package test system lippke 2000 sl - lauper instruments

User Manual

Package Test System

LIPPKE 2000 SL

Gas-Detection

www. lauper- in s t rument s . ch

Lauper Instruments AGIrisweg 16B CH-3280 Murten Tel. +41 26 672 30 50 [email protected] www.lauper-instruments.ch

Package test system LIPPKE 2000 SL Introduction

Paul Lippke Handels-GmbH 2

Contents

1 Safety instructions 5 - 6

2 Introduction 7 - 11

2.1 System survey 7 -9

2.1.1 The LIPPKE 2000 SL control unit 7

2.1.2 Holding stand and needle heads 8 - 9

2.1.3 Clamping device 9

2.2 General operating instructions 10 - 11

3 Commissioning 12 - 16

3.1 Conditions 12 - 13

3.1.1 Electrical supply 12

3.1.2 Environment 12

3.1.3 Compressed air supply 13

3.2 Installation 13 - 16

3.2.1 Electrical connections 13

3.2.2 Mechanical construction of holding stand 14 - 15

3.2.3 Pneumatic connections 15

3.3 Operation 16

4 Burst test 17 - 20

4.1 General instructions for burst test 17 - 19

4.1.1 Safety instruction 17

4.1.2 Standard settings 17

4.1.3 Instructions for clamping device 17

4.1.4 Instructions for holding stand 17 - 18

4.1.5 Measurement 18

4.1.6 After the measurement 19

4.2 Activation of burst test 19

4.3 Carrying out the measurement 19

4.4 Parameter settings 19

4.5 Protocol 19 - 20



5 Pressure loss test 21 - 25

5.1 General instructions for pressure loss test 21 - 22

5.1.1 Safety instruction 21

5.1.2 Standard settings 21

5.1.3 Instructions for clamping device 21

5.1.4 Instructions for holding stand 21 - 22

5.1.5 Measurement 22

5.1.6 After the measurement 22

5.2 Activation of pressure loss test 23

5.3 Carrying out the measurement 23

5.4 Parameter settings 24

5.5 Protocol 24 - 25

6 Configuration 26 - 37

6.1 Number of print-outs 26 - 27

6.2 Auto-Stop-threshold 27

6.3 Compensation time 27

6.4 Interface output 27 - 34

6.5 Printer configuration 35 - 36

6.6 Date and time 36

6.7 Acoustic signal 37

6.8 Pressure unit 37

7 Maintenance 38

8 Error causes 39 - 40

8.1 System errors 39

8.2 Interface errors 39

8.3 Problems during measurements 40

9 Appendix 41 - 44

9.1 Operating principles 41 - 42

9.2 Specifications and certificate 42 - 43

9.3 Dimensions and weights 44

9.4 Spare parts list 44



Index of figures

Figure 2.1: Package test system 7

Figure 2.2: Holding device 8

Figure 2.3: Needle No. 1B 8



Figure 2.6: Clamping device 9

Figure 2.7: Control unit, front panel 10

Figure 3.1: Holding stand 14

Figure 3.2: Construction of filter 15

Figure 3.3: Control unit, rear panel 15

Figure 4.1: Print-out of a burst test 20

Figure 5.1: Print-out of a regular pressure loss test 25

Figure 5.2: Print-out of a pressure loss tests with bursting of package 25

Figure 6.1: Test report, burst test 28

Figure 6.2: Test report, pressure loss test 29

Figure 6.3: Data output at the end of burst test 30

Figure 6.4: Data output at the end of pressure loss test 31

Figure 6.5: Data output, burst test 32

Figure 6.6: Data output, pressure loss test 33/34

Figure 9.1: Pneumatic system 41

Figure 9.2: Sample of works certificate 43

Index of tables

Table 3.1: Environmental conditions 12

Table 3.2: Assignment of connections: Holding and clamping device 16

Table 6.1: Cutting signal 35

Table 8.1: System errors 39

Table 8.2: Interface errors 39

Table 9.1: Dimensions and weights 44

Table 9.2: Spare parts list 44

Package test system LIPPKE 2000SL Safety instructions


1 Safety instructions

• This operator’s manual has to be read, understood and observed before commissioning the test system.

• If one of the following safety instructions is not or only partially observed, the Paul Lippke Handels-GmbH can assume no responsibility for any consequential damages, defects or the reliability of the test system.

• We proceed on the assumption that the operator will use this test system carefully and sensibly.

• You must not continue system operation if any system malfunctions occur.

• The test system must not be modified with regard to its construction and design without prior consultation of the manufacturer.

• This operator’s manual must be enclosed if the test system is resold.

• Please make sure that the test system is only connected to the mains power supply men-tioned on the nameplate.

• Please also make sure that the connection pressure of compressed air supply does not ex-ceed the maximum pressure.

• Please provide sufficient air circulation and install the test system in a sufficient distance to other objects.

• Never clean the test system with any liquids if it is connected to the mains socket-outlet.

• Disconnect the test system from the mains line and remove the compressed air supply be-fore opening its front or rear panel.

• Maintenance works which are possibly required may only be performed by the customer service department of the Lippke company.

Package test system LIPPKE 2000SL Safety instructions


• The following symbols are used in order to obtain more clarity:

• Caution: Please observe instruction by all means.

