Smart Charge Ii Gas Handling System: P/N 861-018 Rev. E

SMART CHARGE II
GAS HANDLING SYSTEM
P/N 861-018
Rev. E
Operational and Maintenance Manual

Vacuum Instrument Corporation
Designers and Manufacturers of Leak Detectors, Gas Handling Equipment, and Complete Leak Detection Solutions
2099 Ninth Avenue Ronkonkoma, New York 11779
Tel 631 737 0900 Fax 631 737 1541 vicsales@vicleakdetection.com www.vicleakdetection.com
TABLE OF CONTENTS
TABLE OF CONTENTS......................................................................................................................................... i
Section 1: Installation and Utility Connection
1.1 Installation ........................................................................................................................................................ 1

1.2 Utility Requirements......................................................................................................................................... 3
1.3 Theory of Operation.......................................................................................................................................... 5
1.4 Operation Cycle ................................................................................................................................................ 6
II. SYSTEM OPERATION ............................................................................................................................... 11
PRE-OPERATIONAL REQUIREMENTS ...................................................................................................... 11
AUTOMATIC MODE ...................................................................................................................................... 13
MANUAL MODE ............................................................................................................................................ 17
MANUAL STEP MODE .................................................................................................................................. 20
III. OPERATOR INTERFACE .......................................................................................................................... 22
MENU PAGES & PARAMETERS .................................................................................................................. 23
SMART CHARGE DEFAULT TERM DEFINITIONS ................................................................................... 25
IV. TRANSDUCER CALIBRATION (ZERO).................................................................................................. 28
V. ALARM/ FAULT CONDITION DEFINITION .......................................................................................... 29
VI. PNEUMATIC DIAGRAM
VII. ELECTRICAL DIAGRAM
861-018 Rev. E toc-i

SMART CHARGE II MANUAL - INDUSTRIAL LEAK DETECTION DIVISION
Section 1 INSTALLATION AND UTILITY CONNECTION
1.1 Installation
1. Place the SMARTCHARGE II unit on a solid surface with good access to the front panel and rear manifold.
Identify the rear utility manifold bulkhead from the following figures:
STANDARD SMARTCHARGE MANIFOLD
SMARTCHARGE WITH HIGH PRESSURE OPTION
NOTE
Bulkhead plates are labeled with all standard option connection ports. Check the order to verify the options
contained on a particular unit.
861-018 Rev. E 1
2. Refer to the UTILITY REQUIREMENTS section. Attach all utility connections to the unit. When
making hose connections to 1/4" NPT fittings, use LOCTITE HIGH TEMPERATURE ANTI-GALLING
PIPE SEALANT, # 567. Loctite item # 56747 or equivalent.
NOTE
Do not use Teflon tape on pipe fittings as the tape particles can cause a pump malfunction or a valve leak.
3. Read the THEORY OF OPERATION section of this manual before proceeding to the SYSTEM
OPERATION section.
1.2 Utility Requirements
ELECTRICAL
• 110-Volt AC, 50 - 60 Hz, 6.5 Amps nominal.
PUMP VENT (VACUUM)

• 1/4" NPT Female (should be positioned to an exterior connection)
VENT (PART)
• 1/4" NPT Female (should be positioned to an exterior connection)
HELIUM INLET
• 1/4" NPT Female, use maximum rated pressure for unit.
• LOW PRESSURE UNIT, 300 PSI.
• HIGH PRESSURE UNIT, 750 PSI.
(FOR AIR/NITROGEN PROOF TEST OPTION)

AIR/NITROGEN INLET
• 1/4" NPT Female, use maximum rated pressure for unit.
• LOW PRESSURE UNIT, 300 PSI.
• HIGH PRESSURE UNIT, 750 PSI.
(FOR HELIUM RECOVERY OPTION)

He OUTLET TO RECOVERY SYSTEM
• 1/4" NPT Female
NOTE
Do not "TEE" vents together as this will cause damage to the vacuum pump.
861-018 Rev. E 2
1.3 Theory of Operation
The Vacuum Instrument Corporation standard Smart Charge II System is designed to provide basic helium and
air/nitrogen gas leak detection. Leak detection is accomplished through a series of test steps that, together, form a
cycle of events. The basic cycle events are venting, evacuation, vacuum decay (pressure rise) testing, helium
charging, pressure decay testing, helium venting to zero (0) PSIG, and final gas evacuation. This system has the
following features:
1. A 3.6 CFM, diaphragm type, two-stage evacuation pump providing vacuum to 25.5" Hg.
2. An operator panel providing controls and testing indication.
3. System alarms for evacuation, vent and charge faults.
4. Operator Interface that allows adjustment to all programmable timer and setpoint values for all pertinent
cycle events.
5. A Siemens CPU214 (S7-200 series) Programmable Logic Controller.
6. A panel Key Switch that provides a hardware lockout of setpoint and timer value changing.
This system can be equipped with a series of factory options used to modify the cycle for specific customer
applications. The table below provides option part numbers, applicable pressures and basic descriptions.
PART NUMBER PRESSURE DESCRIPTION
918-330 300 PSIG PROOF TEST OPTION-WITH HELIUM & N2 BACKFILL OPTION
918-331* 750 PSIG PROOF TEST OPTION - ONLY WITH N2 BACKFILL
918-332* 750 PSIG HIGH PRESSURE OPTION – HELIUM ONLY

