TME Solution Manual

TME
Solution TM
Leak Tester
or
Leak and Flow Tester
Operator’s Manual
TMElectronics, Inc.
45 Main Street, Boylston, MA 01505
508-869-6400
www.tmelectronics.com
TABLE OF CONTENTS PAGE
CHAPTER 1 IMPORTANT INSTRUMENT SAFETY INFORMATION 4

Important Instrument Safety Information 4
Safety Label Design 4
Instrument Safety Labels 5
Important Literature Alerts 9
Recommended Safety Practices 9
CHAPTER 2 INTRODUCTION 11
Introduction to the TME SOLUTION™ 12
Features of the TME SOLUTION 14
TME SOLUTION Instrument Control Locations 16
TME SOLUTION Instrument Connections 17
TME SOLUTION Instrument Controls 19
TME SOLUTION Installation and Power Up Instructions 20
TME SOLUTION Explanation of Main Screen Display 22
TME SOLUTION Explanation of Main Screen Function Keys 25
CHAPTER 3 SOLUTION QUICK START GUIDE 26

Explanation of the Quick Start Guide 27
TME SOLUTION Quick Start 28
Select Test Type 29
Set Test Parameters 30
Run a Pressure Decay Leak Test 33
CHAPTER 4 DETAILED EXPLANATION OF THE SOLUTION

SCREENS 34
Explanation of the TME SOLUTION Main Screen 35
TME SOLUTION Screen Menu Addresses 45
Main Screen 45
Main Menu Screen 47
Programs List Screen 52
Set Parameters Screen 55
Setting Test Parameters 57
Set Options Screen 58
Print/Send Screen 61
Statistics & Datalog Screen 65
Calibration Screen 67
Calibration Check 68
Warning Screen 70
1
PS-346 Rev. D TME SOLUTION™ Operator’s Manual
© 2009 T.M. Electronics, Inc.
TABLE OF CONTENTS (continued) PAGE
CHAPTER 5 LEAK TEST MODE 71
Introduction to Leak Testing 72
Delta P Curve Memorization 74
Typical Decay Curves 75
Establishing Test Specifications 76
Setting the TME SOLUTION Test Parameters 77
TME SOLUTION Normal Leak Test Cycle 79
Programming a Normal Leak Test (Vacuum or Pressure) 81
Running a Leak Test 86
Using the Set Options Mode 90
CHAPTER 6 LEAK TEST WITH FLOW RATE READOUT 98

Introduction to Leak Testing with Flow Rate Readout 99
Pressure Decay Test Mode 100
Setting Leak Test with Flow Rateout Test Parameters 101
Leak Test with Flow Rate Readout Calibration 102
Running a Leak Test with Flow Rate Readout 105
CHAPTER 7 TME SOLUTION-C CHAMBER TEST MODE 106

Introduction to Chamber Leak Testing 107
Setting Chamber Leak Test Mode Parameters 109
Finding the Correct Overpressure 111
Running a Chamber Leak Test 112
CHAPTER 8 CLAMP DRIVE OPTION AND BLEED CYCLE 113

Using the Clamp Driver Option 114
Using the Bleed Cycle 115
CHAPTER 9 FLOW TEST MODE-Leak and Flow Model Only 116

Flow Testing in the TME SOLUTION Leak and Flow Tester 117
Establishing Flow Test Parameters 118
Programming a Normal Flow Test 119
Running a Flow Test 124
APPENDIX A: Concurrent Testing 127

APPENDIX B: Statistics Reference 128
APPENDIX C: TME SOLUTION PLC Interface 129
APPENDIX D: Use of Flow Standard or Calibrated Orifice 132
APPENDIX E: TAL Software 134
APPENDIX F: Filter Drying System 137
APPENDIX G: Specifications 140
ADDENDUM: Custom Design Instruments 141
2
TABLE OF CONTENTS (continued) PAGE
Instrument Maintenance 142
Fuse Replacement 142
Instrument Service 143
Warranty 144
3
IMPORTANT INSTRUMENT SAFETY INFORMATION
This section of the SOLUTION Operator’s Manual has been written to provide the
operator with important safety information related to the installation, setup and operation
of the instrument. It is important:
• to read this manual before installing, setting up or using this instrument to avoid
personal injury and/or instrument damage,
• to follow the safety information included in this section to avoid personal injury
and/or instrument damage,
• to keep this manual for future use, and
• to review and become familiar with all instrument safety labels and their
meanings.
SAFETY LABEL DESIGN
Safety labels are designed and placed on the instrument to alert the user to both
potential personal injury and property damage hazards. The ANSI/ISO harmonized
safety labels consist of a Hazard Severity section, a Symbol panel, and a Word
Message panel.
Hazard Severity Section