•

• Important note, may lead to malfunctions or damage of test system if

• not observed

•

• Note, which is helpful in operating and using the test system.



2 Introduction

2.1 System survey

The system LIPPKE 2000 SL (see figure 2.1) developed by the Paul Lippke Handels-GmbH offers the user the option to test packages with regard to their impermeability and sealing seam stability (burst test = BURST mode) and to their tightness (pressure test = LOSS mode).

In the burst test a linear pressure rise is created in the package until the package bursts. Thus the burst pressure is a measure for the impermeability of the seams of the package.

For measuring the tightness of a package, first a pressure is built up inside the package. There will be a pressure loss in the package during test time if the tested package is leaky. This pressure loss is measured and displayed.

Figure 2.1: Package test system LIPPKE 2000 SL

The serial interface permits the output of test reports to a printer or PC.

2.1.1 The LIPPKE 2000 SL control unit

The LIPPKE 2000 SL control unit houses the micro controller and the pneumatic system. Here the air supply is connected and guided through the package holding device to the package in a controlled way. Operation and display take place via the front panel.

In general, the test result is displayed on the digital display. However, the use of a serial interface is recommended for optimum documentation and for outputs on a printer. It is also possible to

link the system to a PC (e.g. via the ”Terminal Program” by WINDOWS). Apart from this result, all test parameters as well as date and time are transmitted. A corresponding printer can be purchased via LIPPKE.



2.1.2 Holding stand and needle heads

A closed package is connected to the control unit by means of the package holding stand (see figure 2.2).

Figure 2.2: Package holding stand

Two different types of needle heads are used in order to conduct compressed air into the package: the mono needles (type 1B and type 2B) and the double needle type 3B.

Mono needles are suitable for almost all packages. There is no danger of measuring needle clog-ging by the product, since here only one needle is used for air supply and pressure measurement. Pricking into the package is made easier by the needle type 1B (see figure 2.3). Nevertheless the use of a needle type 2B (see figure 2.4) is recommended for flat packages in order avoid undesired damage to the underside of the package.

Figure 2.3: Needle Type 1B




In case of the double needle (see figure 2.5), the sensor line is lead separately into the package. If very large air supply is required for measuring, back-pressure is possible when using a mono needle. This effect occurs above all with packages made of materials permeable to air, like sterile paper, Tyvek etc. An O-ring inside the needle head provides the sealing of both air channels.


2.1.3 Clamping device

A package open on one side is connected to the control unit by means of the clamping device (see figure 2.6). The open end of the package is sealed almost airtight between the clamps. Only the two connections for air supply and pressure measurement are lead to the control unit.

Figure 2.6: Clamping device



2.2 General operating instructions

After switching on (power switch on the rear panel, see figure 3.3, page 16), the LIPPKE 2000 SL control unit first displays the parameter last used (see figure 2.7).

Figure 2.7: Control unit, front panel

The two red LEDs on the left side of the display field indicate the active mode: The BURST TEST LED indicates a burst test and the PRESSURE LOSS TEST LED indicates a pressure loss test. Depending on the four LEDS on the right side, the digital display has different meanings:

� “mbar”: The current pressure is displayed in ”mbar”, if this LED lights up, otherwise in ”PSI”

� “∆ P” signalises pressure loss in ”mbar” or ”PSI” (see above)

� With ”SEC”, test time is indicated in seconds and with

� ”MIN” in minutes.

The LED bar display below the numerical display field has the following meaning:

Burst test: The current internal pressure inside the package is displayed in the overall range of 0 - 3000 mbar on the ”ACTUAL PRESSURE” display. Thus one LED corresponds to 300 mbar.

Pressure loss test: The selected test pressure is displayed on the ”SET PRESSURE” display. All 10 LEDS always light up. The current internal pressure of the package is displayed on the ”ACTUAL PRESSURE” display. One LED is extinguished for each pressure loss of 10%.

Setting of mode and pressure is performed in the left part of the operator panel. The ”TEST MODE” key serves for changing to the desired mode. The function is activated by pressing the ”+”- or ”-” key, i.e. a pressure value or a pressure rise rate is displayed on the display. Then the pressure can be set by means of the ”+”- and ”-” key. The values are changing the faster the longer the key is pressed. In test system configuration (see chapter 6), you can determine whether the factory-set default pressure unit ”mbar” shall be changed into the pressure unit ”PSI”.



Setting of test time (only in LOSS Mode!) is performed on the right panel. The function is acti-vated by pressing one of these three key, i.e. a time value is now displayed. ”SEC MIN” serves for changing to the desired unit of time (seconds or minutes). Test time can be set by means of the ”+”- and “”-” key. The values are changing the faster the longer the key is pressed.

If you press ”TIME” during a test, the elapsed time (burst test) or the remaining test time (pressure loss test) is displayed.

Your system has the standard configuration at the time of delivery. You will find further operating instructions in chapter 6 ”Configuration”, from page 26 on.

Package test system LIPPKE 2000 SL Commissioning


3 Commissioning

3.1 Conditions

3.1.1. Electrical supply

Important note: Connection to a mains power supply unit different from the nameplate can lead to device damage.