918-333 300 PSIG HELIUM RECOVERY OPTION
918-334 750 PSIG HELIUM RECOVERY OPTION
918-336 ALL 230 VAC TO 115 VAC VOLTAGE CONVERSION OPTION
918-337 ALL REMOTE I/O OPTION
* Need both – If 918-332 is ordered, 918-331 is also needed.
There is one (1) standard Smart Charge II unit. Options are added for High Pressure operation (750 PSIG), Proof
Test, Helium Recovery, Input Voltage Conversion and Remote I/O. The standard Smart Charge II unit is rated at
300 PSIG and the high pressure at 750 PSIG. The definition of each of these options is as follows:
861-018 Rev. E 3
Proof Test (Air/Nitrogen @ 300 or 750 PSIG)

This is an additional leak test that provides a gross indication of the parts ability to maintain pressure of an
Air/Nitrogen charge. This Air/Nitrogen charge is 300 or 750 PSIG.
NOTE
For the purpose of proof testing, the use of high pressure air or nitrogen gas is suitable. This gas is referred to as
Air/Nitroten throughout the manual.
Two Step Test Is Performed

1. During the Air/Nitrogen charge, the part is monitored for its ability to hold the charge. If the part has an
uncapped port or a very large hole it will prevent the charge pressure to build in the test part. If the charge
pressure does not meet the charge pressure setpoint value within the watchdog timer value, the test will fail
and the cycle will be safely terminated.
2. After the Air/Nitrogen charge, the part is monitored for its ability to maintain the charge. If the part cannot
maintain the charge pressure setpoint value within the watchdog timer value, the test will fail and the cycle
will be safely terminated.
3. Once the product testing is completed, it can be back-filled with Nitrogen.
High Pressure Option (750 PSIG)

This modification of the standard Smart Charge II allows it to work up to a pressure of 750 PSIG. Operation
remains the same with an extended pressure range.
Helium Recovery Option

This modification of the standard Smart Charge II allows the used Helium gas to be reclaimed to the external
Vacuum Instrument Corporation gas recovery system. The Smart Charge II rear bulkhead panel Recover
connection can be connected to an external Helium Recovery System. At the end of each cycle, the normally vented
Helium gas will be directed to the external gas recovery system.
230 VAC To 115 VAC Voltage Conversion Option

This is a physical option on the unit that provides use of 230 VAC, 3 phase power. The transformer is mounted to
the rear of the unit frame.
Remote I/O Option

This is an option on the unit that provides controller inputs and outputs. Inside the main enclosure are the terminal
blocks allowing external I/O connections.
The standard inputs to the unit are Cycle Start and Cycle End. These inputs allow an external system to start or stop
a cycle.
The standard outputs are defined in the Output Configuration Table in the back of the manual. These outputs allow
the Smart Charge II unit to update the external PLC with the system status.
861-018 Rev. E 4
1.4 Basic Operation
Complete setup of the system is possible through the Operator Interface. See the Operator Interface section of this
manual for details of menu structure.
The System Can Be Tested Using Three (3) Different Operating Modes As Follows
1. AUTOMATIC (AUTO) MODE

2. MANUAL (MAN) MODE
3. MANUAL STEP MODE.
The Automatic and Manual modes are selected by toggling the MAN function key. When the Automatic mode is
selected, the function key LED will be off. When toggled to the Manual mode, the LED will illuminate solid. The
Automatic mode is used to enable the complete automated test cycle using all programmed timer and setpoint
values. The Manual mode is used to enable the manually controlled cycle.
The Manual Step mode is used to enable the system diagnostic routine. This routine is used to verify proper
operation of individual system components. The Manual Step mode can be enabled through the Diagnostic screen
#3 from either Automatic or Manual modes. Again, there are NO watchdog timers enabled, leak or vacuum decay
tests performed in this mode. The only active programmable functions are the pressure setpoints above atmospheric
pressure. This mode allows the operator to sequence all system valves for the purpose of troubleshooting.
Operation Cycle (Automatic and Manual mode)
The standard operation cycle consists of the following steps:

1. READY TO CYCLE
2. VENT BEFORE EVACUATION
3. EVACUATION with VACUUM DECAY (PRESSURE RISE) TEST
4. HELIUM CHARGE
5. SNIFF TEST
6. FINAL VENT
7. FINAL EVACUATION
NOTE
Operation with N2 & backfill.
861-018 Rev. E 5
The operation cycle with the Proof Test & Helium Recovery options consists of the following steps:
1. READY TO CYCLE
2. INITIAL VENT THEN AIR/NITROGEN CHARGE
3. PRESSURE DECAY TEST (PROOF TEST)
4. VENT N2 GAS
5. EVACUATION
6. HELIUM CHARGE
7. SNIFF TEST
8. FINAL VENT (RECOVER HELIUM)
9. FINAL EVACUATION
NOTE:
• The initial vent uses the same values setup for the vent before helium charge step.
• All setpoint and timer values are adjustable at the operator interface.
During Step 3 of the cycle with Pressure Decay, the part is pressure tested with Air/Nitrogen using the pressure
decay test method. During Step 8, the part is vented to the external Helium Recovery System.
This sequence is controlled by a series of valves opening and closing according to pre-selected timer and setpoint
values. See the Setup Menu for actual Setup values and names. The following are detailed explanations of steps 1 -
9 in the operation cycle with the Proof Test and Helium Recovery options:
1. AIR/NITROGEN CHARGE - The part is charged with Air/Nitrogen by the opening of the Air/Nitrogen
valve. This charge function is pressure level dependant and defined by the Air/Nitrogen charge level
setpoint. If the time to reach this setpoint exceeds the Nitrogen Charge Watchdog Time, the part is rejected
and an N2/Air Charge Fault is displayed. When the Air/Nitrogen Charge Level setpoint is met the N2
Stabilization Timer begins. If, during this time, the corresponding pressure falls 50 PSI from the
Air/Nitrogen Charge Level setpoint, a Low N2/Air Charge Fault is displayed. The decay is an adjustable
value through the HMI.
2. PRESSURE DECAY TEST (PROOF TEST) - After the Stabilization Timer ends the Leak Test Time
begins and the current pressure value is captured. The pressure level is dynamically compared to the
captured value for the duration of the leak test. If the resulting difference in pressure exceeds the
programmed Reject Level setpoint before the completion of the Leak Test Time, the part is rejected and a
Leak Detected Fault prompt is displayed.
3. VENT BEFORE HELIUM CHARGE - The part is vented by the opening of the Vent valve. The venting
function is pressure and time dependent. If the part pressure remains above the Vent Level setpoint value, in
excess of the Vent Watchdog Time, the part is rejected and a Vent Fault is displayed.
4. PART EVACUATION, without VACUUM DECAY (PRESSURE RISE) TEST - The part is evacuated
by the opening of the Evacuation valve. The evacuation function is performed by the Part Evacuation
Pump. The evacuation function has three (3) parts; a Delay To Evacuation Time, a pressure level dependant
evacuation and a time dependant evacuation. First the Evacuation is delayed for the duration of the Delay
To Evacuation Part Timer. Next, the evacuation begins and if the pressure rises above 45 PSIG at any time,
the part is rejected and an Evac High Pressure Fault is displayed. Lastly, if the pressure level rises above the
Evacuation Fault Level after the duration of the Evacuation Time, the part is rejected and an Evacuation
Fault is displayed.
861-018 Rev. E 6
5. PART EVACUATION with VACUUM DECAY (PRESSURE RISE) TEST - The part is evacuated as
stated above. The Vacuum Decay (Pressure Rise) Test occurs while the part is fully evacuated. If an
increase in the pressure level of the part occurs, and this change value exceeds the programmed Reject Level
setpoint before the Leak Test Time is elapsed, the part is rejected and a Large Leak Detected Fault prompt is
displayed.
NOTE
The actual setpoint value and the programmed setpoint value differ approximately by a factor or 0.5 or 2 in Hg for
each 1 psi. Therefore, for a programmed value of 20 in Hg (10 psi) the system will alarm at approximately 10 in Hg
(5psi)
6. HELIUM CHARGE - The part is charged with helium by the opening of the Helium valve. The Helium
Charge function is pressure level dependent. This level is operator defined by the Helium Charge Level
setpoint. If the time to reach this setpoint exceeds the Helium Charge Watchdog Time, the part is rejected
and a Helium Charge Fault is displayed.
7. PART SNIFF TEST - When the Helium Charge Level setpoint is met, the Helium valve closes and the
operator is prompted to perform the Sniff Test. This is the beginning of the Leak Test Time and the current
pressure value is captured. The pressure level is dynamically compared to the captured value for the
duration of the leak test. If a decrease in the pressure level of the part occurs, and this pressure change value
exceeds the programmed Low Helium Charge Differential setpoint before the completion of the Sniff Test
Time, the part is rejected and a Low Charge Fault prompt is displayed.\
8. FINAL VENT - The part is final vented by the opening of the Vent valve. The venting function is pressure
and time dependent. If the part pressure remains above the Vent Level setpoint value, in excess of the Vent
Watchdog Time, the part is rejected and a Vent Fault is displayed.
9. HELIUM GAS RECOVERY (OPTION) - The test part gas is vented to an external Helium Recovery
System by the opening of the helium recovery valve. The recovery function is pressure and time dependent.
If the part pressure remains above the Helium Recovery Level value in excess of the Recovery Watchdog
Time, the part is rejected and a Helium Recovery Fault is displayed.
10. FINAL EVACUATION - The part is Final Evacuated by the opening of the evacuation valve. The
evacuation function is performed by the part evacuation pump. The Final Evacuation function has three (3)
parts; a Delay To Evacuation Time, a pressure level dependant evacuation and a time dependant evacuation.
First the evacuation is delayed for the duration of the Delay To Final Evac Timer. Next, the evacuation
begins and if the pressure rises above 45 PSIG at any time, the part is rejected and an Evac High Pressure
fault is displayed. Lastly, if the pressure level rises above the Final Evac Fault level after the duration of the
Final Evacuation Time, the part is rejected and an Evacuation fault is displayed.
NOTE
During an Air/Nitrogen Proof (Pressure Decay) Test or a Helium Pressure Decay Test a small pressure change
occurs when the charge valve is closed. This change can be noted on the process graph during the Stabilization
Time.
This small change in pressure occurs for two reasons:

1. Adiabatic Heating - When a closed cavity is pressurized or evacuated, the air is normally heated above ambient
due to the gas compression or expansion. When this air heats or cools, the resulting pressure increases or
decreases, respectively. During an evacuation cycle a pressure rise will occur and during a pressure cycle. This
is a major factor for small pressure changes.
861-018 Rev. E 7
2. System dynamics - The actual configuration of the system has an effect on gas pressure changes. An example of
specific layout considerations would be piping size, pipe distance between components, valve types and supply
gas pressures.
11. BACKFILL/PURGE OPTION - There are two modes of operation:

a) BACKFILL - At the completion of a test, the part is back-filled to the customers programmed set point.
b) N2 PURGE - At the completion of a test, the part is purged with N2 for the duration of the “Watchdog
Timer”. The will purge any residual helium from the test part.
NOTE
The Backfill option is only available with the N2 option.
861-018 Rev. E 8
DEFINITION TABLE
EVENT TIMES:
T0: CYCLE START

