

S01 Station No Typically 01 for station 1
P01 Part No 1 to 32
G42 seGment no. testing cycle (See seGment table, Figure 152)
S01P01G42,015D 5.13,025D 3.00,120C 60.196,1C29 0.01356
Data Value
01 Variable code - Elapsed Time (See Variable table, Figure 153)
5D Unit code - Seconds (See Unit table, Figure 154)
5.13 Variable 5.13 seconds of elapsed time into the overall test cycle
S01P01G42,015D 5.13,025D 3.00,120C 60.196,1C29 0.01356
Data Value
02 Variable code Segment timer (See Variable table, Figure 153)
5D Unit code Seconds (See Unit table, Figure 154)
3.00 Variable 3.00 seconds of time remaining in segment
S01P01G42,015D 5.13,025D 3.00,120C 60.196,1C29 0.01356

Data Value
12 Variable code Measured Pressure (See Variable table, Figure 153)
0C Unit code psig (see Unit table, Figure 154)
60.196 Variable 60.196 psig pressure
S01P01G42,015D 5.13,025D 3.00,120C 60.196,1C29 0.01356

Data Value
1C Variable code Pressure loss (See Variable table, Figure 153)
29 Unit code - psig (see Unit table, Figure 154)
0.1356 Variable - .01356 psig pressure change
Rev 11/18/08 9-3

Sample of Hex code numbering (0,1,2,3,4,5,6,7,8,9,A,B,C,D,E,F,10,11,..19,1A,..,1F,20,..)
Hexcode for seGment Function

seGment No.
01 19 Internal and setup functions
1A - 21 Pre-fill cycle functions
22 - 30 Fill cycle functions
31 - 40 Stabilization cycle functions
41 5D Test cycle functions
5E - 68 Exhaust cycle functions
69 75 Verification functions
76 - 80 Action functions
8B 91 Time functions (like Relax)
92 98 Transducer functions
99 9E Pressure functions
9F A9 Tooling motions
Figure 152 Segment Table to identify phase of test sequence
Hex code
Variable Measurement Type
01 Elapsed time with Segment (incrementing time in test)
02 Segment timer (decrementing time remaining in segment)
03 Isolation decay timer
07 Total test time
0D Test Pressure
12 Measured Pressure
1C Pressure loss (Corrected)
44 Measured flow
4B EDC offset
Figure 153 Variable table for Measurement Type
Rev 11/18/08 9-4

Hex Units Hex Units Hex Units Hex code Units

code Pressure code Delta code Flow Units Time
Units Units Pressure Units
02 Atm 1F Atm 3C sccm 5B Hour
03 bar 20 bar 3D sccs 5C Minutes
04 cmHg 21 cmHg 3E scch 5D Second
05 inHg 22 inHg 3F scfm 5E millisecond
06 kPa 23 kPa 40 slpm
07 Mpa 24 MPa 41 slps
08 mbar 25 mbar 42 scfh
09 mmHg 26 mmHg 43 scfs
0A Pa 27 Pa
0B Torr 28 Torr
0C psig 29 psig
0D psiv 2A psiv
0E inWC 2B inWC
0F cmWC 2C cmWC
02 mmWC 2D mmWC
Figure 154 Unit of measurement code table
TERMINAL TEST RESULTS OUTPUT AFTER EACH TEST
This Test output is a result of setting the Interface to Terminal and Output to include
Test. The result information has more complete descriptions of each test result parameter.
Test result Station No. Part No. Date Time Unique ID Part Result
Test type
S01 P02 07/11/08 09:04:45.06 0000005319 PART ACCEPT

PLRq P Leak Rate 0.080466 sccm Pressure Loss 0.008801 dpsig
Test Pressure 30.551664 psig EDC Offset 0.000000 sccm Predict
ed Leak 0.080466 sccm Quik Loss 0.008801 dpsig Quik Test Press
ure 30.556084 psig
Figure 155 Test output report for RS232 Port: Terminal (Pressure Decay Test)
FIXED WIDTH TEST RESULTS OUTPUT AFTER EACH TEST
With Interface set to Fixed Width Out, the Sentinel C28 can output the results in one of three
ways at the completion of each test via RS232 or TCP/IP.
Part result only

First 2 test results
Custom
Rev 11/18/08 9-5

PART RESULTS ONLY AFTER EACH TEST
With the Output set to Part results only the following test result data appears. Test results
are in order of most recent data at bottom.
Part no. Link info Date Time Unique ID. Part result
S01 P01 R-- 04/11/07 15:17:11.570 0000022408 R

S01 P01 R-- 04/11/07 15:17:19.590 0000022409 A
Figure 156 Part results only report
FIRST 2 TEST RESULTS
First 2 test results are for each part for Station 01. The results are in order of most recent data at
the bottom. The First 2 test results output is established by setting the Interface to Fixed
Width Out and Output to First 2 test results.
Part No. Link Info Date Time Unique ID. Part Result Test Type Leak Rate
SPC Flag Test Result
S01 P01 R-- 04/11/07 16:17:44.720 0000022861 R - PLRq F LR 5.278410 sccm

PL 0.024620 dpsig
Part pressure loss
Figure 157 First 2 test results output (for single pressure decay test)
Rev 11/18/08 9-6

ALL RESULT INFORMATION
The All result information output is established by setting the Interface to Fixed Width Out
and Output to All Result Information. All result information is for each part for Station 01.
The results are in order of most recent data at the bottom.
Part No. Link Info Date Time Unique ID SPC Flag

Part Result Test Type Test Result Leak Rate
S01 P01 R-- 04/07/07 00:08:04.860 0000050193 R - PLRq F LR 0.036461 sccm

PL 0.015409 dpsig Pt 49.998657 psig EDC 0.000000 sccm PQ -0.0378 sccm
QL 0.04889 dpsig QP 49.89456 [psig
Quik Test Leak Rate
Quik Test Pressure loss Quik Test Pressure Environmental Drift Correction
Part pressure loss Test Pressure
Figure 158 Each Test All result information output (for pressure decay test)
STATION COUNTERS
The Counters report provides the counter data for the current active part number. To
obtain reports for the other part numbers, Change Part to the desired part number and
request the Counter report again.
Part 01 counters 07\12\08 13:52:42

===========================================================
Cycles Since New 63262
Accept Cycles 6263
Reject Cycles 6545
Malfunction Cycles 5
Cycles Since Cal 5986
Clear Part Counters No
Clear Stn Counters No
Clear Stn Results No
Figure 159 Counters report
Rev 11/18/08 9-7

CHAPTER 10 TEST DATA

This display function shows past test results, counter information, and statistics for the selected
active part program. To review test data for other parts, push the CHANGE PART key on the
Functions panel.
COUNTER INFORMATION
Press the TEST DATA key to see the Counters screen.
Figure 160 Counter screen within TEST DATA routine
Cycle Since New This count is an instrument count. It reflects the total number of tests initiated
for the instrument since the instrument was manufactured or the memory chip was changed.
Accept Cycles This is the total Part Accept results for the active part program shown in the
lower right corner of the display since the counters were reset.
Reject Cycles This is the total Part Reject results for the active part program shown in the
lower right corner of the display since the counters were reset. This includes Severe Leaks in the
pre-fill, fill, and stabilization cycles and rejects in the test cycle.
Malfunction Cycles This is the total number of tests that did not complete cycle because of
faults in the test process excluding test integrity errors. Any disruption in the test cycle except a
severe leak (which is classified as a reject) results in a malfunction.
Cycles Since Cal This is the total number of part tests initiated for the active part program
shown in the lower right corner of the display since the last completed calibration.
Clear Part Counters (No or Yes) This function resets the counters for Accept Cycles, Reject
Cycles, Malfunction Cycles, and Cycles since Calibrated for the active part program shown in the
lower right corner of the display.
Rev 11/18/08 10-1

Clear Stn Counters (No or Yes) This function resets the counters for all the part programs of
the instrument except the Cycles Since New.
Clear Stn Results (No or Yes) This function clears all the Test Result data shown in the next
display for all the part programs in the instrument.
TEST RESULTS
The second display is test results stored in the system for the instrument since the test data was
cleared. The most recent results are on top. Use the Up or Down arrow keys to scroll through the
test results. The scroll bar on the right side indicates the relative location of the test data within all
results stored.
Press the TEST DATA key twice to see the data on recent parts tests.
Figure 161 Test Results screen
The displayed variables are:
Part program number (P#) Part program number used to perform the test.
Date (MM/DD) Month and day when the test was performed.
Time (HH:MM:SS) Hour, minute, and second when the test was performed.
Part Test Result (Accept, Reject, or message) Brief result information about part test. See
Figure 64 on page 4-11 for the possible Part Test Result codes.
Test Type Code (PLR, Plo, DPT, OCC) Test type performed
Test Result (P, F, E, L, M, N) Result of individual tests
Code Test Type Code Test Type

PLR Pressure Decay Leak Rate OCC Occlusion
PLo Pressure Loss or Drop DPT Pressure Rate of Loss
Rev 11/18/08 10-2

Figure 162 Test Type code
Code Test Result Code Test Result

E Test Error M Test Completed-AutoCal Master
F Test Failed N Test Skipped
L Test Completed-AutoCal Leak Std P Test Passed
Figure 162 Test Result code
Test Pressure (psig, psiv, kPa, etc) Measured pressure during test (for all pressure tests)
Pressure Loss (psig, psiv, kPa, etc.) Measured pressure loss during test cycle (for
pressure decay or loss tests only)
Pressure Loss Rate (psi/s, kPa/s, etc) Pressure rate of change during test cycle (for rate of
change test only)
Leak Rate (sccm, scfm, etc.) Calculated leak rate value for the test (for pressure decay leak rate
tests)
STATISTICAL INFORMATION
For Leak Rate Results only. This function does not work for pressure loss, rate of loss, or
occlusion tests.
Press the TEST DATA key three times to see the statistical report on recent parts tests.
Figure 162 Statistics screen within TEST DATA
The statistical calculations are performed on test results for a selected part program shown in the
lower right corner of the display. To view statistics for different part programs push the
CHANGE PART key until the desired part number appears or press and hold the CHANGE
PART key and then enter part number.
Rev 11/18/08 10-3

Stat History Length Defines the number of most recent test results within the selected part
program over which to perform the statistical analysis.
The instrument performs the following calculations on the specified history of test results within
the selected part program. It calculates the results on the accept parts only and the reject parts
only. It ignores severe leaks and malfunctions that occur.
Accept Average Average value of leak rate (pressure loss for pressure loss tests) of accept parts
for the selected part program.
x1 x2 ... xn
xmean
n
Reject Average Average value of leak rate (pressure loss for pressure loss tests) of reject parts
for the selected part program
x1 x2 ... xn
xmean
n
Accept Std Dev + of accept parts for the selected part program
Std Dev = [ n X2 - (x)2 ]/ n(n-1)
Accept SPC Std Dev. Standard deviation of the accept parts that were identified by the
Universal digital input SPC Test Part before these parts were tested.
Accept Percentage Percentage of accepts out of total accept and reject test results. Does not
account for malfunction tests.
Reject Percentage Percentage of rejects out of total accept and reject test results. Does not
account for malfunction tests.
Rev 11/18/08 10-4