A mains power supply of 230 V∼ ± 10 % at a frequency of 50 Hz ± 1 Hz is required for the sys-tem (other options upon request). Please note that the above-mentioned conditions are not always kept in direct vicinity of large electrical machines. Wherever necessary and in case of doubt, a mains filter must be connected in series. In case of power failures, the current test may be inter-rupted.

3.1.2. Environment

Important note: Operating the test system outside the above-mentioned limits may lead to malfunctions and device damage. Never install the system close to heat sources. It must be protected from direct sunlight, heavy dust contamination, vibrations, liquids and extreme air humidity. If any liquid is accidentally introduced into the control unit, have the system checked by Lippke before continuing the operation. It is important to observe the following limits:

Condition Limits

Ambient temperature + 5 ... 400C

Air humidity 0 ... 90% relative humidity without condensation

Table 3.1: Environmental conditions



3.1.3. Compressed air supply

Caution: If it is not ensured that maximum pressure is kept in any case, there is danger of bursting of hoses and other parts.

Important note: Perfect function is not guaranteed if the pressure value remains under the above-mentioned input pressure.

Compressed air should be dry, clean and free from oil and be supplied with an input pressure of 4 ... 7 bar (at least 1 bar above measurement pressure) (please use adequate pressure reducer). We recommend a compressed air quality according to ISO standard 343. If air quality is not suffi-ciently known, it is recommended to process the air by means of a filter combination (5µ and 0,01µ) and by a end position drier with regenerative cartridge (e.g. Zander Min-DRY MDK and KT 2016) connected in series. The possible expenditure for this cleaning effects exact measuring results and trouble-free long-time operation of the entire pneumatic system. Air consumption basically depends on size, stability and porosity of packages and number of measurements.

3.2 Installation

Important note: Please read the following notes by all means before beginning installation.:

First check all devices and systems for possible transportation damage and immediately assert warranty claims, should the occasion arise.

3.2.1. Electrical connections

All connections are arranged on the rear panel of the LIPPKE 2000SL control unit (see figure 3.3, page 16). First connect the mains power cable (connection ”230V~ MAINS”). After that, you may connect the optional connecting cable (nine-pole interface cable) to the output unit (printer, PC). For this purpose, use the port marked with ”RS 232”.



3.2.2. Mechanical construction of holding stand

In general, the package holding stand is delivered already completely assembled, so that you don’t have to read this chapter.

Assembly according to 3.1 only requires a few movements of the hand. The bar must be screwed into the base plate. Then you have to tighten the lock ring. An arm with height and angle adjust-ment, which must be attached next, if necessary, is optionally available for smaller sized packages. Now the flexible holding arm for the test head can be mounted.

Figure 3.1: Package holding device

The needle head can be screwed onto the test head. This connection is sealed with an O-ring.

If you use packages filled with pulverised or liquid substances, you must insert the optionally available filter between test head and needle head (see figure 3.2).



O-RingO-Ring

Filterschaum-stoff

Filtereinsatz Filterröhrchen

Prüfkopf Filter Nadelkopf

Figure 3.2: Construction of filter

First screw the filter element with foam filter into the test head for this purpose. Then the small filter tube and the needle head can be attached. For the positions of the individual O-rings please see figure 3.2.

3.2.3. Pneumatic connections

The pneumatic connections are also on the rear panel of the module (s. figure 3.3).

Paul Lippke Handels GmbH

230V~MAINS

RS 232FUSE 1A

AIR SUPPLY FEED SENSE

Figure 3.3: EPS module, rear panel

Connect the compressed air supply unit to “AIR SUPPLY”.

Fuse

Power Switch RS 232

Feed

Sense

Air Supply



The connections for holding stand and clamping device are also on the rear panel of this module.

For the assignment of connections, see the following table:

Table 3.2: Assignment of connections, holding device and clamping device

Important note: Please make sure that all hoses are firmly and tightly connected. Please use the union nuts delivered with the test system in any case for protecting and sealing the connections.

3.3 Operation

First switch on the output device (printer, PC, etc.) and then the control unit LIPPKE 2000SL (power switch on the rear panel). Now the LED ”STOP” lights up. Moreover, the parameters last used are displayed: burst or pressure loss test and pressure rise rate or test pressure in mbar. Test time and selected unit of time are displayed by pressing of one of the keys in the ”TIME” field (“SEC MIN” or ”-”, ”+”)

Control unit Holding device Clamping device Connection Mark Connection Mark SENSE thin hose no thin hose no FEED thick hose no thick hose no

Package test system LIPPKE 2000 SL Burst test


4 Burst test

4.1 General instructions for burst test (LOSS mode)

The general information about burst tests is presented in brief outlines and sorted in the order valid for carrying out a measurement procedure. This will facilitate subsequent retrieving of special information during operation.

4.1.1. Safety instructions

Caution: In a burst test, the package will in general burst. This may lead to consid-erable noise. Thus wear suitable hearing protection.

Important note: In case of filled packages you must further make sure that the product doesn’t soil users or system, if possible. Depending on the package con-tents we recommend to wear safety glasses. A silencing protective hood placed over the package holding device offers perfect protection.

4.1.2 Standard settings

In most cases, each package type will require its own special measuring conditions. A standard pressure rise rate is 5 mbar/s. In rare cases, further parameters may be matched (see chapter 6, page 26).