T1: VENT VALVE OPENS
T2: VENT DELAY BEGINS
T3: VENT DELAY ENDS
VENT VALVE CLOSES
EVAC. VALVE OPENS
EVAC. VALVE CLOSES
T4: STABILIZATION TIME BEGINS
T5: STABILIZATION TIME ENDS
PRESS RISE TEST BEGINS
T6: PRESS RISE TEST ENDS
He CHARGE VALVE OPENS
T7: He CHARGE VALVE CLOSES
STABILIZATION TIME BEGINS
PRESS DECAY TEST BEGINS
T9: PRESS DECAY TEST ENDS
VENT VALVE OPENS
T11: VENT DELAY ENDS
VENT VALVE CLOSES
EVAC. VALVE OPENS
T12: EVAC. VALVE CLOSES
CYCLE ENDS
OPERATIONAL EVENTS
1: PART INITIALLY CHARGED

2: PRESSURE VENT
3: TIME VENT
4: EVACUATION
5: STABILIZATION TIME
6: PRESSURE RISE TEST
7: He CHARGE
8: PRESSURE STABILIZATION TIME
9: PRESSURE DECAY TEST
SNIFF TEST
10: PRESSURE VENT
11: TIME VENT
12: EVACUATION
SET POINTS
S1: VACUUM DECAY DIFFERENTIAL SETPOINT

S2: He CHARGE LEVEL SETPOINT
S3: He DECAY DIFFERENTIAL SETPOINT
Fault Condition Initiates Final Vent, Final Evacuation And Cycle End
861-018 Rev. E 9
DEFINITION TABLE
EVENT TIMES:
T1: PART INITIALLY VENTED

N2 CHARGE VALVE OPENS
T2: N2 CHARGE VALVE CLOSES
PRESS DECAY (N2 PROOF) BEGINS
T4: PRESS DECAY (N2 PROOF) ENDS
VENT VALVE OPENS
T6: VENT DELAY ENDS
EVAC VALVE OPENS
T7: EVAC VALVE CLOSES
He CHARGE VALVE OPENS
T8: He CHARGE VALVE CLOSES
PRESS DECAY (He) BEGINS
SNIFF TIME BEGINS
T10: PRESS DECAY (He) ENDS
SNIFF TIME ENDS
VENT VALVE OPENS
T12: VENT DELAY ENDS
VENT VALVE CLOSES
EVAC VALVE OPENS
T13: EVAC VALVE CLOSES
CYCLE ENDS
OPERATIONAL EVENTS
1: AIR/NITROGEN (N2) CHARGE

2: PRESSURE STABILIZATION
3: AIR/NITROGEN PRESSURE DECAY
4: PRESSURE VENT
5: TIME VENT
6: EVAC
7: HELIUM (He) CHARGE
8: PRESSURE STABILIZATION
9: He PRESSURE DECAY TEST
SNIFF TEST
10: He RECOVERY VALVE OPENS
11: He RECOVERY VALVE CLOSES
EVAC VALVE OPENS
12: TIMED EVAC BEGINS
13: TIMED EVAC ENDS
EVAC VALVE CLOSES
SETPOINTS
S1: AIR/NITROGEN (N2) CHARGE LEVEL

S2: AIR/NITROGEN (N2) DECAY DIFF
S3: HELIUM (He) CHARGE LEVEL
S4: HELIUM (He) DECAY DIFF
Fault Condition Initiates Final Vent, Final Evacuation And Cycle End
861-018 Rev. E 10
II. SYSTEM OPERATION
WARNING
Before servicing this unit always disconnect the main power to avoid an unsafe condition that could result in
personal injury.
Before a part can be disconnected from the system verify that the cycle has been completed and the pressure gauge
reads 0 psig to avoid sudden high pressure gas expulsion and possible personal injury. The vacuum gauge should
indicate approximately 12 in Hg at this time. This is a normal and safe condition.
Before a cycle can be initiated, a part must be connected to the system, avoiding sudden high pressure gas expulsion
and possible personal injury.
NOTES
a. Pressing the "Emergency Stop" (red mushroom head pushbutton) at any time will cause the test line to vent
immediately and return all valves to a safe condition. Electrical power to the vacuum pump, solenoid valves
and controller will be disconnected.
b. Turning the AUTO\OFF\MAN selector switch to the "OFF" position will automatically vent the part and
terminate the cycle.
c. Depressing the "CYCLE END" push button at any time will cause a systematic termination of the cycle and
return the machine to the READY condition.
PRE-OPERATIONAL REQUIREMENTS
There are Pre-Operational requirements that must be checked as follows:

• Verify that the system has been properly installed with all connections verified before beginning a Test
Cycle.
• Verify that all bottled gases and shop air are properly connected to the header and at the correct pressures.
• Verify that the vent lines are properly connected to the bulkhead.
• Verify that all the Setup Screens have been properly set.
• Verify that all the Machine Parameters have been properly set.
1. Rotate the Power Switch to the ON position. The following will be displayed on the Operator Interface.
UNIOP V X.XX
OPERATION MODE
AUTOMATIC MODE
CRM POWER OFF
861-018 Rev. E 11
2. Press the CRM power pushbutton, it will illuminate solid. The following will be displayed on the Operator
Interface;
AUTOMATIC MODE
READY TO CYCLE
NOTE
The system will start-up in the last mode it was powered down in.
861-018 Rev. E 12
AUTOMATIC MODE
Standard Unit Operational Steps