CHAPTER 11 DIGITAL INPUTS AND OUTPUTS

The Sentinel C28 instrument includes selectable digital inputs and outputs to increase the
functionality and simplify the application to various test requirements. The available inputs and
outputs are partly defined by the tooling control functions set in the Tooling tab. Within the
tooling tab you define the zero or one tooling motion option for each part program. The inputs
and outputs are also programmed individually within each part program based on the Tooling
control setup and the Universal or Part Program Specific functions. This gives the flexibility to
use different inputs and outputs as required by each part program. The OUTPUT SEQUENCE
CHART details when each of the 17 outputs occurs. The time increment along the top of the
chart is set within the TIMERS function. The sequence of events cannot be altered. However,
there are several outputs occurring at different times in the test process that can be utilized to
accomplish many basic functions. The inputs and outputs are either 24 VDC or 120 VAC
depending on how the circuit board is configured. The test valves and test result lights are always
24 VDC outputs.
These input and output functions are selected in the PART CONFIG function (Tooling, Inputs
and Outputs).
The inputs and outputs are divided into two basic groups Universal and Part Program
Specific. When a Universal input or output is assigned in a part program, it is automatically
assigned within all part programs to the same terminal. When deleting one of these inputs or
outputs using Unassigned all parts within any part program, it automatically removes it from all
the other part programs. When a Part Program Specific input or output is assigned in a part
program, that terminal is Constrained in other part programs to functions that are in a common
group.
UNIVERSAL DIGITAL INPUT FUNCTIONS

Because of the function of these input terminals, they are universal or common to all part
programs if assigned to any one program. If any of these functions are Unassigned for all
within any part program, they will be unassigned in all the part programs because they are
Universal inputs.
Test Cycle Inputs Test Result Binary Part Program

Inputs Selection Inputs
Start Station SPC Test Part Part Select B1
Stop/Reset Station Part Select B2
Hold Part Select B3
Vent/Halt Part Select B4
Part Select B5
Figure 163 Universal Digital Input options
Rev 11/18/08 11-1

Start test signal(s)

The Sentinel C28 features a universal Start Station input and a part specific Start Part input (to be
discussed later). The single input (START STATION) is the available universal start test option.
An additional condition to start a test can include a Part Presence input that must be high
before receiving the one start input. This input is Part Presence. It will be discussed below
within the Part Program Specific input options.
Vent/Halt and Stop/Reset
There are two basic methods to stop the Sentinel C28 during test operation. The first is a
Stop/Reset request (whether via keypad, communications, digital input, or test malfunction).
The second is a Vent/Halt request (via digital input or test malfunction). Regardless of the stop
type, the Sentinel C28 will always produce a result and I/O indicating result (Part Accept, Part
Reject, Severe Leak, or Malfunction). With no tooling control functions performed by the
instrument, these two functions are the same. When the Sentinel C28 is controlling the one
tooling function, the Vent/Halt function deactivates the test process to the quickest and safest
point of no tooling motion and part de-pressurization. Stop/reset conducts the vent/halt function
of the testing process and continues with the reset of the tooling process back to a known
retracted state for the next test.
The Vent/Halt would typically be used by the Emergency Stop function to quickly get any
tooling functions to a safe state, de-pressurize the instrument, and control the instrument until
released for a stop/reset request to reset any tooling back to the start position.
Vent/Halt
The Vent/Halt input safely ceases the operation of any tooling motion (described below
under Vent/Halt request), removes all energy from the part by advancing through the
exhaust cycle, and stops operation. Any programmed tooling motion required to return to
the fully retracted positions must be initiated by the Stop/Reset input. While the
Vent/Halt input is high, no additional test activity or tooling resets can occur.
Besides a user generated Vent/Halt input, a number of test errors will generate a
Vent/Halt request. Possible scenarios include:
Transducer Malfunction (zero or over-range),
External Switch Fault (not low or high at appropriate time)
Severe Leak
Pressure Low/High
Calculation Faults
Calibration Errors
General Part Fault (setup errors)
Stop/Reset
Stop test/Reset input is available to stop tests and retract tooling. When a stop/reset input
is received the test cycle goes immediately through a Vent/Halt routine and then
advances to retract the tooling. The Malfunction output (if programmed) will go high at
the end of the last tooling motion for errors defined as malfunctions.
In addition Stop/Reset input is required:
After any tooling motion or test malfunction where the instrument completed
Vent/Halt to safe state and stopped.
Tooling must be reset to fully retracted position to start next test
Rev 11/18/08 11-2

Stop Request
The design of a Stop request is to safely remove all energy from the part, place the tooling into a
fully retracted state, and stop operation. Depending upon whether the instrument is actively
testing or idle, the stop request has two modes of operations.
Besides a user generated Stop, a number of test errors will generate a Stop/Reset request that
causes a Vent/Halt routine and continues with the tooling reset. The possible scenarios include:
Transducer Malfunction (zero or over-range), External Switch Fault (not low or high at
appropriate time), Severe Leak, Pressure Low/High, Calculation Faults, Calibration Errors, and
General Part Fault (setup errors).
Stop - Instrument Testing

If actively testing, a Stop request will cause the instrument to exhaust any pressure within the
part (if pressure was achieved), and then process the tool retract motion.
Stop - Instrument Idle

If the instrument is idle or in a safe state with the part pressure exhausted, a Stop
request will cause the instrument to execute a tooling reset sequence (only if
tooling is enabled). The retract motion will be executed into a known retracted
state for the next test.
Vent/Halt Request
The design of a Vent/Halt request (including initial phase of the Stop/Reset request) is to cease
operation of tooling motions, safely remove all energy from the part, and stop operation.
A Vent/Halt request operation has multiple operations depending upon the state of the instrument
while testing. For better understanding the test sequence can be broken into three basic groups:
Tooling Extend, Part Testing, and Tooling Retract. The Part Evaluation (Accept Part/Reject
Part/Malfunction/Severe Leak) is always after the Tooling Retract.
Besides a user generated Vent/Halt input, a number of test errors will generate a Vent/Halt
request. Possible scenarios include:
Vent/Halt - Instrument Idle

While the instrument is idle, a high Vent/Halt input will prevent the instrument from performing
any test activity or tooling reset. Any type of Start or Stop request will be ignored until the
Vent/Halt input is low.
Vent/Halt - Instrument execution during Tooling Extend Group

While actively testing and execution fell under the Tooling Extend group, a Vent/Halt request
will cause the output related to an executing Tooling Extend to be turned off. If the extend output
is completed, it will remain in its current state. Since the part has not been charged no exhaust is
necessary and execution will cease. A Tooling Reset will be required.
Vent/Halt - Instrument execution during Part Testing Group

While actively testing and execution fell under the Part Testing group, a Vent/Halt request will
cause the instrument to exhaust any pressure within the part (if pressure was achieved) and
execution will cease. Any output relating to Tooling Extend will remain in its current state. A
Tooling Reset will be required.
Rev 11/18/08 11-3

Vent/Halt - Instrument execution during Tooling Retract Group

While actively testing and execution fell under the Tooling Retract group, a Vent/Halt request
will cause the output relating to the current executing Tooling Retract to be turned off. Since the
part has already been exhausted, execution will cease. A Tooling Reset will be required.
Hold
The Hold input halts or suspends the testing sequence as long as this input is high. This can be
used to stop the testing while awaiting some other action to occur.
SPC Test Part

The SPC Test Part input identifies the next part to test as an SPC Part. This input must be high
when receiving the Start input. This will mark the test results for the part with an * which the
Sentinel C28 uses to separate its test results for special SPC Std Dev calculation in TEST DATA.
Also all test result information output via the communication channels will include the * to
identify these parts for separate analysis. SPC identified parts will not be marked by Part Accept
or Part Reject outputs.
Binary Part Program Selection

Part programs can be remotely selected using the Binary Part Program Selection inputs or using
one of the communication methods like RS232 or TCP/IP. The number of required inputs for
Binary Part Program Selection depends on the highest part number of the program to which
access is required. Since this is a binary part selection, Figure 164 below defines the number of
terminals required to select the part program number.
Part Program Numbers Binary Part Program Inputs

1 B1
2, 3 B1 and B2
4-7 B1, B2, and B3
8-15 B1, B2, B3, and B4
16-31 B1, B2, B3, B4, and B5
Figure 164 Binary Part Program Selection Input
PART PROGRAM SPECIFIC DIGITAL INPUTS

The inputs in Figure 165 below are Part Program Specific. If these inputs are selected within a
specific part program, they are not automatically assigned within other part programs. The
terminals to which the inputs for Start Part, AutoCal, Part presence and Open Leak Std are
assigned can only be used for that function or not at all. These terminals cannot be assigned to a
different function within other programs without unassigning for all programs first. When
reviewing the Digital Inputs, terminals that are assigned to these functions within other programs
will show Constrained or show the same function in the active program for that terminal.
When editing the function of these input terminals the choice will be either the function that was
assigned in another program, or Unassign for all. After pressing Edit, if you want to leave the
function as unassigned or constrained, you can push Exit or you must select the function and
press ENTER, and then press EDIT again to get the option of selecting Unassign, Unassign
for all, or the functional input. Select Unassign and ENTER.
When reviewing these Digital Inputs, terminals that are assigned to these functions in other
programs will show Constrained. The use of different functions can vary from one part
program to another.
Rev 11/18/08 11-4