The hazard severity section of the label consists of the ISO “General Warning Symbol”,
a specific safety color, and the appropriate signal word to convey the seriousness of the
hazard.
ISO General Warning Symbol
A black triangle with a black exclamation point on a yellow

background is the ISO “General Warning Symbol”. It is used to alert
the user to a potential personal injury hazard. The general warning
symbol can be used alone or in combination with a signal word to call
attention to hazard information. Obey all safety messages that follow
this symbol to avoid possible injury or death.
Signal Word
The Signal Word that follows the General Warning Symbol, combined with a
specific colored background, is used to convey the seriousness of the hazard.
DANGER is used to indicate an imminently hazardous situation, which, if

not avoided will result in death or serious injury. The severity panel
background is red for the Danger signal word.
4
WARNING indicates a potentially hazardous situation, which, if not
avoided could result in death or serious injury. The severity panel
background is orange for the Warning signal word.
CAUTION indicates a potentially hazardous situation, which, if not avoided

may result in minor or moderate injury. CAUTION used without the
General Warning Symbol indicates a potentially hazardous situation,
which, if not avoided may result in property damage. The severity panel
background is yellow for the Caution signal word.
Safety Symbol Panel
The symbol panel contains an ISO symbol chosen to convey the specific alerting
message and supplement the word message.
Word Message Panel
The word message panel is designed to communicate the type of hazard, the
consequence of interaction with the hazard and how to avoid the hazard.
INSTRUMENT SAFETY LABELS
The following Safety Labels have been placed on the instrument to alert the user to
potential safety hazards.
Hazardous Voltage Warning
5
The hazard severity portion of this label warns the user of a potentially hazardous
situation, which, if not avoided, could result in death or serious injury. The hazard is
Hazardous Voltage. This voltage is inside the instrument
The safety symbol conveys “shock” as the potential consequence of not avoiding the
hazard.
The word message communicates to the operator that there is hazardous voltage that
poses the potential for shock and communicates to the operator that there are NO user
serviceable parts inside the instrument. The message directs the operator to contact
the Manufacturer for Service/Repair as the means of avoiding the potential hazard.
Compressed Air Warning
situation, which, if not avoided, could result in death or serious injury. The hazard is a
compressed air input pressure above the instrument rated 150 PSIG Maximum.
The safety symbol conveys the explosion/release of pressure as the potential

consequence of not avoiding the use of compressed air above 150 PSIG.
The word message on the label alerts the operator that the compressed air hazard is
avoided by using a compressed air source that is rated for 150 PSIG Maximum. If
maximum pressure is exceeded the release of pressure could result in death or serious
injury to the user. Exceeding maximum input pressure will cause property damage to
the instrument.
6
Compressed Air Warning-300 PSIG
compressed air input pressure above the instrument rated 300 PSIG Maximum.

consequence of not avoiding the use of compressed air above 300 PSIG.
avoided by using a compressed air source that is rated for 300 PSIG Maximum. If
the instrument.
Custom Compressed Air Warning
Instruments designed to have a compressed air input pressure other than 150 or 300
PSIG Maximum will carry a Compressed Air Warning with the Maximum Compressed
Air input pressure handwritten on the label.
compressed air input pressure above the instrument rated Maximum PSIG indicated on
the label.

consequence of not avoiding the use of compressed air above the indicated PSIG.
7
avoided by using a compressed air source that is rated for indicated PSIG Maximum. If
the instrument.
Fuse Safety Alert-Non-CE Configured Instruments
This ISO formatted label consists of the ISO “General Warning Symbol”, the fuse
symbol and the required voltage and amperage rating of the instrument’s fuse.
This label is used to CAUTION service personnel that fuse replacement with an
incorrectly rated fuse could result in minor or moderate injury or property damage to the
instrument.
Fuse Safety Alert-CE Configured Instruments
situation, which, if not avoided, could result in death or serious injury. The hazard is
Hazardous Voltage. This voltage is inside the instrument
The safety symbol conveys “shock” as the potential consequence of not avoiding the
hazard.
The word message panel is designed to provide service personnel with the replacement
fuse characteristics including fuse type, size, voltage and amperage. The Dual Fuse
symbol, below the safety symbol, indicates to service personnel that the instrument
requires two fuses.
8
IMPORTANT LITERATURE ALERTS
The signal words “WARNING!” and “CAUTION!” are integrated into sections of this
manual to alert the reader/operator to important literature that is included regarding
potentially hazardous situations which, if not avoided, may result in personal injury or
property damage. These words appear in bold font and are embedded in the general
text of the manual. Therefore, the information that follows these signal words should be
read carefully to avoid personal injury and/or instrument damage.
RECOMMENDED SAFETY PRACTICES
Use of the SOLUTION in a manner not specified in this manual may impair the
protection provided by the SOLUTION to other equipment.
DO NOT OPEN OR REMOVE THE INSTRUMENT COVER. There is hazardous