1. Install part to test port.
2. If the system was powered in Manual mode, press the MAN key to place it in Automatic mode. The MAN
LED should cease to illuminate.
3. Press the PUMP key. The evacuation pump will be enabled and the PUMP LED will illuminate.
4. Press the Cycle Start pushbutton. The system automatic (AUTO) cycle will run. The sequence of events
and Operator Interface screens are as follows:
The automatic mode is initiated.
AUTOMATIC MODE
READY TO CYCLE
The test part is vented.
AUTOMATIC MODE
VENTING PART
The test part is evacuated.
AUTOMATIC MODE
EVACUATING PART
The test part is leak tested.
AUTOMATIC MODE
LEAK TESTING PART
The test part is Helium charged.
AUTOMATIC MODE
HELIUM CHARGE
861-018 Rev. E 13
The test part is Sniff tested. A beep occurs to alert the operator of the beginning of the Sniff Test.
AUTOMATIC MODE
SNIFF TEST PART
A beep occurs to alert the operator of the ending of the Sniff Test.
The test part is Final Vented.
AUTOMATIC MODE
FINAL VENT
The test part is Final Evacuated.
AUTOMATIC MODE
FINAL EVACUATION
A double beep occurs to alert the operator of the ending of the cycle completion.
When the system is equipped with the Air/Nitrogen Proof Test option, the following screens will appear on the
display at the beginning of the cycle:
The test part is Air/Nitrogen charged.
AUTOMATIC MODE
N2/AIR CHARGE
The test part is allowed to pressure stabilize.
AUTOMATIC MODE
STABILIZING PRESSURE
The test part is Proof tested.
AUTOMATIC MODE
LEAK TESTING PART
861-018 Rev. E 14
When the system is equipped with the Helium Recovery option, the following screens will appear on the display at
the end of the cycle:
The test part is vented to the Helium Recovery Port.
AUTOMATIC MODE
RECOVERING HELIUM
The test part is Evacuated.
AUTOMATIC MODE
FINAL EVACUATION
NOTE
To disable set to –14.0 psig
BACKFILL OPTION
From the “Main Menu” Scroll to access Backfill Charge Setup Screens.
This screen allows access to the Backfill

BACKFILL CHARGE SETUP Setup parameters.
This is the pressure level the test part is back

filled to at the end of a test. A value of -14.7 psi
#1 BACKFILL CHARGE LEVEL will indicate that the backfill option is disabled
#2 BACKFILL CHARGE Maximum time allowed charging the part to

the charge pressure set point.
WATCHDOG TIME
Pressing F1 to exit Backfill setup menu or

PRESS F1 TO EXIT pressing the arrow key for the following
additional setup screens
MORE SETUP ►
861-018 Rev. E 15
Cycle setup allows access to additional setup

CYCLE SETUP screens
This indicates the status of the vent valve when not in test
#1 NOT IN CYCLE/VENT cycle. To open the vent valve press F6 a check [ √ ]
indicates valve open. To close the vent valve pressing F6
OPEN F6 > CHANGE [ X ] with an “X” [ X ] indicating vent
861-018 Rev. E 16
MANUAL MODE
Standard Unit Operational Steps

2. Press the MAN key to place it in Manual mode. The MAN LED should illuminate solid.
3. Press the PUMP key. The evacuation pump will be enabled and the PUMP LED will illuminate.
4. Press the Cycle Start pushbutton. The system manual (MAN) cycle will run up to the Sniff Test. The Cycle
End pushbutton will be required to be pressed to continue the cycle to the end. The sequence of events and
Operator Interface screens are as follows:
The manual mode is initiated.
MANUAL MODE
READY TO CYCLE
MANUAL MODE
VENTING PART
MANUAL MODE
EVACUATING PART
The test part is leak tested.
MANUAL MODE
LEAK TESTING PART
The test part is HELIUM charged.
MANUAL MODE
HELIUM CHARGE
861-018 Rev. E 17
The test part is SNIFF tested. A beep occurs to alert the operator of the beginning of the SNIFF TEST.
MANUAL MODE
SNIFF TEST PART
A beep occurs to alert the operator of the ending of the SNIFF TEST.
The test part is FINAL VENTED.
MANUAL MODE
FINAL VENT
The test part is FINAL EVACUATED.
MANUAL MODE
FINAL EVACUATION
When the system is equipped with the AIR/NITROGEN PROOF TEST option, the following screens will appear on
the display at the beginning of the cycle:
The test part is AIR/NITROGEN charged.
MANUAL MODE
N2/AIR CHARGE
The test part is allowed to pressure stabilize.
MANUAL MODE
STABILIZING PRESSURE
The test part is PROOF tested.
MANUAL MODE
LEAK TESTING PART
861-018 Rev. E 18
When the system is equipped with the HELIUM RECOVERY option, the following screens will appear on the
display at the end of the cycle:
The test part is vented to the HELIUM RECOVERY PORT.
MANUAL MODE
RECOVERING HELIUM
The test part is EVACUATED.
MANUAL MODE
FINAL EVACUATION
861-018 Rev. E 19
MANUAL STEP MODE
STANDARD UNIT OPERATIONAL STEPS
2. Press the F3 key, DIAGNOSTICS. The following screen will appear;
DIAGNOSTICS
3. Press the Down Arrow key until SCREEN #3 appears as follows;
MANUAL STEP MODE