Start Auto Test Part Leak

Test Cal Control Control Std
Group Group Group Group Group
Start Auto Ext Part Open
Part Cal Press Present Leak
Sw Std
Figure 165 Part Program Specific Digital Input options
Start Part
This part program specific input starts a test using the one part program in which it is selected.
The instrument continuously scans for this input between tests. This input can link the test result
output of another part program by wiring from that test result output programmed specifically to
that part to the Start Part input specifically programmed to the second test part. When the first
part finishes its test with the desired outcome, its test result output will trigger the start of the next
part test by activating the Start Part input for the next part program. Care must be taken when
tooling control is involved between tests. See page 5-17 for more information.
Auto Cal
The Auto Cal input prepares the instrument to perform an Auto Cal routine as defined within Part
Config/MISC/Cal Method (one or two parts and Leak std internal or external). A Start input
initiates the tooling motion and Auto Cal routine. If the Auto Cal routine is setup for two parts, a
second Start input will be required for the second test after the parts are exchanged. For One
Part Auto Cal routines, the instrument does not retract the tooling between tests.
Part Presence
A digital input (PART PRESENCE) can be used as an additional input required to start a test.
The PART PRESENCE input must be high before a start test input is received. It also must go
low between part tests (after any tooling motion and before the start of the tooling motion for the
next test). If the input does not go low between tests, a Malfunction output and display Error:
Part Not Changed are initiated. If a tooling motion were initiated when receiving a Part Presence
Error, a Stop/Reset input will be required to reset the tooling.
The Part Presence function must be setup.
Part Config/INPUTS assign a terminal to Part Presence
Open Lk Std
The Open Leak Standard input will open the Leak Standard Calibration valve during the pre-fill,
fill, stabilization, test, and exhaust cycles. The valve will only open during the testing cycle when
the Open Lk Std input is high. If the Open Lk Std input goes low during the testing cycle, the
Leak Std Calibration valve will close. This input is generally used to automatically verify the
calibration of a system by indexing or placing a good part in the test fixture and adding the
internal leak standard to measure a part with the leak rate equal to the internal Leak Standard.
Ex Pres Sw
The External Pressure Switch input must go high before the end of the fill cycle. This input
indicates that a detected response occurred by the end of the fill cycle. This input is generally
used to validate that the test part is properly charged by detecting pressure downstream of a
potential blockage point. Failure to receive this input before the end of the fill cycle causes a
malfunction result and a Ext Switch did not go high error message.
Rev 11/18/08 11-5

The Sentinel C28 instrument has high impedance, solid-state inputs. Therefore, prox sensors,
solid-state palm buttons, and other devices that have leakage current may require a pull down
resistor (sized as required) across the input for proper operation.
A 22k 0.5 Watt resistor is a typical value used as a pull down resistor. The input and output
terminals are 24 VDC or 120 VAC depending on the I/O circuit board supplied. Additional drain
resistors across the inputs may be required.
DIGITAL OUTPUT FUNCTIONS

Like the Digital Inputs there are Universal and Part Program Specific outputs. The Universal
Outputs apply to the overall part testing process. The Part Program Specific outputs apply the
tooling motion and test specific functions. The timing chart in Figure 166 shows the output
sequences verses the timers for single tests.
Digital Outputs Pre-

Fill Fill Stabilize Test Exh.
Tooling Extend 1
Press Select
Pre-fill
Fill
Stabilization
Test
Exhaust
Tooling Retract 1
Test Passed
Test Failed
Test Below Limits
Test Between Limits
Test Above Limits
Part Accept
Part Reject
Severe Leak
Malfunction
Figure 166 Digital Outputs for single test
Universal Digital Output Functions

The following outputs in Figure 167 below are Universal outputs. If one of these Universal
outputs is assigned to a terminal in any part program, it will be automatically assigned to the same
terminal in all other part programs. If any of these Universal outputs is edited to Unassigned for
all within any part program, it will be unassigned in all the part programs.
Testing Process Results

AutoCal Mode Severe Leak
Malfunction
Part Accept
Part Reject
Figure 167 Universal Digital Output options
Rev 11/18/08 11-6

AutoCal Mode
The Auto Cal Mode output goes high whenever the instrument is performing an Auto Cal cycle.
It goes high at the beginning of the pre-fill for the Master Part test. It stays high until the end of
the exhaust for the Master plus Leak test. This output signals to a PLC that the station is in the
calibration mode so that part movement or another test cycle cannot be initiated until the Auto
Cal cycle is completed.
Severe Leak
If a test fails to reach Minimum Test Pressure within the Pre-fill timer or fails to maintain at least
the Minimum Test Pressure during the Fill and Stabilization timers, the instrument will exhaust
the pressure in the part and output Severe leak high. The tooling will retract. A reject output also
goes high.
Malfunction
If a test has an error or disruption to the normal process and faults out of cycle before the normal
completion, a malfunction will occur. With tooling control if the error or disruption occurs
during initial tooling action, the tooling will retract. If the error or disruption occurs during the
testing cycle, the test will advance immediately to exhaust and the tooling will retract
automatically. The Malfunction output goes high at the end of the completion of the last tooling
motion.
Part Accept
The Part Accept output goes high at the completion of the tooling motion if the test passes.
Part Reject
The Part Reject output goes high at the completion of the tooling motion if the test fails. Part
Rejects also include Severe Leaks when Minimum Pressure is not reached within Pre-fill timer or
maintained during the fill or stabilization timers.
PART PROGRAM SPECIFIC DIGITAL OUTPUTS

The following outputs found in Figure 168 below are grouped by function type and are Part
Program Specific. This means, if any terminal is assigned to one of these outputs, that terminal
can only be assigned to the same output function, one of the other output functions within its
group, or not used by other part programs. When one of these outputs is assigned to a terminal
within another part program, it will appear as Constrained within a new part program. When
attempting to edit the function of this terminal, the choices will only include the other functions
within its group, Unassign, or Unassign for all.
Rev 11/18/08 11-7

Test Cycle Test Result Group Test Control

Calibration Group Test Passed Tooling Control Group
AutoCal Master Test Failed Tooling Extend 1
AutoCal LS Below low limit Tooling Retract 1
Between limits
Test Cycle Timer Group Above high limit Test Indication Group
In Relax Press Select 1
In Pre-fill
In Fill
In Stab
In Test
In Exhaust
Figure 168 Part Program Specific Output Option groups
Calibration Group
The Auto Cal process is a two-step process. During the first test the instrument is testing a
Master (non-leaking) part to determine the baseline pressure change for the testing cycle. The
second test measures the Master part with a Leak Standard added to determine the scaling factor
for the test method to the Leak Standard. Either the AutoCal Master or AutoCal LS outputs
defined below can be assigned to a terminal within different part programs.
AutoCal Master
The AutoCal Master output goes high during the first complete test on the Master part starting at
the beginning of pre-fill timer to the end of the exhaust timer. This output is used to alert an
external process that the instrument is in the first test of calibration.
AutoCal LS
The AutoCal LS output goes high during the second complete test cycle on the Master part when
the Leak Standard is added beginning with the pre-fill timer to the end of the exhaust timer. This
output is used to alert an external process that the instrument is in the second test of calibration.
Test Cycle Timer Group

The test cycle timer outputs go high while their associated timers are controlling the testing
process. These outputs are used to coordinate external functions with the testing process. Any
timer output defined below can be assigned to a timer terminal within different part programs.
Relax timer output

The relax timer output goes high during the Relax timer between the two tests of the Auto Cal
routine described above. It would go high at the end of the first test exhaust cycle until the start
of the second test pre-fill cycle. The relax timer is also functional between tests in the Auto Setup
routine.
Pre-fill timer output

The Pre-fill timer output goes high during the pre-fill cycle. This output is frequently used to
control an external fast-fill valve when testing large volume parts. The external fast-fill valve
opens until the instrument reaches the Minimum Pressure when the instrument advances to the
Fill cycle.
Rev 11/18/08 11-8

Fill timer output

The Fill timer output goes high during the Fill cycle.
Stabilization timer output

The Stabilization timer output goes high during the Stabilization timer.
Test timer output

The Test timer output goes high during the Test timer.
Exhaust timer output

The Exhaust timer output goes high during the Exhaust timer. This output is frequently used to
open an external exhaust valve that vents the test air from the part through a larger valve for fast
exhaust or to bypass the instrument and avoid polluting the instrument pneumatics with dirty part
air.
Test Indication Group

Press Select
The Press Select output goes high at the beginning of the pre-fill cycle and stays high until the
end of their exhaust cycle. For linked tests there can be a unique output for each test. These
outputs indicate when a test is in process or activate valves to switch to a selected test volume.
Test Result Group

The Test Result Group outputs define the outcome of single tests on a part. For linked test
sequences there are unique test result outputs for each program. Any of these outputs can be
assigned to a particular terminal within different part programs.
Test Passed
This output goes high at the beginning of the exhaust cycle for tests that pass and stays high until
the start of the next part test.
Test Failed
This output goes high at the beginning of the exhaust cycle for tests that fail and stays high until
the start of the next part test.
Below Lo Limit
This output goes high at the beginning of the exhaust cycle for tests where the result is less than
the Low Limit set point and stays high until the start of the next part test.
Between Limits
This output goes high at the beginning of the exhaust cycle for tests where the result is between
the Low and High Limit set points and stays high until the start of the next part test.
Above Limit
This output goes high at the beginning of the exhaust cycle for tests where the result is greater
than the High Limit set point and stays high until the start of the next part test.
Tooling Control Group

The Tooling Control Group includes one Tool Extend and Tool Retract output. These outputs are
used to activate pneumatic valves to advance and return tooling cylinders for clamping or sealing
parts for testing. Each part program can use the tooling outputs in a different way depending on
that parts clamp and seal requirements. The tooling motions must be set up for each part
Rev 11/18/08 11-9

program before the Extend and Retract outputs can be assigned. There is also corresponding
Extend and Retract timers that must be set for the tooling motions.
Part Config/TOOLING - Motions must be selected as ON

Part Config/TOOLING - Number of desired tooling motions must be selected (0 or 1)
Part Config/TIMERS -Timers for the Extend and Retract motions requested will be
available
Part Config/OUTPUT - Terminals must be assigned to the desired Tool Extend or Retract
Motion
Tool Extend (1)

This output goes high before the initiation of the Press Select output and start test. The start of
the subsequent motion is controlled by the Tool Ext timer. This output stays high until start of
the Tool Retract motion.
Tool Retract (1)

This output goes high in reverse order from the Tool Extend. If a cylinder actions does not
require an output to retract the tooling, there is no need to assign an output to that Tool Retract
Motion. The corresponding Tool Extend output will go low to release tooling action. Therefore it
is possible that the retract motion maybe skipped. This output stays high until the start of the next
part test tooling sequence or power interruption.
The Sentinel C28 instrument has one circuit board. The main circuit board contains the Test
Module, test firmware, input A/D, terminals for the transducer, battery backup, USB port, TCP/IP
connection, power supply terminals, three output terminals, six input terminals, and a supply
fuses. This circuit board is mounted to the door of the wall mount enclosures.
Rev 11/18/08 11-10

Two similar parts with a Output 1

Neutral or V-
common body but
Output 2 different port locations
Neutral or V-
(A or B)
Part 1 has a port at A
Part 2 has a port at B
A
B
Seal A
Input 4 and 6
Part Presence Input 3and 5
Switch B Part Presence
Switch A
Seal B Start Stop