4.1.3. Instructions for clamping device

The clamping device for packages open on one side can only be used in the burst test mode.

Fix the package between the clamps, if possible in the middle. Make sure that the nozzle, with the openings for air supply and pressure measurement, is clamped into the package opening. When testing extremely hard and stable packages it is possible that the package comes loose from the clamping device. Increase the clamping pressure in this case by screwing the clamping pins further out. If this is not sufficient, glue a strip of emery cloth on the sponge rubber gibs of the clamping device, at the top and bottom.

4.1.4. Instructions for holding device

In order to ensure a linear pressure increase in the package and to avoid unnecessarily high con-sumption of air it may be required to seal the prick-in point with a diaphragm. Additionally, this diaphragm protects the packing material from tearing at the prick-in point. When testing flat packages, the black diaphragm is recommended. Due to the thickness of the rubber material (3 mm), the flat needle head type 1B can be utilised. This needle head already provides good sealing without penetration of the needle tip into the inside of the package.



For small-sized packages which will deform under pressure also in the area of the sealing dia-phragm, you should use the grey diaphragm ( 1mm thin and very flexible).

However, when performing burst tests it is not necessary in many cases to seal the package with a diaphragm at the prick-in point. But if too much air comes out during measurement, a diaphragm (with glueing side to the needle) or an O-ring around the needle tip can already be helpful.

Glueing spots and seams are less suitable for prick-in. Pricking in should be in the middle of the package, if possible, in order to ensure that the package will blow up steadily. This is important, because the needle must lie evenly and tightly on the package. The test head will be lifted due to the volume enlargement, but this will be compensated by flexible guiding of the test head.

� Testing flat packages: Here, there is the danger that the needle sticks through the package. In this case it is safer to glue on a black diaphragm and to carefully prick the package with a sharp object (e.g. needle no. 1 B). After that the use of the needle head no. 2 B is recommended. The flattened and blunt tip of this needle remains sticking in the black dia-phragm without penetrating into the package. Furthermore you have to make sure that the package material was pierced through sufficiently in order to avoid too much pressure in front of the package. As soon as the package has blown up so much that there is no more danger of damage to the underside of the package, you should pass the needle fully into the package in order to ensure that the needle head surface lies evenly on the diaphragm.

� Testing filled packages: It is important to avoid clogging of the needle with the product during introduction. In any case the opening must remain free since otherwise pressure measurement may be affected. When testing packages with liquid or pulverised contents the filter must be mounted.

� Testing small-sized packages: We recommend the use of the auxiliary arm (see figure 3.2, page 16). Positioning may then be carried out easier and faster.

4.1.5. Measurement

It is important to watch the package carefully during measurement. If you hear air coming out, you have to seal, if necessary (see above).

Furthermore, valuable information can be gained during measurement, like for example:

• Does the sealing seam open slowly before the package bursts?

• The leaky point is signalised by bubbles when the package is tested submersed in a liquid

• Where does the package burst ? So where is the weak point ?



4.1.6. After the measurement

Caution: If the package did not burst, it is still under pressure! Remove the pack-age carefully, since pressure falls rather quickly through the prick-in point.

In case of package bursting, the burst pressure is displayed by the 2000 SL and you can take out the package.

4.2 Activation of burst test

The burst test is activated (if necessary, switch mode by ”TEST-MODE”), as soon as the LED ”BURST-TEST” lights up. After that, all you have to do is starting the measurement by ”START”.

4.3 Carrying out the measurement

You may start the measurement by pressing the ”START” key. After that, pressure is increased linearly with the selected pressure rise rate. Below the digital value, the current pressure is also displayed on the bar display. If the package did burst, burst pressure is displayed and a print-out is output (see chapter 4.5).

A test can be interrupted at any time by pressing the ”STOP” key. (If this key is pressed for two seconds, there will be no print-out.)

At the end of the test, the ”STOP” LED lights up.

4.4 Parameter settings

Apart from the test mode, the pressure rise rate must be set.

It may be set with the following graduation: 5, 10, 20, 30, 40, 50, 70, 80, 90 and 100 mbar/s.

4.5 Protocol

In case of package bursting, the data of this test will be output on the serial interface (e.g. to a printer). You can read details about formatting this output in chapter 6, page 26. The standard type of data output at the end of the test is shown on the following page:



PACKAGE TEST SYSTEM

LIPPKE 2000 SL

Date: 28.08.98

Time: 22:51

Mode: Burst test

Product:

Batch:

Tester:

Remark:

Pressure rise rate: 10 mbar/s

Burst pressure: 265 mbar

Figure 4.1: Print-out of a burst test

You can now enter product, batch, tester and a remark if necessary.

Package test system LIPPKE 2000 SL Pressure loss test


5 Pressure loss test

5.1 General instructions for pressure loss test

The general information about pressure loss tests is presented in brief outlines and sorted in the order valid for carrying out a measurement procedure. This will facilitate subsequent retrieving of special information during operation.

5.1.1 Safety instruction

Caution: Also in this test, it is possible that the package bursts. Please note also that pressure has not entirely dropped immediately after the test.