"MAN" > ON/OFF
Press the MAN key to toggle the mode to MANUAL STEP. The MAN LED will illuminate and blink.
4. Press the CYCLE START push button. The manual step mode will run a diagnostic machine cycle by the
operator pressing the CYCLE START button once to start and the CYCLE START push button at the end of
each step to continue. The operator must wait three (3) seconds between push button presses. This mode is
used primarily as a diagnostic tool to troubleshoot problems in the AUTOMATIC and MANUAL
sequences. The sequence of events and console screens are as follows:
The manual step mode is initiated.
MANUAL STEP MODE

PRESS CYCLE START
MANUAL STEP MODE

PART VENT
861-018 Rev. E 20
MANUAL STEP MODE

EVACUATING PART
The test part is helium charge.
MANUAL STEP MODE

HELIUM CHARGE
NOTE: THE PART IS FINAL VENTED AS THE LAST STEP. THIS PROMPT IS NOT DISPLAYED.
When the system is equipped with the AIR/NITROGEN PROOF TEST option, the following screens will appear on
the display at the beginning of the cycle:
The test part is AIR/NITROGEN charged.
MANUAL MODE
N2/AIR CHARGE
When the system is equipped with the HELIUM RECOVERY option, the following screens will appear on the
display at the end of the cycle:
The test part is vented to the HELIUM RECOVERY PORT.
MANUAL MODE
RECOVERING HELIUM
The test part is EVACUATED.
MANUAL MODE
FINAL EVACUATION
861-018 Rev. E 21
III. OPERATOR INTERFACE
The OPERATOR INTERFACE allows the operator to completely configure and operate the SMARTCHARGE II
system. The front panel of the interface contains a series of key switches and LED's. There are four (4) arrow keys
that allow movement through the menu structure. There are also six (6) function keys that have specific functions,
which are continuously active.
Function
Keys
Arrow Keys
Operator Interface Front Panel
FUNCTION KEYS
.The function keys have the following definitions:
F1: EXIT (RETURNS TO THE "READY TO CYCLE" PROMPT.

F2: SETUP
F3: DIAGNOSTICS
F4: MACHINE CONFIGURATION
F5: (NOT USED)
F6: (NOT USED)
SPECIAL KEYS
There are six special keys that have the defined functions as follows:
PUMP: PUMP ENABLE

MAN: MODE ENABLE
ZERO: TRANSDUCER ZERO FUNCTION
HELP: PROVIDES A SERIES OF ON-LINE HELP SCREENS
CLEAR: CLEARS VALUES FROM SCREENS
ENTER: CONFIRMS ENTERED VALUES
861-018 Rev. E 22
MENU PAGES & PARAMETERS
These pages and parameters are accessed using the arrow keys. Pressing the 8 and 9 arrows permit movement
through the parameters listed under each setup section. The 6 and 7keys permit movement among the sections
themselves.
The following is a list of SETUP sections:
PROOF CHARGE SETUP : LEAK TEST SETUP : VENT BEFORE HELIUM CHARGE SETUP :
HELIUM CHARGE SETUP : SNIFF TEST SETUP : FINAL VENT SETUP :
FINAL VENT SETUP : FINAL EVAC SETUP :BACKFILL CHARGE
The following are the parameters listed under each section:
PROOF CHARGE SETUP
#1 NITROGEN CHARGE LEVEL

#2 NITROGEN CHARGE WATCHDOG
LEAK TEST SETUP
#1 PRESS. STABILIZE TIME

#2 LEAK TEST TIME
#3 REJECT LEVEL
#4 LOW N2 CHG. DIFF.
VENT BEFORE HELIUM CHARGE SETUP
#1 VENT WATCHDOG
#2 VENT LEVEL
HELIUM CHARGE SETUP
#1 DELAY TO EVACUATE PART

#2 EVACUATION TIME
#3 EVACUATION FAULT LEVEL
#4 HELIUM CHARGE LEVEL
#5 HELIUM CHARGE WATCHDOG
861-018 Rev. E 23
SNIFF TEST SETUP
#1 LOW He CHG DIFF LEVEL
FINAL VENT SETUP
#1 FINAL VENT WATCHDOG

#2 FINAL VENT LEVEL
FINAL EVAC SETUP
#1 DELAY TO FINAL EVAC.

#2 FINAL EVACUATION TIME
#3 FINAL EVAC FAULT LEVEL
The following are the parameters listed under the DIAGNOSTICS section:
#1 CYCLE TIME
#2 PRESSURE OFFSET
#3 MANUAL STEP MODE
#4 CPU PROGRAM
#5 HMI PROGRAM
The following are the parameters listed under the MACHINE PARAMETERS section:
#1 TXDR FULL SCALE

Maximum scaled range of the transducer
Factor setting for standard low-pressure unit 329.76

Factory setting for High pressure unit 764.70
#2 MAXIMUM TXDR PRESSURE

Maximum transducer operating pressure.
Factory setting for standard unit 315 psig

Factory setting for high pressure unit 750 psig
#3 MAXIMUM MACHINE PRESSURE
Maximum operating pressure of unit
Factory setting for standard unit 300 psig

Factory setting for high pressure unit 750 psig
861-018 Rev. E 24
To change these values:
1. Press and HOLD the CLEAR button for 10 seconds.