Button Button
Input 1 Input2
IOH IOH
Figure 169 Tooling example for two similar parts in a common tooling fixture
Setup for tooling control
Programming of Sentinel C28 to perform the required tooling control for a part
The programming for the tooling control for the part is performed within the Part Config menu.
Because each part requires different tooling action, the part programs will be different. The
following table shows the set up required for operating the tooling to these parts where part
presence sensors detect which part is in the fixture and automatically selects the correct part
program setup as Part 1 and 3. Common start station and stop/reset buttons initiate and stop the
tests. The individual part presence sensors are wired to the part present input specific to a part
and also to the appropriate binary coded Part Select input to select either Part Program 1 or
Program 3. Depending on the part detected, the corresponding seal, manually placed in the part
opening, will activate for the test when the Start station button is pushed.
Use this as an example for setting up the appropriate tooling control for other parts.
Part Config, TOOLING

Part #1 Part #2
Tooling Motion On On
Number of Motions 1 1
Figure 170 Configuration of the Part Configuration, Tooling menu, for the two parts
Rev 11/18/08 11-11

Part Config, INPUT

Input Terminal Hardware Part #1 Part #2
Terminal #1 Start button Start Station Start Station
Terminal #2 Stop button Stop/Reset Stn Stop/Reset Stn
Terminal #3 Part select sw Part Select B1 Part Select B1
Terminal #4 Part select sw Part Select B2 Part Select B2
Terminal #5 Part Presence Part Presence Constrained
sensor A
Terminal #6 Part Presence Constrained Part Presence
sensor B
Figure 171 Configuration of the Part Configuration, Input menus, for the one part
Part Config OUTPUT

Output Hardware Part #1 Part #2
Terminals
Terminal #1 Seal A Tool Extend 1 Constrained
extend
Terminal #2 Seal B Constrained Tool Extend 1
extend
Terminal #3
Figure 172 Part Configuration, Output menus, for the two parts
Rev 11/18/08 11-12

Check instrument catalog number on label located on the right side of the instrument. It will
indicate the Supply Voltage and I/O Voltage. The instrument Supply Voltage can be different
than the I/O voltage. The instruments incoming power can be wired to the instrument using the
power cord supplied. For 120 VAC models the power cord will have a three-prong plug on the
end. For 24VDC and 220 VAC models the power cord will be a pigtail cord.
For AC incoming power source
Use supplied power cord or replace with new wiring for incoming main power. The Neutral (or
white) wire is connected directly to terminal 2 on the power supply. The Line (or black) wire is
interconnected to the blue wire from the On/Off switch. The switched power then goes to the
Power Supply (120VAC or 220VAC on terminal 1. Supply for the digital inputs and outputs
should be supplied separately to the main circuit boards power terminals.
Yellow Blue
+24V Clear
Rtn Common White
Black
Egn Ground Shield Gnd Common
Line
ION
IOH Green
Black
Black
Ground
24V
Line AC
Com
Neutral AC
Lid Base
enclosure
Instruments with 220 or 120 Power Supply

VAC power source inputs have
the AC Power Supply mounted
and wired within the enclosure.
Figure 173 AC Source Power (120 VAC with plug or 220 VAC without plug) diagram
Rev 11/18/08 11-13

The 24 VDC wires are use a reverse color code. The white wire in the supply power cord is +24
volts. It is connected directly to the blue wire of the power switch. The black wire of the supply
power cord is -24V or common. It is connected to a black wire from the Common (RTN)
terminal of the main circuit boards power terminals. The green ground wire is connected to the
enclosure ground located at the top left side inside the enclosure.
Yellow Blue
Clear
+24V Black
RTN Common White
Shield Gnd Black Common
EGN Ground +24 V
ION
IOH Green
Lid Base
enclosure
Figure 174 DC Source Power wiring diagram
Rev 11/18/08 11-14

Drivers
Inputs
Valve
IION
+V1
+V5
+V4
+V3
+V2
ST2
ST4
IN6
IN5
IN4
IN3
IN2
IN1
-V5
-V4
-V3
-V2
-V1
Outputs
terminals
Power
+24V
I/O Fuse
EGN
OT3
OT2
OT1
RTN
IOH
IOH
ST3
Power 120VAC I/O (3)Resistors
ION
ST1
Supply 2.5 amp 24 VDC I/O (no resistors)
Fuse
2.5 amp
Transducer
Pin 5 = Shield
(Black wire)
Pin 4 = PEX-
(Negative Supply, white wire)
Pin 3 = PVO-
(Negative Output, blue wire)
Pin 2 = PVO+
(Positive Output, yellow wire)
Pin 1 = PEX+
(Positive Supply, red wire)
Memory
Backup 3V
Jumper System USB Jumper
TCP/IP
Position Reset port Position
Port
Button
Figure 175 Main circuit board with input power, I/O, and transducer terminals
Valve Driver Terminations
Different manifold types have dedicated outputs for the test valves. No connection should be
made to these outputs except for the individual test valves on each module. The connection
pinouts below are only provided as a reference for service and installation. To utilize equivalent
signals for external use (external valves, etc.) select the appropriate programmable outputs in
software and use the provided output terminals. Any connection to these valve drivers other than
that listed below will void the warranty. Since each manifold has potentially different
connections, each is listed below.
Rev 11/18/08 11-15

ST4 Description PA, PB, PN

Pin Manifolds
V1+ Supply 1A Fill/Exhaust Valve
V1- Return 1B
V2+ Supply 2A Part Isolation Valve
V2- Return 2B
V3+ Supply 3A Calibration Valve
V3- Return 3B
V4+ Supply 4A
V4- Return 4B
V5+ Supply 5A
V5- Return 5B
Figure 176 Manifold Valve Terminals on Test Module Board
Transducer(s) Connector for Pressure Decay

These terminals provide 10V excitation and 100mV signal return for the pressure transducer. If
a custom transducer is used, it must not generate more than a 100mV signal. The colors in
parenthesis correspond to the PDCR1000 series Druck transducer wiring.
ST5 Wire Function Wire

Pin code Color
1 PEX+ Positive Red
Supply
2 PVO+ Positive Yellow
Output
3 PVO- Negative Blue
Output
4 PEX- Negative White
Supply
5 Shield Shield Black
Figure 177 Pressure Transducer Terminals and Transducer Wiring Codes
Ethernet
Provides Ethernet communications for remote process monitoring and system updates. This is an
industry standard RJ-45 connector following IEEE 802.3 (10Base-T).
Input Terminals
Check instrument cataiog number and electrical specifications contained on the label located on
the right side of the instrument. It will indicate the Supply Voltage and I/O Voltage. The
instrument Supply Voltage can be different than the I/O voltage. Wire the supply voltage via the
optional external interface cable to the I/O connector on the top of the enclosure. These
terminals are also the common terminals for the input and output signals.
Rev 11/18/08 11-16

The 6 inputs are selected uniquely for each part program via PART CONFIG, TOOLING and
INPUT screens. There are 15 available input functions that can be assigned to these terminals
within the constraints of their Universal and Part Program Specific group functions The inputs
are identified in Figure 175 above and corresponding numbers in the PART CONFIG, INPUT
screen. Use the source voltage and common to the external interface cable for the sinking the
inputs.
Output Terminals
Check instrument cataiog number and electrical specifications contained on the label located on
the right of the instrument. It will indicate the Supply Voltage and I/O Voltage. The instrument
Supply Voltage can be different than the I/O voltage. Wire the supply voltage via the external
interface cable to the I/O connector on the top of the enclosure. These terminals are also the
common terminals for the input and output signals.
The 3 outputs are selected uniquely for each part program via PART CONFIG, TOOLING and
OUTPUT screens. There 19 available output functions that can be assigned to these terminals
within the constraints of their Universal and Part Program Specific group functions The outputs
are identified in Figure 175 above and corresponding numbers in the PART CONFIG, OUTPUT
screen. Use the source voltage and common to the external interface cable for the sourcing
outputs.
Main Power Supply and Input/Output Circuit Fuses

The main fuse provides overload protection for all internal components. The separate I/O fuse
protects the input and output terminals. If a replacement is needed, we recommend 2.5A 250V,
time lag fuse.
Backup Battery
Button battery located on the main circuit board provides uninterrupted memory for storage of
test parameters, counters, and test results. (Panasonic 3V, BR2032)
Rev 11/18/08 11-17

CHAPTER 12 PREVENTIVE MAINTENANCE

PERIODIC MAINTENANCE
Calibrate instrument periodically when:
- Changing model of parts being tested

- After an idle period when temperature conditions of the part or production
environment have changed.
Highly recommend the use of Environmental Drift Correction (EDC) discussed in

Chapter 6. Environmental Drift Correction will continuously monitor and correct for
cyclical changes in the manufacturing environment that affect the calibration parameters
of the test. For most applications Environmental Drift Correction will save calibration
time. It will greatly reduce the need to re-calibrate the instrument to the part and reduce
the number of false accepts and rejects due to cyclical changes in the test environment.
Periodically conduct visual check of the clear air line going into the inlet port of the
instrument for dirt or water.
Conduct Self Test on pneumatics periodically to verify integrity of internal pneumatics.
Replace inlet air filters (5.0 and 0.3 micron) quarterly
Re-certify leak standard (every 6 months or annually) - return leak standard to CTS for re-
certification.
Clean the front panel with a damp cloth and dry thoroughly - Do not use solvents.
All the unique parts supplied by Cincinnati Test Systems including operator panel, electronics,
and pneumatics are specific to the Sentinel C28 and should be supplied solely by CTS or our
authorized service agents.
UPLOADING PROGRAM FIRMWARE
If changes are required in the operating firmware of the instrument, it is easy to perform an
upload of new firmware. Insert the USB flash memory stick with the new firmware into the USB
connection port located on the bottom of the circuit board mounted to the door of the enclosure.
The aluminum protection plate must be opened to access the USB
connector.
Press INSTR CONFIG key repeatedly until the USB tab is
highlighted on the top line of the display.
Move the > next to Update firmware. Press the EDIT key.
Use the up or down arrow keys to select Yes and press
ENTER key.
The instrument display will show the versions of firmware Figure 178 USB Port
stored on the USB flash stick. Use the arrow keys to select the
latest version of firmware and press ENTER.
The instrument will upload the new firmware automatically
and indicate when it is complete. This takes several minutes.
Rev 11/18/08 12-1

Figure 179 Instr Config USB screen
If new firmware is obtained via a file attachment, it will be sent as a zip file.
1. Save the zip file on the hard drive of your computer.