5.1.2 Standard settings

In most cases, each package type will require its own special measuring conditions. Despite of their diversity a possible parameter setting would be: test pressure 300 mbar, compensation time 20 seconds, test time 60 seconds.

5.1.3 Instructions for clamping device

The clamping device for packages open on one side can only be used in the burst test mode.

5.1.4 Instructions for holding stand

When performing pressure loss tests it is very important to totally seal the prick-in point. Thus the use of a diaphragm is absolutely necessary. Additionally, this diaphragm protects the packing ma-terial from tearing at the prick-in point. When testing flat packages, the black diaphragm is recommended. Due to the thickness of the rubber material (3 mm), the flat needle head type 1B can be utilised. This needle head already provides good sealing without penetration of the needle tip into the inside of the package.

For small-sized packages which will deform under pressure also in the area of the sealing dia-phragm, you should use the grey diaphragm (1 mm thin and very flexible).

A double needle cannot be used in this test for two reasons: firstly, only small quantities of air are required and secondly, a diaphragm cannot be used due to design and construction of a double needle.

Pricking in should be in the middle of the package, if possible, in order to ensure that the package will blow up steadily. This is important, because the needle must lie evenly and tightly on the package. The test head will be lifted due to the volume enlargement, but this will be compensated by flexible guiding of the test head.



� Testing flat packages: Here, there is the danger that the needle sticks through the package. In this case it is safer to glue on a black diaphragm and to carefully prick the package with a sharp object (e.g. needle no. 1 B). After that the use of the needle head no. 2 B is recommended. The flattened and blunt tip of this needle remains sticking in the black diaphragm without penetrating into the package. Furthermore you have to make sure that the package material was pierced through sufficiently in order to avoid too much pressure in front of the package. As soon as the package has blown up so much that there is no more danger of damage to the underside of the package, you should pass the needle fully into the package in order to ensure that the needle head surface lies evenly on the diaphragm.

� Testing filled packages: It is important to avoid clogging of the needle with the product during introduction. In any case the opening must remain free since otherwise pressure measurement may be affected. When testing packages with liquid or pulverised contents the filter must be mounted.

� Testing small-sized packages: We recommend the use of the auxiliary arm (see figure 3.2, page 16). Positioning may then be carried out easier and faster.

5.1.5 Measurement

It is important to watch the package carefully during measurement. If you hear air coming out, check if the sealing diaphragm does adheres properly to the package.

Furthermore, valuable information can be gained during measurement, like for example:

� Expansion effects of the package

� How does the package blow up ?

5.1.6 After the measurement

Caution: In general, the package is still under pressure! Remove the package carefully, since pressure falls rather quickly through the prick-in point.

At the end of the test, the measured pressure loss is displayed by the 2000 SL.

5.2 Activation of pressure loss test

This mode is activated (if necessary, switch mode by ”TEST MODE”), as soon as the ”PRESSURE LOSS TEST” LED lights up. After that, all you have to do is to start the measure-ment by means of ”START”.



5.3 Carrying out the measurement

You may start the measurement by the ”START” key. After that pressure is built up in the pack-age. The first 50% of the desired test pressure are built up relatively quick, whereas the second 50% are built up more slowly in order to exactly reach the nominal value.

After having reached the nominal value, compensation time will start, while pressure is kept con-stant. The START LED flashes during this stage of measurement. The test time starts only after this. In this stage, the START-LED lights up permanently. The pressure loss is displayed and the �P LED lights up. Below the digital value, the current pressure is also displayed on the bar dis-play.

A test can be interrupted at any time by pressing the ”STOP” key. (If this key is pressed for two seconds, there will be no print-out.)

At the end of the test, an acoustic signal can be output and the ”STOP” LED lights up. The pres-sure loss at the end of test time is displayed.

Basically, you should select a test pressure value with which bursting of the package during the pressure loss test is avoided.

For your guidance, we recommend the following test pressure:

Not more than 50% of the burst pressure of the package, but maximally 300 mbar.

You can of course carry out measurements with pressures > 300 mbar, but you should note that - depending on the used packing material - the packing material under the diaphragm may tear or that the diaphragm expands together with the packing material. Both can lead to leakage in the diaphragm area.

If the package bursts after the test pressure was reached (i.e. during compensation or test stage), you will find the following remark in the print-out: ”busted after xx seconds”. This fact gives in-formation on how long the package was able to resist the test pressure and allows conclusions to sealing seam stability.

If you abort the test by means of the ”STOP” key, there will be no print-out.

5.4 Parameter settings

There are three parameters apart from the test mode:

• Test pressure (setting range 10 to 3000 mbar)

• Test time (1 - 999 seconds, or 1 - 999 minutes)

• Compensation time (see chapter ”Configuration”)



5.5 Protocol

In any case, test data will be output on the serial interface (e.g. to a printer). You can read details about formatting this output in chapter 6, page 26. The standard type of data output at the end of the test is shown on the following page:



PACKAGE TEST SYSTEM

LIPPKE 2000 SL

Date: 29.08.98

Time: 20:41

Mode: Pressure loss test

Product:

Batch:

Tester:

Remark:

Test pressure: 500 mbar

Compensation time: 0 seconds

Test time: 300 seconds

Pressure loss: 5 mbar

Figure 5.1: Print out of a regular pressure loss test

You can now enter product, batch, tester and a remark, if necessary.