2. The letter ( U ) will appear on the display
3. Press the INS button, the cursor will begin to flash
4. Change the values to correspond with type of unit
NOTE: Changing the set up parameters to high pressure without changing the transducer or valving can
result in personal injury or may damage the unit.
.
HELP MENUS
The HELP function is a series of screens accessible using the 8 and 9 keys. It is used to globally change the
prompts to the Spanish language and to define function keys.
SMART CHARGE DEFAULT TERM DEFINITIONS
Evacuation Time- Time the evac valve is open for Initial Evacuation.
Delay to Evac part- Length of dwell after part is vented until Evac begins... May be required to
allow for full venting in some cases.
Evacuation Fault Level- Setpoint (in PSIG) that the transducer must reach during Evacuation time or a
fault will be triggered.
Pressure Stabilize Time- Length of dwell after evacuation valve closes until the Pressure Rise test
begins. Allows for dynamic/thermal effects to subside.
Leak Test Time- Length of dwell during which the pressure rise is observed in the part.
Reject Level- Amount of pressure rise allowed during Leak Test time.
Low Vacuum Fault Level- Setpoint (in PSIG) for the pressure rise the part can experience after
evacuation (during stabilize time) but before vacuum decay test begins.
Guards against loss of vacuum level before decay test starts.
861-018 Rev. E 25
Nitrogen Charge Level- Setpoint (in PSIG) that the transducer must reach during Nitrogen charge or a
fault will be triggered.
Nitrogen Charge Watchdog- Length of time allowable for transducer to reach Nitrogen charge level.
Pressure Stabilization Time- Length of dwell after nitrogen charge valve closes until Pressure Decay test
begins.
Leak Test Time- Length of dwell during which the pressure drop is observed in the part.
Reject Level- Amount of pressure drop allowed during Pressure Decay test.
Low N2 Diff Charge Level- Amount of pressure drop (in PSIG) (from Nitrogen charge level) allowable
@ any time during testing or test is failed.
Vent Watchdog- Length of time allowable for part to vent to (vent level setting, in PSIG)
before Helium charge.
Vent Level- Pressure (in PSIG) that system must vent to before initiating Evac. This is
set above atmosphere, since pump can handle some pressure and venting to
"zero" would take too long & produce false rejects. Note that delay to Evac
also allows for added venting.
Helium Charge Level- Setpoint (in PSIG) that the transducer must reach during Helium charge or
a fault condition will occur.
Helium Charge Watchdog- Length of time allowable for transducer to reach Helium charge level.
Sniff Test Time- Set length of time from attaining full helium charge until the automatic
venting of helium to allow for sniffing part.
Low Helium Charge Diff.- Amount of pressure drop (in PSIG) from Helium charge level allowable @
any time during testing, or test is failed.
861-018 Rev. E 26
Recovery Watchdog- Length of time allowable for transducer to attain (Helium Recovery level, in
PSIG) pressure.
Helium Recovery level- Setpoint that the transducer must reach while recovery valve is open.
Final Vent Watchdog- Length of time allowable for transducer to reach Final Vent level setpoint.
Final Vent level- Pressure (in PSIG) that system must vent to @ end of cycle before Final
Evac. This is set above atmosphere. Note: delay to Final Evac allows for
added venting- since pump can handle some pressure and venting to "zero"
would take too long and produce false rejects.
Delay to Final evac- Length of dwell after part is vented until Final Evac begins, required in some
cases to allow for full venting.
Final Evac Time- Time the evac valve is open for Final Evacuation.
Final Evac Fault level- Setpoints (in PSIG) that the transducer must reach during Final Evac or a
fault is triggered.
Final N2 charge level- Setpoint (in PSIG) that the transducer must reach during Final Backfill
Nitrogen charge.
Final N2 charge Watchdog- Length of time allowable for transducer to reach Final Nitrogen charge level.
Backfill/Purge- At the completion of a test, the part is back-filled to the customers

programmed set point.
861-018 Rev. E 27
IV. TRANSDUCER CALIBRATION (ZERO)
The pressure transducer is responsible for providing accurate test part pressure readings to the PLC. It is
recommended that this transducer be calibrated a minimum of once each day or each time the unit is powered-on
from a cold start. Calibrate the transducer using these steps:
1. Start the system in accordance with Section II., SYSTEM OPERATION.
2. Press the F1 function key to advance to the "READY TO CYCLE" prompt.
3. Press the 9key to access the "PRESSURE - DELTA" screen.
4. Press the ZERO key on the OPERATOR INTERFACE panel.
NOTE: THE SYSTEM MUST BE CALIBRATED WITH THE MANIFOLD AT ATMOSPHERIC