2. To save this firmware on a USB flash drive, the flash drive must be formatted FAT32.
3. Place your flash drive into the USB port of your computer.
4. Using Windows Explorer, locate the drive with the flash drive.
5. Right click on the flash drive and then left click on Format
6. Under File System select FAT32 and left click on START.
7. Window Explorer will format your Flash chip for FAT32.
8. THIS WILL ERASE ANY OTHER INFORMATION STORED ON THAT DRIVE.
9. Go back to Window Explorer and find the saved zip file.
10. Right click on the zip file.
11. Click on Extract All and click NEXT
12. Use Browser to identify the flash drive as the location to send the unzipped file.
13. After the firmware is stored on your flash drive, repeat the procedure outlined before for
loading the new firmware to the Sentinel instrument.
CALIBRATED LEAK STANDARD CERTIFICATION

The Sentinel C28 pressure decay instrument uses a certified leak standard located on the
pneumatic test manifold to calibrate the pressure loss to leak rate relationship for testing. The
leak standard should be re-certified once a year.
1. Remove the leak standard from the Sentinel C28 manifold using a wrench or socket.
2. When installing the re-certified leak standard into the manifold, make sure that an oring
is present in the threaded leak standard hole.
3. The leak standard is certified at a test pressure and has a traceable flow value.
4. Enter the pressure and flow value into the part programs that use the leak standard value
(PART CONFIG/TEST:PLR/Leak Std Flow and Leak Std Cal Press.
5. The Leak Std Cal value must be changed within each Part Program.
Rev 11/18/08 12-2

SPARE PARTS
Pressure Transducer Assembly
(Includes transducer, connector cable, and O-ring.)
SENTINEL-24-TRANS ASSY 0-20 Vacuum and 5 psig

SENTINEL-28-TRANS ASSY 0-2 2 psig
Mechanical Regulator Assembly

(Includes regulator and mounting screws)
SENTINEL-24- REGULATOR VAC VAC-2 psi

SENTINEL-24-REGULATOR 2 0.5 2.0 psig
SENTINEL-24-REGULATOR 10 0 10 psig
SENTINEL-24-REGULATOR 30 0.5 - 30 psig
SENTINEL-24-REGULATOR 100 1-100 psig
SENTINEL-24-REGULATOR 200 2-200 psig
Pneumatic Manifold Block (Pneumatic block, valves and all hardware fittings). Does not
include pressure transducer, leak standard, regulator, or mounting bracket.
-MANIFOLD ASSY PA Pressure Decay Std Cv

-MANIFOLD ASSY PB Pressure Decay High Cv
-MANIFOLD ASSY PN Pressure Decay Low Cv, Low volume
Battery (for Main circuit board)
SENTINEL C28BATTERY (Panasonic 3V, BR2032)
Power Supply Assembly
SENTINEL C28--POWER SUPPLY
Quick Connect fitting for part test line
COUPLING-
Self Test Cap Assembly for Sentinel C28 instrument

(Cable and Quick connect plug)
C28-SELF TEST KIT
USB Memory Stick
SENTINEL--USB MEMORY
Rev 11/18/08 12-3

Leak Standard Assembly - 1% of specified value

(Specify pressure and leak rate)
520- leak rate test pressure 24

(i.e. 520 10 sccm 100 psi 24)
Extra Operator Manuals
SENTINEL C28 -MANUAL
Circuit board exchange program
SERVICES
Instrument Refurbishment
Includes new valves if needed, manifold cleaning, O-rings, and leak standard re-certification. All
components are inspected for damage and wear. Instrument is functionally tested to original
specifications. Includes 1 year warranty.
Rev 11/18/08 12-4

CHAPTER 13 TEST MESSAGES

Test messages appear on the operator screen after each test. On the MONITOR screen, the
message will appear on the line next to the part name where the bar chart appears. When any
other screen like PART CONFIG, INSTR CONFIG, etc. is active, the message will appear on the
bottom line of the screen.
The instrument has messages and test codes to define the outcome of each test initiation.
The following tables provide the Messages, Codes and Explanations for the messages.
CALIBRATION ROUTINE MESSAGES

The calibration process establishes the test parameters specific to a part program. The Auto Cal
routine tests a Master No-Leak part and a Master No-Leak part with a known traceable leak
standard to define the measurements that represent good parts and reject parts. To check the
validity of the calibration there are error check parameters. The following messages and test
codes indicate the progress of the Auto Cal routine and any error conditions encountered.
Message Code Description Corrective Actions

Auto Setup AC Auto Setup routine completed without any
Complete errors
Auto Cal AP Auto Cal cycle completed without any
Passed errors
Auto Cal AF Auto Cal cycle was not successful due to
Failed some error
Auto Cal AM Auto Cal of the Master Part completed

Master Part successfully
Complete
Calibration CP The stabilization or test timers, target Recalibrate the
Required- pressure, Leak Std Flow, or Leak Std instrument for this
Parameters Pressure have been changed since the last part program.
Changed calibration and therefore the part needs to
be recalibrated. There is no output
resultant.
Minimum CM The Performance Factor calculated at the Check that the
Performance end of Auto Cal exceeds the Minimum Minimum
Factor Error Performance Factor set in the Test Factors Performance Factor
was correctly set.
Increase stabilize
and test timers
Master + C1 During the Auto Cal routine, the Increase the
Leak Loss< instrument measured a greater pressure stabilization and
Master Part loss for the master part by itself than for possibly test time
Loss the master part with the leak in the second
test. This results in a Malfunction.
Rev 11/18/08 13-1

Master Part C2 The pressure loss during the first test of Check the seals and
Loss> Max Auto Cal on the Master part exceeded the master part for
Mstr+Leak Max Mstr+Leak Loss set point. This leaks, or extend
Loss results in a Malfunction, stabilization timer.
Check that Max
Mstr+Leak Loss
was correctly set.
Master C3 The pressure loss during the second test of Check the seals and
+Leak Loss > Auto Cal for a differential mass flow test master part for
Max on the Master part exceeded the Max leaks, or extend
Mstr+Leak Mstr+Leak Loss set point. This results in stabilization timer.
Loss a Malfunction, Check to leaks
about leak standard.
Check that Max
Mstr+Leak Loss
was correctly set.
Master C9 The pressure loss reading during the first Check for blockage
Loss<Min test of Auto Cal cycle for a pressure decay in the test line of
Master Loss test was less than the Min Master Loss set part.
point. This results in a Malfunction.
Calculation CE This result occurs from illegal part
Error configurations, calculation errors when
trying to convert vacuum pressures to
positive pressure readings, and other
occurrences.
Calibration ID The calibration data for the part is not Check the data in
Data Invalid consistent with the test. There will be no PART CONFIG,
output resultant Cal to make sure it
is appropriate.
Figure 180 Auto Calibration messages
SELF TEST MESSAGES

The Self Test function is a routine requested by the operator to verify the leak integrity of the
instruments pneumatic circuit. This will show either that the test circuit is leak tight or has an
internal leak.

Self Test SP Self Test process indicates no internal leak
Passed
Self Test SF Self Test process indicates excessive Check oring on self
Failed pressure loss or flow. test plug, probable
dirt on valve seats
Figure 181 Self Test Messages
Rev 11/18/08 13-2

TRANSDUCER ERRORS
At the beginning of each test the instrument quickly performs initial transducer checks to verify
the atmospheric zero pressure reading and zero flow (for mass flow version). Excess pressure or
flow will stop the testing process.

Transducer XZ The pressure transducers atmospheric Perform transducer
Zero Bad pressure reading at the beginning of the calibration routine
testing cycle is outside of tolerance. This in Self Test
results in a Malfunction.
Transducer XO During the testing process the pressure Check the pressure
Over Range exceeded the range of the transducer. This regulator setting
results in a Malfunction.
Figure 182 Transducer Error Messages
PART PROGRAM ERRORS

Before a test begins, if there are some inconsistencies between the part programming and
input/output/tooling/timers setup, error messages will occur to request corrective action before
starting a test.

Part PE There is an error in how the part program Check PART
Configuration is configured. This results in a CONFIG to make
Malfunction. sure that all
parameters are set.
Invalid Part IP An invalid part program was selected for Re-select the part
testing. There will be no output resultant. program making
sure to request a
valid part number
Figure 183 Part Program Errors
PART PRESENCE
If activated within a part program in the INPUT screen, the Part Presence input checks for a high
input when the Start input is received .
Rev 11/18/08 13-3


Part Not PP The part present input was not high when Check the part
Present the Start input was received. This results presence input
in a Malfunction. device.
Part Not PC The part present input signal did not go Remove the part
Changed low between tests to indicate that the part after each test.
was removed from the fixture after the last
test. This results in a Malfunction.
Figure 184 Part Presence Errors
TOOLING ERRORS
Each part program can have a unique combination of input and output functions to perform a leak
test. If these function inputs and tooling motions do not properly sequence, there are error
messages to identify the faults.

I/O IO There is some inconsistency in the setup Verify the tooling
Configuration of the inputs and outputs. There will be setups have the
Invalid no output resultant. appropriate inputs
and outputs
assigned.
External XL The External Pressure Switch input did Check pressure
Switch did not go low between tests. This results in a switch to make sure
not go low Malfunction. it is functioning.
External XH The External Pressure Switch input did Check the pressure
Switch did not go high before the end of the fill timer. switch. Make sure
not go high This results in a Malfunction. that the path to the
pressure switch is
not blocked.
Tooling Not TE If a tooling error occurs involving any Push the Stop/Reset
Reset motions, there will be a tooling error. Input and possibly
Before the start of the next test, the tooling Common to return
needs to be reset by the Stop/Reset input. the tooling to the
This results in a Malfunction. Start position.
Tooling TS Most tooling errors or some test errors
Reset may require a tooling reset with the
Stop/Reset input. After completion of the
reset, this message appears.
Stop Button SB The stop button on the operator panel was
Pressed pressed during a test cycle causing the test
to stop and tooling to retract. There is no
resultant output.
Stop Input S1 The digital input assigned to
Received STOP/RESET went high during a test
cycle causing the test to stop and tooling
retract. There is no resultant output.
Rev 11/18/08 13-4

Stop Input SH The Stop input was high when the Start Check the Stop
High input is received. This results in a input wire for a
Malfunction fault.
Figure 185 Tooling Errors
TEST AND ERROR MESSAGES

Once the testing process begins, the outcome will result in either a successful test or a failure for
some reason. The test result or error messages define outcome of tests.
Test Errors
Part Accept A Part tested successfully, for multiple tests
all tests passed
Part Reject R Part test was not successful, for multiple
tests if any test fails, the part is rejected
Sequence QC Sequence Complete
Complete
Severe Leak SL Severe Leak indicates the test process did Check pressure
not achieve Minimum Pressure within Pre- regulator setting,
fill timer or failed to maintain Minimum cut seals, bad parts,
Pressure during fill or Stabilization timers. or tooling control
This results in a Reject Part. pressure by testing
with Master part
Test Pressure PL Test pressure was below Minimum
Low Pressure during Pre-fill or fill cycles.
This results in a severe leak.
Test Pressure PH Test pressure was above the Maximum Check pressure
High Pressure during fill or stabilization cycles regulator setting
resulting in a Malfunction and tooling control
pressures
Below Target PB The test pressure during test was below the Check the test
Pressure Target Pressure by more that 50%. This is pressure regulator
outside the range for acceptable pressure setting
correction. This results in a Malfunction.
Above Target PA The test pressure during test was above the Check the test
Pressure Target Pressure by more that 50%. This is pressure regulator
outside the range for acceptable pressure setting
correction. This results in a Malfunction.
Part Program A Start Input is received and there are no
Not program parameters stored for that part
Configured program.
Part Error EP This results in a Reject.
Figure 186 Test and Error Message
Rev 11/18/08 13-5