If the package bursts during compensation or test time, the print-out looks as follows:

PACKAGE TEST SYSTEM

LIPPKE 2000 SL

Date: 29.08.98

Time: 20:41


Product:

Batch:

Tester:

Remark:




Burst after: 4 s

Figure 5.2: Print-out of a pressure loss test with bursting of package

Package test system LIPPKE 2000 SL Configuration


6 Configuration

Important note : Wrong settings may lead to test system malfunctions. If in doubt, ask a service technician from Paul Lippke Handels-GmbH.

The configuration serves for matching the following items:

• Number of print-outs

• Auto-Stop-threshold

• Compensation time in pressure loss test

• Interface output

• Date and time

• Acoustic signal

• Pressure unit

In the standby state (”STOP” LED lights up), you may activate the configuration mode by simultaneously pressing the ”TIME” and ”STOP” keys. An acoustic signal will be output and the ”STOP” LED will be extinguished. This will directly take you to the first menu item (number of print-outs, see above).

The individual menu items are marked by a code (one or two digits) and are on the left side of the digital display. You can scroll through the configuration range by means of the ”+” or ”-” key of the ”PRESSURE” field on the left side of the operating panel. The two digits on the right of the display show the current setting of each configuration item. These settings can be changed by means of ”+” or ”-” on the right side (”TIME” field). All changes will be stored immediately and automatically.

By again pressing the ”TIME” and ”STOP” keys you will quit the configuration mode and the LIPPKE 2000SL control unit will return to the standby mode. An acoustic signal will be output and the ”STOP” LED lights up again.

6.1 Number of print-outs

After activating the configuration the display will change as follows:

“Copy 1”



Here, you can specify the number of printed-out measuring report copies in the range from 1 to 99. The setting is not valid if output takes place on the PC (see chapter 6.4, page 27).

6.2 Auto-Stop-threshold

Setting of the Auto-Stop-threshold in the range from 0 to 99. If the current pressure drops within 1/10 by this percentage or more, LIPPKE 2000 SL judges this as ”bursting of package” and fin-ishes the test. The display will change as follows:

“Auto-StoP 20”

6.3 Compensation time

The compensation time is only valid for the pressure loss test, during which pressure is held at a constant level before test time has expired. For the values 0 to 999, the same unit of time like for the measuring time is valid:

“Ausgleichszeit 0” (compensation time 0)

6.4 Interface output

After that, the following display will appear:

Test report in German language (s. figures 6.1 and 6.2), ”OUtput

deutsch” (German)

Test report in English language (corresponding to figures 6.1 and

6.2), ”OUtput English”



Test report in French language (corresponding to figures 6.1 and

6.2), ”OUtput French”

Test report in Spanish Language (corresponding to figures 6.1 and

6.2), ”OUtput Spanish”

Test report in Italian Language (corresponding to figures 6.1 and

6.2), ”OUtput Italian”

PACKAGE TEST SYSTEM

LIPPKE 2000 SL

Date: 28.08.98

Time: 22:51

Mode: Burst test

Product:

Batch:

Tester:

Remark:

Pressure rise rate: 10 mbar/s

Burst pressure: 295 mbar

Figure 6.1: Test report, burst test



PACKAGE TEST SYSTEM

LIPPKE 2000 SL

Date: 29.08.98

Time: 20:41


Product:

Batch:

Tester:

Remark:




Pressure loss: 5 mbar

Figure 6.2: Test report, pressure loss test

Data are output at the end of the test (”OUtput PC”) in the follow-ing format: First, date and time are transmitted, followed by the mode (“B”urst or “L”oss). Then test pressure or pressure loss rate, compensation and test time (only in case of pressure loss test) and result will follow. Output (see figures 6.3, 6.4) takes place without units; pressure is indicated in mbar and time generally in seconds.

01.08.98 (Date)

16:55 (Time)

B (Mode B = Burst test)

mbar (Pressure unit)

5 (Pressure rise rate)

21 (Burst pressure)

m (only in case of manual abort)

Figure 6.3: Data output at the

end of burst test



01.08.98 (Date)

16:55 (Time)

L (Mode L = Loss Mode)

mbar (Pressure unit)

100 (Test pressure)

20 (Compensation time)

30 (Test time)

5 (Pressure loss1)

8 (burst after x seconds2)

Figure 6.4: Data output

at the end of pressure loss test

1 Empty line if package bursts within compensation time. 2 Line is displayed only if package bursts within test time.



”OUtput Continuous”. Upon the start of the test, the test parameter data ”Date and time”, mode (“B”urst or “L”oss), pressure rise rate (burst test) or test pressure, test time and compensation time (pressure loss test) will be output. This is followed by the output of the current pressure five times a second. Additionally, the test sequences will be documented:

• "Start": Desired pressure is built up

• "Readjustment Time”: Compensation time starts (only in pressure loss test)

• "Start Test": Test time starts running.

• "Burst Pressure": Burst pressure

• "Pressure Loss” Pressure loss within test time

• "Stop Test": Test time elapsed

• "Break off” Abort of test

Figures 6.5 and 6.6 show the corresponding print-outs:

01.08.98 (Date)

16:55 (Time)

B (Mode)

00005 (Pressure rise rate)

Start Test

00001 (Measured pressure)

00001

00002

00002

00002

00003

00003

...