PRESSURE. FAILURE TO DO THIS WILL CAUSE INACCURATE TEST PRESSURE
READINGS. NEVER ZERO THE SYSTEM WHILE A CYCLE IS IN PROGRESS.
861-018 Rev. E 28
V. ALARM/ FAULT CONDITION DEFINITION
VENT FAULT: If the part pressure remains above the VENT LEVEL setpoint value,
in excess of the VENT WATCHDOG time, the part is rejected and a
VENT FAULT is displayed.
EVACUATION FAULT: After the EVACUATION LEVEL setpoint has been reached; if the
pressure level rises above the EVACUATION FAULT LEVEL after
the duration of the EVACUATION TIME, the part is rejected and an
EVACUATION FAULT is displayed.
EVAC. HIGH PRESSURE: If the pressure rises above 45 PSIG at any time, the part is rejected
and an EVAC HIGH PRESSURE fault is displayed.
HELIUM CHARGE FAULT: If the HELIUM CHARGE LEVEL setpoint is not met within the
HELIUM CHARGE WATCHDOG time, the part is rejected and a
HELIUM CHARGE FAULT is displayed.
LARGE LEAK DETECTED: If an increase in the pressure level of the part occurs, and this change
value exceeds the programmed REJECT LEVEL setpoint before the
LEAK TEST TIME is elapsed, the part is rejected and a LARGE
LEAK DETECTED fault prompt is displayed.
LEAK DETECTED FAULT: If an increase in the pressure level of the part occurs, and this
differential change value exceeds the programmed REJECT LEVEL
setpoint before the LEAK TEST TIME is elapsed, the part is rejected
and a LEAK DETECTED FAULT prompt is displayed.
LOW CHARGE FAULT: If a decrease in the pressure level of the part occurs, and this pressure
change value exceeds the programmed LOW He. CHARGE
DIFFERENTIAL setpoint before the completion of the SNIFF TEST
TIME, the part is rejected and a LOW CHARGE FAULT prompt is
displayed.
861-018 Rev. E 29
LOW N2/AIR CHARGE FAULT: If, during the N2 STABILIZATION TIMER, the pressure falls 50
PSI from the AIR/NITROGEN CHARGE LEVEL setpoint, a LOW
N2/AIR CHARGE FAULT is displayed.
N2/AIR CHARGE FAULT: If the time to reach the AIR/NITROGEN CHARGE LEVEL setpoint
exceeds the NITROGEN CHARGE WATCHDOG TIME, the part is
rejected and an N2/AIR CHARGE FAULT is displayed.
He RECOVERY FAULT: If the part pressure remains above the He RECOVERY LEVEL value
in excess of the RECOVERY WATCHDOG time, the part is rejected
and a He RECOVERY FAULT is displayed.
861-018 Rev. E 30
Vacuum Instrument Corporation
2099 Ninth Avenue, Ronkonkoma, NY 11779
Tel # (631) 737-0900 – Fax # (631) 737-1541
www.vicleakdetection.com - sales@vicleakdetection.com
Sales/Service Offices
California, New York, Ohio,
Mexico, France, Germany, Japan
Exclusive Sales & Service Representatives Worldwide
Vacuum Instrument Corporation has the broadest experience with comprehensive leak detection solutions required
to design, build, sell, and service the most innovative and versatile leak detectors anywhere in the world. That is
because leak detection is and always has been our only business. We are dedicated to leak detection, and our
customers have made us the largest leak Detector Company in the world.

Smart Charge Ii Gas Handling System: P/N 861-018 Rev. E

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Smart Charge Ii Gas Handling System: P/N 861-018 Rev. E

Uploaded by

Copyright:

Available Formats

SMART CHARGE II

GAS HANDLING SYSTEM

Operational and Maintenance Manual

Section 1: Installation and Utility Connection

1.1 Installation ........................................................................................................................................................ 1

II. SYSTEM OPERATION ............................................................................................................................... 11

PRE-OPERATIONAL REQUIREMENTS ...................................................................................................... 11

AUTOMATIC MODE ...................................................................................................................................... 13

MANUAL MODE ............................................................................................................................................ 17

MANUAL STEP MODE .................................................................................................................................. 20

III. OPERATOR INTERFACE .......................................................................................................................... 22

MENU PAGES & PARAMETERS .................................................................................................................. 23

SMART CHARGE DEFAULT TERM DEFINITIONS ................................................................................... 25

IV. TRANSDUCER CALIBRATION (ZERO).................................................................................................. 28

V. ALARM/ FAULT CONDITION DEFINITION .......................................................................................... 29

VI. PNEUMATIC DIAGRAM

VII. ELECTRICAL DIAGRAM

861-018 Rev. E toc-i

Section 1 INSTALLATION AND UTILITY CONNECTION

STANDARD SMARTCHARGE MANIFOLD

SMARTCHARGE WITH HIGH PRESSURE OPTION

1.2 Utility Requirements

PUMP VENT (VACUUM)

(FOR AIR/NITROGEN PROOF TEST OPTION)

(FOR HELIUM RECOVERY OPTION)

1.3 Theory of Operation

PART NUMBER PRESSURE DESCRIPTION

918-332* 750 PSIG HIGH PRESSURE OPTION – HELIUM ONLY

* Need both – If 918-332 is ordered, 918-331 is also needed.

Proof Test (Air/Nitrogen @ 300 or 750 PSIG)

Two Step Test Is Performed

High Pressure Option (750 PSIG)

Helium Recovery Option

230 VAC To 115 VAC Voltage Conversion Option

Remote I/O Option

1.4 Basic Operation

1. AUTOMATIC (AUTO) MODE

Operation Cycle (Automatic and Manual mode)

The standard operation cycle consists of the following steps:

This small change in pressure occurs for two reasons:

11. BACKFILL/PURGE OPTION - There are two modes of operation:

T0: CYCLE START

1: PART INITIALLY CHARGED

S1: VACUUM DECAY DIFFERENTIAL SETPOINT

T1: PART INITIALLY VENTED

1: AIR/NITROGEN (N2) CHARGE

S1: AIR/NITROGEN (N2) CHARGE LEVEL

II. SYSTEM OPERATION

There are Pre-Operational requirements that must be checked as follows:

Standard Unit Operational Steps

The automatic mode is initiated.

The test part is vented.

The test part is evacuated.

The test part is leak tested.

The test part is Helium charged.

The test part is Final Vented.

The test part is Final Evacuated.

The test part is Air/Nitrogen charged.

The test part is allowed to pressure stabilize.

The test part is Proof tested.

The test part is vented to the Helium Recovery Port.

The test part is Evacuated.