Rev 11/18/08 13-6

CHAPTER 14 SPECIFICATIONS
Pressure Regulators
Precision mechanical pressure regulator (bleeding)
Ranges: 0.5 to 2, 0.5 to 10, 2 to 30, 2 to 100, 2 to 200 and
0.5 to 14.7 psiv
Holds pressure to +0.25 in. water column (0.01 psi)
Transducers
Absolute pressure transducer
Ranges: 20, 45, 115, and 215 psia
Valves
Test valves on pneumatic test manifold
Pilot operated cartridge valves with standard flow or high cv capability and long cycle
life (PA, PB)
Solenoid valves: Ultra low heat gain activated by pulse-modulated outputs (Pneumatic
Manifold versions PN only)
Calibration system: NIST traceable calibrated leak standard (1% accuracy) sized to within 0 and
+5% of specified reject leak limit
Digital Outputs: Dry contact relays (120 VAC (50-60 Hz) or 24 VDC) depending on the
separately supplied power to I/O. The sourcing outputs are fused for a total of 2.5 amps. The
three terminals located on internal circuit board are wired to an external connector on top of the
enclosure.
Test sequence outputs:

Pre-fill timer Fill Timer StabTimer Test Timer Exhaust timer
Relax timer Press Select
Part Result outputs:
Part Accept Part Reject Severe Leak Malfunction
Test Result outputs:
Test Passed Test Failed Above HL Below LL Between Lim
AutoCal process outputs:
Auto Cal Mode AutoCal Master AutoCal LS
Tooling Control:
Tool Extend 1 Tool Retract 1
Total output capability: Outputs are fused for total output of 2.5 amps.
Digital Inputs: Optically isolated 120 VAC (50-60 Hz) or 24 VDC depending on the separately
supplied power to I/O. All inputs are sinking. Six input terminals located on internal circuit
board are wired to an external connector on top of the enclosure.
Optional 14 pin industrial I/O cable is available to simply wiring to external devices.
Rev 11/18/08 14-1

Test Control Inputs:

Start Station Start Part Stop/reset Part Presence Hold
Vent/Halt AutoCal SPC Test Part Open Leak Std Ext Pres Sw
Part Program Selection Inputs
Part Select B1 Part Select B2 Part Select B3 Part Select B4 Part Select B5
Test Data Storage

5000+ test results
Remote Part Program Selection

RS232 or TCP/IP input with part number code
Binary Digital Inputs (Part Select 1-5)
Communication input/output:
Serial output to printer or portable computer
9600, 19200, 33600, 57600 or 115200 baud
No parity 8 bits 1 stop bit none
RS232 port on operator terminal (Nine-pin) of instrument for communication to PLCs,

computer, or serial printers.
TCP/IP internal port on bottom of circuit board
Firmware Update Terminal

USB Flash Memory port on circuit board inside of door. Formatted to FAT32.
Dimensions:
Nema 12 Die Case Aluminum Industrial Enclosure, painted
8.8 W x 6.75 H x 7.5 D
Weight: 12.3 lbs
Environmental Conditions:
Indoor use only
Barometric pressure variation: 12.2 to 17.2 psia
Operating temperature: 5C (41F) to 40 C (109 F)
Maximum relative humidity: 80% up to 31C decreasing linearly to 50% at 40C
Installation category II
Pollution category II
Declaration of Conformity (ALL models only)

Conforms to protection requirements of Council Directive 89/336/EEC: 3 May 1989, as
amended, relating to Electromagnetic Compatibility, by the application of the following
EMC standard:
EN61010 Electrical Safety

EN50081-2 ENC (Radiated)
EN50082-2 ENC (Radiated immunity and Electrostatic Discharge)
Rev 11/18/08 14-2

Electrical rating: 220 V (+10%), 50-60 Hz, 0.5 A

120 V (+10%), 50-60 Hz, 1.0 A
24 volts DC, 2 A (Internal 24 volt power supply is not sufficient to
handle 24 volt I/O
Fuses: Input/Output Circuit: (1) 250 V, 2.5 amp

Circuit board (1) 250 V, 2.5 amp
Pneumatic Supply rating

S1 supply air for test
250 psi max or at least 10 psi greater than test pressure
Vacuum supply for vacuum pressure version: 14.7 psiv
Pilot air:
Regulated to 65-110 psi depending on test pressure
Test connector: Standard pressure connector - 200 psig (or vacuum at 14.7 psiv)
Rev 11/18/08 14-3

CHAPTER 15 OPTIMIZING THE TEST PERFORMANCE
CHAPTER 15 OPTIMIZING THE TEST

PERFORMANCE
Optimal test performance is a compromise between obtaining the best acceptable 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 test. 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 (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.
Volume
The laws of physics require that test volume and test accuracy be inversely 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 (as long as the pre-fill or fill timers does not
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 tooling pressure must be great enough so that it overcomes the
counter force in the part when it is pressurized for the test.
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.
Cycle time
The easiest way to improve repeatability performance is to increase the total cycle time. Total
cycle time includes Pre-fill + Fill + Stab + 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.
Rev 11/18/08 15-1

Pre-fill 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.
For large parts, adding an external fill valve through a larger test line can reduce the time it takes
to reach Min Test Press because it will get air into the part faster. The high Cv manifold offering
provide 5 times higher flow rates than the standard valves. This configuration will fill and
exhaust parts faster. Make sure there are no restriction in the test line less than for the
standard and high flow manifold circuits
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 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 circuit and therefore will be leak tested during each test. To avoid
exhausting dirty part air back through the instrument, use a 3-way valve that direct all the exhaust
air out the valve and avoid the instrument.
Test Time
Performance can often be improved by removing time from the Fill and Stabilization timers and
putting this time into the Test timer, (this is especially true when the test time is less than 5
seconds). To determine if this strategy will help, look at the Master Part Loss value in the
PART CONFIG, Cal tab. If the Master Part Loss value is very small (<0.0010 psi) or the
PERFORMACE FACTOR is greater than 50, we would expect better performance by increasing
the test time at the expense of fill/stab times. Similarly, if the Master Part Loss is more than
75% of the Master+Leak Loss (and especially if these numbers are greater than 0.050), then
you should increase the Fill and Stab time (at the expense of the test time if necessary).
Ideal Example: For a medium or large part

Master Part Loss < 0.0010
High Limit Loss > 0.0250
Performance Factor ~96
Conditions are rarely this good for testing. It would be possible to reduce the Fill/Stab timers to
increase production throughput.
Realistic Example: For a large part

Master Part Loss 0.221
Master +Leak Loss 0.241
Performance Factor ~ 8
This calibration should be improved. There is very little difference between Master Part Loss
and Master+Leak Loss when compared to the "Master Part Loss". It will take some trial and
error work here to find the optimal setting. Reducing the Fill and Stab timers and increasing
the Test timer will make Master Part Loss larger but increase the difference between Master
Part Loss and Master+Leak Loss. For instance -
Master Part Loss 0.289
Master+Leak Loss 0.340
Performance Factoir ~ 15
Because the ratio is larger, the calibration is enhanced. Continue to increase Test timer at the
expense of the Fill/Stab timers until the ratio starts to decline. Ideally try to reach the maximum
performance factor possible.
Rev 11/18/08 15-2

Min Performance Factor

After a satisfactory calibration has been completed with a Performance Factor that provides good
repeatability, set the Min Performance Factor within the PART CONFIG, TST function to a value
that is 5 to 10% below the Performance Factor. This will prevent future calibrations from being
accepted if an unsatisfactory change occurs in the system. Problems like a leaking master part or
fixture/seals, plugged orifice or malfunctioning cal valve, or altered test timers may change the
calibration to an unacceptable level.
Rev 11/18/08 15-3

CHAPTER 16 WARRANTY-SENTINEL INSTRUMENTS

ACCEPTANCE OF PROPOSAL
All proposals, quotations and sales of Cincinnati Test Systems, Inc. (CTS) (i) Products, (ii)
custom-engineered test systems, instrumentation and equipment and/or (iii) standard test
machines (collectively Products or Product) are governed by these terms and conditions of
sale. Acceptance by CTS of Buyers Order or Buyers acceptance of CTS proposal is expressly
limited to and conditioned upon Buyers acceptance of, and assent to, these terms and conditions.
Any additional, inconsistent or different terms and conditions contained in Buyers purchase
order or other documents submitted by Buyer to CTS at any time, whether before or after the date
hereof, are hereby expressly rejected by CTS. Buyer acknowledges that, notwithstanding
anything to the contrary contained in its purchase order or other documents, receipt and
acceptance by Buyer of the Products shall constitute acceptance by Buyer of these terms and
conditions. All orders are subject to acceptance in writing by CTS at its office at 5555 Dry Fork
Road, Cleves, Ohio 45002.
SHIPMENT
CTS reserves the right to designate the method and means of shipment. All Products will be
shipped F.O.B. the CTS plant, Cleves, Ohio. Title, right of possession (unless liens are imposed),
and all risk of loss or damage shall pass to Buyer and delivery shall deem to be completed, upon
delivery of Products to the carrier, its agent or designee.
ACCEPTANCE OF PRODUCTS
Unless notice of defect, nonconformity or disparity in quantity (as compared to shipping
manifest) is received by CTS within thirty (30) days from receipt of the Products by Buyer, the
Products shall be deemed to be accepted by Buyer.
All quotations or proposals are for a gauged system for measuring production parts in a
production environment. Performance of the custom engineered test systems will be tested and
documented with a standard Gage R&R study performed at CTS as part of run-off procedures
prior to shipment. Such testing and qualification is independent of any Buyer part variation or
production environment variables. Unless expressly stated to the contrary, quotations do not
include time for Process Capability Studies using production parts. CTS will ensure that
fixturing will not introduce unacceptable variations in the testing process.
For custom-engineered test systems, Buyer will be given two weeks advance notification of the
intended run-off date. At such time, Buyer may inspect the Products. After inspection and
acceptance by Buyers representative, the Products will be shipped and payment will be due as
quoted. If Buyer elects to waive the inspection, the Products will be deemed to have met the
Buyers requirements and the Products will be shipped and payment will be due as quoted.
CANCELLATION
Buyers purchase order, when accepted by CTS, shall not, for any reason, be canceled in whole or
in part by Buyer without CTS prior written consent. If CTS consents to cancellation, Buyer shall
pay CTS reimbursement for all the applicable costs incurred and the reasonable allowance for
profit as stated by CTS in its written consent to cancellation by Buyer.
Rev 11/18/08 16-1