...

Stop Test

Burst pressure:

000295 (Burst pressure)

Manual Stop (In case of manual abort of test)

Figure 6.5: Data output, burst test



01.08.98 (Date)

16:55 (Time)

L (Mode)

00100 (Test pressure)

00015 (Compensation time)

00030 (Test time)

Start

00000 (Measured pressure)

00001

00001

00002

00002

00002 ...

Readjustment time

00100

00100

00101

00100 ...

Start Test

00100

00100

00099

00099

00098 ...

Stop Test

Pressure Loss:

00012 (Pressure loss)

If the package bursts during compensation time, data transmission is stopped with:

...

Burst after

00012

If the package bursts during test time, data transmission is stopped with:

Pressure Loss

00009

Burst after

00012

Figure 6.6: Data output, pressure loss test



6.5 Printer configuration

When using a printer, the following settings are relevant:

Number of line feeds at the end of a print-out ("LineFeed 6") within a setting range of 1 to 99; in this way, you can e.g. match the print-out to label size

Form feed at the end of print-out ("FormFeed 0") yes (=1) or no (=0); guarantees e.g. that a new print-out is always started in the upper left corner.

Cutting signal ("Cut 0") for label printing:

• 0 = No cutting signal

• 1 = Cutting signal after each copy

• 2 = One cutting signal after all copies

• If you do not the standard printer (STAR TSP 442), you may also match the cutting signal under this menu item. For this purpose, proceed as follows:

• Press the “START” key for 6 seconds.

• 5 ASCII characters can be entered successively (left half of the display ”1H” to ”5H”)

The ASCII code will be then displayed on the right side in hexadecimal format (see the following example for the STAR TSP 442):

ASCII Code (hexadecimal)

ASCII Code (decimal)

ASCII character

Remark for STAR TSP 442

1b 27 <ESC> Cutting signal

64 100 d consists of 3 digits

00 0 <NUL>

Table 6.1: Cutting signal



• By pressing the ”STOP” key, you can store all changes and quit this item.

• By pressing the ”TIME” key, the standard settings for the STAR TSP 442 will be reactivated (see ...).

6.6 Date and time

Using the ”+” and ”-” key on the left side (”PRESSURE” field) you may also get to this setting. The following options are available:

Year (0 - 99)

Month (1 - 12)

Day (1 - 31)

Hour (0 - 23)

Minute (0 - 59)

As soon as one of these 5 values is changed, the display flashes. Now the configuration mode can only be left by quitting the configuration range ”Date and Time”. This is done by pressing the ”Pressure” ”+” or ”-” keys.



6.7 Acoustic signal

Setting the acoustic signal which will be output at the end of the test:

"ALarm 1"

• 0 = No signal

• 1 to 60 = Signal ON, duration in seconds

• 99 = The signal will be output until you press the "STOP" key.

6.8 Pressure unit

Here you can select the pressure unit for measurements:

Display in ”mbar” (“mbar” LED lights up) “Pressure Unit mbar”

Display in ”PSI” (“mbar” LED doesn’t light up) “Pressure Unit

PSI”

In case of pressure unit change, the LIPPKE 2000 SL control unit is set to the following default values:

Pressure unit mbar: Test pressure (LOSS) = 100 mbar

Pressure rise rate (BURST) = 5 mbar/s

Pressure unit PSI: Test pressure (LOSS) = 1,50 PSI

Pressure rise rate (BURST) = 0,1 PSI/s

Package test system LIPPKE 2000 SL Maintenance


7 Maintenance The LIPPKE 2000 SL control unit is maintenance-free. This particularly applies to pneumatic system and electronic control system.

After switching off the system, you can clean its outside surface using a moist cloth, if it becomes necessary.

Please always make sure that the holding stand is clean. For this purpose, screw off the needle head from time to time and check whether the needle is completely clean. The same applies to both openings on the test head (air supply and pressure sensor opening). Solid residues can be removed carefully by means of a needle. Liquids should be best blown out. Flushing with water and alcohol is also possible. After that, all hoses should be blown through thoroughly (apply com-pressed air to all hose connections) to make sure that no liquids remain in the holding stand.

Corresponding measures may be taken for the optional filter between test head and needle head. The filter foam material should be replaced at regular intervals or if it is soiled.

For cleaning the hoses, it is recommended to just blow them through.

The O-rings on the needle head guarantee tightness and functioning of the system and must therefore be replaced periodically. Applying some silicone grease on the O-rings may prolong their service life and durability and may increase system tightness.

It is recommended to have the system checked by a LIPPKE technician in the framework of a service contract (in most cases sufficient for ISO 9000 and following) every year. During such an inspection all functions (especially control valve and system tightness) as well as the pressure sensor’s calibration (including works certificate) will be checked. A calibration by the DKD (Deutscher Kalibrierdienst, German Calibration Service) is also possible.

Package test system LIPPKE 2000 SL Error causes


8 Error causes The following list of possible error causes and their remedies is not necessarily complete. Should your system reveal any errors which are not mentioned at all or just incidentally, please do not hesitate to contact us. We will be glad to help you in any way.