DRAWINGS, SCHEMATICS AND OPERATING INSTRUCTIONS

Standard electrical and pneumatic schematic prints and one copy of Operating Instructions are
provided for each Product.
ENGINEERING CHANGES
If Buyer requires changes to be made to the Products, once a design of the Product is proposed
and accepted, the additional engineering time, material and shop time required for fabrication as a
result of the change will be subject to negotiation and additional charges will be invoiced
accordingly for the negotiated amount.
OSHA
The Products will be designed and manufactured to meet CTS interpretation of the Occupational
Safety and Health Act (OSHA). Specific Buyer requirements are not included as part of any
quotation or proposal unless the specified requirements were included in the request for quotation
or proposal. After a quotation or proposal is submitted, any other requirements shall be a
supplement to the quotation or proposal or be the subject of a new contract, and the price for such
requirements shall be subject to negotiation. While the Products have been designed to conform
to CTS interpretation of applicable OSHA standards, such compliance is neither warranted nor
guaranteed. Compliance with OSHA requirements is the sole responsibility of Buyer, and CTS
assumes no responsibility for damages suffered by Buyer relative to compliance with OSHA
regulations.
SOUND LEVELS
Sound levels produced by the Products quoted or proposed will not exceed 80 dba when
measured at the operators position and three feet around the perimeter of the Products. When
sound levels exceed 80 dba due to the characteristics of the part being assembled or tested,
special provisions which are not part of the initial quotation or proposal will be made wherever
possible to reduce the sound level. Such alterations to reduce sound level will be charged to
Buyer separately. In the event of a conflict between noise specifications and preferred
equipment, design specification waivers must be granted. When the Instrument is of a design or
manufacture which may be subject to state or municipal ordinances or insurance company
regulations, such Products will be designed and manufactured in accordance with generally
accepted practices and will be adequately tested. Unless expressly stated in the quotation or
proposal, the Products will not be designed or manufactured to conform to any particular
ordinance or regulation.
CTS assumes no liability for the failure of the products to comply with any particular
ordinance or regulation unless the quotation or proposal expressly warrants that the
products will conform to said ordinance or regulation. It is the responsibility of the buyer
upon inspection at the CTS facility to inform CTS of nonconformance with a particular
safety or design standard. Upon inspection by buyer or waiver of inspection by buyer, CTS
is released from any and all liability for failure of the equipment to conform to safety or
design standards.
WARRANTY
CTS warrants that the Products, under normal and proper use, shall be free from defects in
material and workmanship that impair its usefulness, for a period of twelve (12) months from the
date of shipment. Other manufacturers component parts installed in or on the Products are
products of reputable manufacturers sold to CTS under their respective brand or trade names and
shall carry the standard guarantee of the manufacturer thereof, if any, and CTS shall not be
responsible for any defective part thereof.
Rev 11/18/08 16-2

All tests performed on Buyers manufactured products are performed pursuant to the Buyers
specifications for its manufactured products, and by performing such tests CTS shall not assume
any liability for defects in such manufactured products, test data or test specifications. Buyer has
ultimate responsibility for the safety of Buyers manufactured product, including establishment of
leak standards. It is Buyers obligation to report any suspected defect as soon as possible after
discovery. Support service will be provided as soon as practicable to work with Buyers
personnel to remedy a suspected defect. If a service person is required to visit Buyers site, a
purchase order from Buyer to CTS will be required to cover the cost of such service call in the
event that the item serviced is not covered by the applicable warranty. No on-site service is
available for standard test machines unless the cost is prepaid by Buyer. If support service is not
successful in correcting the problem, the Products shall be returned to CTS at Buyers cost.
Products may not be returned without obtaining prior authorization from CTS. All Products
returned for warranty inspection must be securely packaged and shipped prepaid. The Products
will be inspected upon receipt for shipping damage and Buyer shall be notified by CTS if such
damage has occurred. In the event of damage, it is Buyers responsibility to notify and file
damage claims with the delivery company. After receipt of Products at the CTS facility in
Cleves, Ohio, and inspection by CTS, CTS will determine the extent or existence of defect.
CTS obligation under this warranty is limited to repairing or replacing, at CTS option, any
defective non-consumable parts. Consumable parts are specifically excluded from this warranty,
including but not limited to lamps, elastomers, seals, valve seats, and other wear surfaces. This
warranty is conditioned upon Buyer furnishing satisfactory evidence that the Products alleged to
be defective has been properly maintained and correctly operated under normal conditions with
competent supervision and within the operating limits for which such Products are offered and
sold. This warranty shall not apply to any Product that has been subjected to misuse, abuse,
neglect or improper storage, handling or maintenance, or modifications or repairs by any party
other than CTS. The installation of the Products must 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.
Except as expressly stated in this warranty section, CTS makes no warranty, express or
implied, whether of merchantability or fitness for a particular purpose or use or otherwise,
with respect to any products.
LIMITATION OF LIABILITY
In no event shall CTS be liable for special, indirect, incidental or consequential damages, whether
in contract, tort, negligence, strict liability or otherwise, including without limitation damages for
injury to person or property, lost profits or revenue, lost sales or loss arising from or pertaining to
the use of any Products. Buyers sole and exclusive remedy against CTS and its distributors or
sales representatives shall be the repair or replacement of defective parts as provided herein.
CTS liability on any claim, whether in contracts, tort, negligence, strict liability or otherwise, for
any loss or damage arising out of or in connection with Buyers order, shall in no case exceed the
purchase price of the Products actually paid to CTS by Buyer.
SAFETY
Buyer hereby covenants that the Products sold hereunder shall be operated by Buyers employees
and agents utilizing all guards, warning signs and other safety devices that are provided with or
are a part of the Products. In addition to any other rights CTS may have against Buyer for breach
of this covenant, no warranty on the Products whatever, expressed or implied, shall be applicable
in the event such covenant is breached. Buyer further agrees: (i) that disconnections,
disassembly or nonuse of any of the guards, warning signs or other safety devices provided with
or which are part of the Products constitute a substantial change in the Products; and (ii) that it
Rev 11/18/08 16-3

shall indemnify and hold harmless CTS from all claims for damages and injuries made by any
and all parties through the use of such substantially changed Products.
INSTALLATION AND SERVICE

If CTS personnel are required to supervise, check installation, make adjustments, inspect or repair
Products 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 may apply for overtime, Saturday,
Sunday and holidays. Travel time and expenses are charged to and from the CTS facility in
Cleves, Ohio. The repair or replacement of parts will be charged in addition to services
performed, unless parts are covered under the CTS warranty.
SALES AND SIMILAR TAXES

Any tax imposed by any present or future law of Federal, State or any other governmental
authority on the manufacture and/or sale of the Products covered by a CTS quotation or proposal
shall be added to the amount paid by Buyer.
PAYMENT
Buyer shall pay the purchase price as stipulated in the attached proposal, and shall in no event
exceed thirty (30) days after acceptance of the Products to make full payments. International
orders outside of the US and Canada require payment in full prior to shipment of the Products.
CHOICE OF LAW
All proposals, quotations and sales of Products shall be governed by and interpreted in
accordance with the laws of the State of Ohio, USA The applicability of the UN Convention on
the International Sale of Goods is hereby expressly excluded. Any legal action or proceeding
arising from or in connection with a proposal, quotation or sale of an Instrument shall be
brought exclusively in the courts of Hamilton County, Ohio, USA or in the U.S. District Court for
the Southern District of Ohio and shall not be transferred or removed to any other court,
provided, however, that CTS may commence an action in any jurisdiction where Buyer or its
assets may be located, for an injunction, collection or similar relief to enforce the provisions
hereof.
Rev 11/18/08 16-4

CHAPTER 17 GLOSSARY
CHAPTER 17 GLOSSARY
Word Meaning
A-to-D Analog to Digital
Adiabatic The gas compression causes temperature of the gas to rise. The heat will
temperature effects cause metal parts to expand. The cooling gas will reduce the pressure.
atm atmospheres, Units of pressure
Bar million dynes per square centimeter, Units of pressure
Cv factor Flow coefficient
FNPT Female National Pipe Thread
iHG inches of mercury
iWC inches of water column
kPa kilo Pascals
ksc Kilogram per square centimeter
linking Joining several test programs into one sequential test
lpm liters per minute, measurement of Leak Rate
lps liters per second, measurement of Leak Rate
lph liters per hour, measurement of Leak Rate
Manifold Pneumatic circuit paths including valves and transducers
mHg millimeters of Mercury, Units of pressure
mbr millibar, Units of pressure
MPa Mega Pascals, Units of pressure
NPT National Pipe Thread
ozi ounces per square inch, Units of pressure
PLC Programmable Logic Controller
Psi pounds per square inch, Units of pressure
psia Pounds Per Square Inch Absolute
Psig Pounds per square inch gage, pressure difference from atmospheric
Regulator Device to control the pressure from the supply source to the desired
pressure for the test
scch standard cubic centimeters per hour, measurement of Leak Rate
Sccm Standard cubic centimeters per minute, measurement of Leak Rate
sccs standard cubic centimeters per second, measurement of Leak Rate
Stab Timer Timer to delay test after pressurization so that the temperature can equalize
or stabilize within the part under test and the test instrument.
Transducer An electrical device to convert energy from one form to another, such as a
sensor to convert pressure to an electrical signal
Rev 11/18/08 17-1

CHAPTER 17 GLOSSARY
Rev 11/18/08 17-2

CHAPTER 18 INDEX
CHAPTER 18 INDEX
Above Limit.......11-6,11-9 INSTRUMENT CONFIGURATIONS. ... ..2-7,2-11,
Absolute pressure transducer4-4, Ch 6, 13-7 3-2,Ch 4,6-1
ACCESSORIES.1-17 Instrument Startup ................................................... 1-1
Air supply....1-1, 1-10 Leak Rate ..................................... 2-6,3-6,4-9,5-4,Ch.6
AlphaNumeric..2-4 Leak Rate Units ............................................... 3-3,5-13
Arrow keys......2-4 Leak Standards.1-2,1-16,2-10,Ch.3,Ch.5,Ch .6,
AutoCal1-3,2-6,2-15, Ch 3, 4-20, Ch 5, Ch 6, 7-6,12-4,13-1.14-1
12-5, 13-1, 14-1 Linking...5-17
Auto Run.5-5, 5-11 Low Limit ............................ 2-9,3-4,5-8,5-20,6-4,11-9
Auto Setup1-2, 2-6, Ch 3, 5-5 MAC Address4-12,8-9,9-1
Backup Battery...11-17, 12-3 main power ................................................ 11-18,11-14
Below limits....1-15,5-7,5-19,11-9 Malfunctions ..... 1-14,5-1,5-19,5-22,6-6,9-7,10-1,
Between limits...1-15,5-19,5-21,11-9 Ch 11,Ch 13,14-1
Binary inputs..4-3, 5-15,11-4 Manifold types4-2,5-3,Ch.6,8-9,9-2.11-16,12-3
Calibration. 1-3,Ch .2,Ch 3,Ch 4,Ch 5,Ch 6, Master part .... 1-3,2-6,3-5,4-10,5-7,7-5,Ch.6,13-1,15-1
Ch 11,Ch 13 Master+Leak Loss.4-10,5-6,6-7,Ch.13,15-2
Calibration methods...3-7,5-10 Master pressure guage....1-17,7-1,8-3
Calibration Verification........................2-6,2-12,7-6 Max Master+Leak Loss ................. 4-11,5-2, 6-7,Ch 13
Catalog Number1-6 Maximum test pressure .................... 5-6,6-8,6-19,11-5
CHANGE PART...2-11,2-14,4-3,4-20,5-1 Measurement units.....2-11,5-12
CHANGE PART key...2-11,4-3 Minimum Performance Factor.3-9,4-11,15-3
Constrained Inputs/Outputs...5-17,5-21,11-1,11-4 Minimum test pressure ..............................5-6,6-9,11-7
Controller board.....1-12,5-24 Monitor ................................................................. Ch 2
Counters2-6,4-7,4-17,8 -3,9-7,10-1,11-13 MOUNTING CONSIDERATIONS ........................ 1-8
Custom output formating....4-9 Occlusion testing...2-9,4-3,5-3,5-8,6-8
Cycle time.....1-2,2-14,3-2,6-10,15-1 Operator panel....1-4,2-1
Desired Cycle time1-2,2-14,3-4,6-27 Orifice (Leak Standard) value2-14,5-5,7-6,Ch.6, 12-
Digital Inputs....1-14,,2-6,5-3, 5-15,5-23, 2,13-5,14-1
Ch 11, 14-1 output functions ................................. 1-14,5-18, Ch 11
Digital Outputs..1-17, 2-7,5-6,5-18,5-25, Output Terminals ......................... 1-16,5-19,5-24,12-6
Ch 11,14-1 Output Timing Charts....5-19,5-22,11-6
Dimensions..1-9,,14-2 Part Accept.1-15,4-11,5-19,,10-1,Ch.11,
DISPLAY Panel.......1-4,2-2,2-6 13-5,14-1
Electrical Connections .......................................... 1-12 Part Configuration .................................. 1-14,Ch 5.8-9
ENTER key ............................................................. 2-5 Part Linking...5-17
Environmental Conditions .................................... 14-2 Part Name ..................................................2-4,2-7,5-10
Environmental Drift Correction.......5-8,6-5,9-7,12-1 Part Present ........ 5-20,5-30,11-1,11-5,11-11,13-3,14-2
Error messages .............................................. 2-6,Ch 13 Part program ................... 1-14,2-5,3-3,4-2,Ch.5,,Ch.11
Ethernet .................................... 1-1,2-7,4-14,8-1,11-16 Part Program Specific Inputs/Outputs..5-16,5-19,
Exhaust valve ......................................Ch 6,11-16,15-1 11-1,11-4,11-7
EXIT ....................................................................... 2-5 Part Reject.1-15,4-11,5-19,10-1,11-7,13-5,14-1
Fill time.............................. 3-6,5-4,5-20,6-9,11-6,11-9 Part select ............................. 1-14,5-1,11-1,11-12,14-2
Filters .............................................. 1-1,1-10,1-17.12-1 Part test........................................................... 5-1, 5-20
Firmware Update...............................2-12,4-15,12-1 Part Test Result codes.4-11
Fixed Width output..4-4,4-8,4-14,9-5 Password .................................................2-2,4-17,4-20
FUNCTION PANEL ...................................... 2-2,2-14 Performance Factor1-3,2-7,3-8,4-105-7,13-1,15-2
Fuses ................................................................... 11-15 Periodic Maintenance ............................................ 12-1
High limit ............................. 2-9,3-4,5-7,5-21,6-4,11-9 Pilot air..1-1,1-7,1-10,14-3
High Limit Loss ........................................ 5-7,6-7,12-2 Plumbing Recommendations ................................. 1-10
HOLD .................. 1-14,2-10,2-14,5-15,11-1,11-4,14-2 Pneumatic block ........................ 1-10,3-75-10,7-5,12-3
Hyper-Terminal. Ch 8 Pneumatic connections .......................................... 1-11
Incoming power connections ............ 1-12,11-13,11-14 Power Connection ....................................... 1-12,11-13
Inlet air .................................................................. 1-10 Power supply ...................... 1-13,5-24,11-13,12-3,14-2
Input Terminals ............ 1-13,5-3,5-24,11-4,11-16,14-2 Pre-fill output ............. 1-14,5-19,5-22,11-6,11-18,14-1
Installation1-7 Pre-fill timer ......................... 3-6,5-1,5-6,6-9,11-7,14-1
Press Select...1-14,5-19,5-20,5-22,11-6,11-9
Rev 11/18/08 18-1

INDEX
Pressure decay testing....Ch.6 Target Pressure.1-2,2-11,3-4, 4-11,5-5,Ch.6,

Pressure Streaming.4-6,9-2 7-2, 13-7
Pressure units ......................................1-2,3-6,5-12,7-4 Target Pressure Window....5-6,6-6
Preventive maintenance ................................ 1-11,12-1 TCP/IP..................................... 2-7,4-1,4-12,Ch.8,Ch.9
Quik Test...2-7,3-6,4-7,5-7,6-20 Test Passed/Failed1-14,4-11,5-17,5-19,10-3,
Rate of Loss (Change)...2-5,4-11,6-2,5-26 11-8,11-9
Regulator setting ................................. 2-13,3-4,7-1,7-2 Test data ................................... 2-6,2-12,4-7,8-8,Ch.10
Regulators .................................. 1-6,4-3,Ch 6,7-3,14-1 Test evaluation ..................................... 2-9,3-4,5-8,6-5
Relax time ....................................... 5-5,5-11,5-22,6-20 Test Manifold4-2,5-3,8-9,Ch.7,,9-2,11-16,12-3
Remote commands ............................. Ch 8,Ch.11,14-2 Test parameters ......................... 2-7, Ch.5,Ch.5-6,8-10
Reports ....................................................4-7,4-13,Ch 9 Test ports ......................................................... 1-4,1-12
Security setup................................... 2-3,2-134-18,4-19 Test Pressures ............................... 2-12,3-3,4-7,5-5,6-6
Self Test ........................... 1-4,1-12,2-6,2-12,Ch.7,13-2 Test results ......................... 2-7,4-8,5-9,5-25,10-5,11-2
Sequential Testing..12-3 Test Result codes4-11
Serial Number ...................... 2-7,4-1,4-12,4-18,8-9,9-2 Test sequence outputs............................5-19,11-8,14-1
Set regulator .......................................... 2-6,3-4,6-6,7-2 Test Time ........................................... 3-6,5-2,5-4,6-10
SPARE PARTS .................................................... 12-3 Test Type..2-7,3-3,4-3,5-3,Ch.6
SPC Part.5-16,11-4 Timers ................................ 2-11,5-4,6-8,8-8,11-8,15-1
SPC Standard Deviation.............10-4 Tooling Extend/Retract..1-14,5-19,11-6,13-4
Specifications ...................................................... Ch.14 Transducer calibration ...................... 2-6,2-12,7-1,13-3
Stabilization time ....................... 3-6,5-4,5-20,6-9,11-9 Transducers . 2-7,4-3,Ch.6,7-1,11-16,12-3,13-3,14-1
Start Part..1-14,5-3,5-16,5-1711-2,11-5,14-2 USB.......1-4,2-12,4-15,8-1,12-1
Start test ................... 1-14,2-15,3-6,5-1,5-16,5-20,11-2 Units of measurement.................................... 2-11,5-12
Startup............................................................... 1-1,3-1 UNPACKING .........................................................1-5
Statistics .................................................. 2-6,2-12,10-3 Vent/Halt....1-14,5-15,11-2
Stop/Reset ...................................... 2-14,5-15, 6-9,11-1 WARRANTY ...................................................... Ch.16
Rev 11/18/08 18-2

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Sentinel C-28 Compact

Precision Leak Test

Rev 11/18/08 1-1

Rev 11/18/08 1-2

Rev 11/18/08 1-3

Self Test plug

Figure 1 Overview of Sentinel C28 wall mounted instrument

Rev 11/18/08 1-4

INTERNAL INSTRUMENT LAYOUT

Digital Input/Output terminals Transducer terminals

Main instrument circuit board TCP/IP connection Regulator Pressure Transducer

Figure 2 Internal layout of the Sentinel C28 instrument

Figure 3 Quick connect test fitting

Rev 11/18/08 1-5

VERIFICATION OF PROPER INSTRUMENT SPECIFICATION

i.e. Sentinel C28-1W3BE-PA11A4-P02U10A1

Pneumatic Test Manifold

Rev 11/18/08 1-6

Transducers and Test Fittings

Clean, dry instrument air for test and pilot air

Rev 11/18/08 1-7

Mounting bolt channel

Figure 4 Sentinel C28 Mounting Bolt Channels

Rev 11/18/08 1-8

Power Entry (three conductor cable Top View

17 (435 mm) Lid opening

3.66 Mounting holes

Figure 5 Sentinel C28 Dimensional diagram

Rev 11/18/08 1-9

See Figure 6 below for Plant plumbing recommendations.

Figure 6 Plant Plumbing Recommendations

Rev 11/18/08 1-10

Self Test plug

Figure 7 Inlet Air supply connection

Interior Air Supply

Air supply (green tubing)

Rev 11/18/08 1-11

Self test plug and holder

Figure 9 Bottom view of Sentinel C28 vacuum instrument

Rev 11/18/08 1-12

24V supply terminals

(3) red mobs for 120 VAC

Power On/Off Switch

Source power cable

Power on-off switch

Digital Input and Output connector

Rev 11/18/08 1-13

Digital Input function

Digital Output function

Rev 11/18/08 1-14

____ Test Failed

Digital Input/Output wiring

I/O Power (ST1)

Figure 14 Digital input/output wiring to instrument connector and I/O cable

Rev 11/18/08 1-15

INPUT/OUTPUT TERMINAL TABLE

Rev 11/18/08 1-16

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

* Leak standard (spare or remote)

* External three-way test valve to test two parts

USB Flash memory chip

Input/Output Cable 6 meters (14 pin connector)

14pin I/O Cable