8.1 System errors

Symptom Cause Solution

No display after switching on control unit

- loose mains cable - defective fuse

- Check the connection. - Replace the 1 A fuse.

- Call LIPPKE.

System switched on, but test cannot be performed

- Overpressure on sensor - Evacuate air from inserted pack-age

Table 8.1: System errors

8.2 Interface errors

For reasons of clearness, the following error causes are explained for a printer, but they also apply to the PC. Please observe that all errors are output just once, i. e. the output cannot be repeated.

Symptom Cause Solution

No printer output - loose interface cable - printer not switched on

- Printer is OFF line

- Check the connections - Switch on printer

- Switch printer ON line

Output not in desired lan-guage

- wrong configuration - Change configuration according to chapter ”Configuration”, page 26

“Strange” characters, (e.g. ”ü” not displayed

- wrong character set - Check settings of printer (see manual)

Table 8.2: Interface errors

Package test system LIPPKE 2000 SL Error causes


8.3 Problems during measurements

If the system doesn’t build up pressure during measurement, this may have various causes which can easily be removed:

� prick-in point leaking

� pressure rise too high

� very porous package

� no compressed air supply

Either the compressed air supply of the system is interrupted or the supply pressure is not high enough, if the package internal pressure is adjusting on a constant level during a running measurement.

After bursting of a package, the system should terminate the measurement automatically. How-ever, if a very high value was selected for the Auto-Stop-threshold, it is possible that there is no automatic termination. Then you have to reduce the threshold value.

The following is a symptom for a clogged needle: the package is not blown up although a pressure rise is displayed. In this case abort the measurement by pressing the ”STOP” key and clean the needle (see chapter 7, page 36).

If you have noticed that pressure loss is far too high for one package, this may have the following causes:

� Diaphragm leaky

� Poor adherence of diaphragm, because of e.g. dirty package surface

� Porous O-Ring

� Your package is not as good as you think ...

Package test system LIPPKE 2000 SL Appendix


9 Appendix

9.1 Operating principles

The following diagram shows the operating principle of the LIPPKE 2000 SL package test system:

Figure 9.1: Pneumatic system



If pressure shall be built up in a package, both valves open, i.e. passing of air through both of them is possible. The ”SENSE” line is connected to the pressure sensor in the control unit so that the control circuit is closed by this. After reaching 95% of test pressure, air supply is metered by the two-way valve to control the test pressure. In the pressure loss test, the two-way valve closes after having reached the nominal pressure so that pressure loss can be calculated by the EPS module.

9.2 Specifications and certificate

• Current consumption: 1 A

• Type of protection: IP40

• Ambient temperature: + 5 .. + 40 0C

• Air humidity: 0 ... 90% relative humidity, without condensation

• Power voltage: 230 V ± 10 %

• Power frequency: 50 Hz ± 1 Hz

• Languages: German, English, French, Spain, Italian; other languages upon request

• Units: mbar, PSI

• Measuring range: 0 ... 3000 mbar, relative overpressure

• Accuracy: ± 1 % of final value (standard for burst test)

• Hysteresis: ± 0,5 % of final value (standard for pressure loss test)

• Internal resolution: ± 0,25 mbar

You will find a sample work certificate on the following page. From this certificate you can espe-cially learn which reference manometer is used in general.



Figure 9.2: Sample of works certificate



9.3 Dimensions and weights

The following table lists dimensions and weights of the system including accessory:

Width / mm Height/ mm Depth / mm Weight / kg

Control unit 350 180 350 6,5

Holding stand 330 250 400 3,6

Table 9.1: Dimensions and weights

9.4 Spare parts list (extract)

The following spare parts are available for the LIPPKE 2000 SL:

Part number Unit Name of item

SK 765 1 Control board LIPPKE 2000 SL

SK 770 1 Power supply board LIPPKE 2000 SL

SK 775 1 Control valve

SK 780 1 Three-way solenoid valve

SK 785 1 Two-way solenoid valve

SK 405 1 Mains cable

SK 662 2 O-Rings, 18 x 2 mm

SK 720 1 Housing cover

SK 721 1 Housing bottom

SK 665 1 Needle 1B

SK 666 1 Needle 2B

SK 667 1 Needle 3B

SK 680 1000 Diaphragms, black, 21 x 3 x 3 mm

SK 685 1000 Diaphragms, grey, 21 x 3 x 1 mm

SK 701 1 Pressure sensor

SK 640 1 Filter set

SK 650 25 Filter, foam material, 15 x 8 x 20 mm

SK 056 1 Hose for compressed air, blue, 3 mm

SK 057 1 Hose for compressed air, blue, 4 mm

TO 945 1 Paper for thermoprinter SEIKO DPU 414

TO 948 1 Endless label paper for STAR TSP 400

TO 946 1 Normal paper reel for STAR SP 200, Ø 83 mm

TO 948 1 Endless label paper for STAR TSP 400

Table 9.2: Spare parts list

Gas-Detection

www. lauper- in s t rument s . ch

Lauper Instruments AGIrisweg 16B CH-3280 Murten Tel. +41 26 672 30 50 [email protected] www.lauper-instruments.ch

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