voltage inside the instrument. Opening or removing the cover will expose the operator
to a potential shock hazard and WILL VOID THE WARRANTY.
Do not attempt to change the FACTORY SET Power Supply. Refer all servicing to
authorized T.M. Electronics, Inc. Service Centers.
THERE ARE NO USER SERVICEABLE PARTS INSIDE THE INSTRUMENT. Refer all
servicing to authorized TM Electronics, Inc. Service Centers.
Replace a blown fuse ONLY with a fuse that meets the fuse specifications in this
manual. Replacement of a fuse with a non-specified fuse WILL VOID THE
WARRANTY.
The air or gas used for the instrument must be clean, dry, instrument quality air free of
moisture, oil and dust. To ensure instrument quality air refer to Appendix F “Filter
Drying System” or contact T.M. Electronics, Inc. for information on ordering a “Filter
Drying System”. The instrument Warranty does not cover instrument damage due to
water, water vapor, oil vapor or oil damage to the instrument. It is the customer’s
responsibility to maintain dry, clean instrument quality air.
The air or gas used for the instrument must be at a recommended pressure between 90
and 150 PSIG MAX. A minimum of 60 PSIG must be supplied for proper instrument
operation. For instrument models with a maximum test pressure higher than 50 PSIG,
the inlet pressure must exceed the maximum test pressure by at least 10PSIG.
Do not exceed the Maximum Input Pressure of the instrument’s Compressed Air
Warning label as release of pressure may expose the operator to serious injury and
cause instrument damage.
9
Do not use the instrument near water. Do not spill any liquids into the instrument. Use
caution when testing fluid filled products. Contamination of the instrument with fluids
voids the Warranty
Do not place this instrument on a sloping or unstable cart, stand or table as the
instrument may fall, causing serious damage to it.
Do not place any heavy objects on the power cord. Damage to the cord may cause
shock or fire.
Handle with care when transporting the instrument. Save packaging for transporting or
return for recalibration or servicing.
Immediately unplug the instrument from the wall outlet and refer servicing to an
authorized service center under the following conditions:
• If the power supply cord or plug is damaged,
• If liquid has been spilled into the instrument,
• If the inside of the instrument has been exposed to liquid during testing, or
• If the instrument has been dropped or damaged.
10
CHAPTER 2 INTRODUCTION PAGE
Introduction to the TME SOLUTION 12

Features of the TME SOLUTION 14
TME SOLUTION Instrument Control Locations 16
TME SOLUTION Instrument Connections 17
TME SOLUTION Instrument Controls 19
TME SOLUTION Installation and Power Up Instructions 20
TME SOLUTION Explanation of Main Screen Display 22
TME SOLUTION Explanation of Main Screen Function Keys 25
11
INTRODUCTION TO THE TME SOLUTION
Thank you for purchasing a TME SOLUTION. Please take the time to find and read the
pertinent information contained in this manual for your specific instrument. This will help
to ensure that you get the best possible service life from your instrument.
This manual covers the following TME SOLUTION Models: SOLUTION Leak Tester,
SOLUTION Leak and Flow Tester and the SOLUTION-C Chamber Tester. Any
reference in this manual to Flow testing is not applicable to an instrument purchased as
a Leak Tester or a Chamber Tester. The TME SOLUTION is also available as a single
or multi-port instrument. Multi-port instruments are either sequential or concurrent
instruments. Any reference in this manual to concurrent testing is not applicable to a
sequential SOLUTION.
The TME SOLUTION-C Chamber Tester is a SOLUTION Leak Tester that has the
added capability of leak testing sealed devices in a chamber. The TME SOLUTION-C
Chamber Tester has no Flow Testing capability.
This manual does not cover Custom Models of the TME SOLUTION. Please
reference the Addendum shipped with your instrument for specific information related to
your Custom SOLUTION.
A multi-port SOLUTION will be either a sequential or a concurrent instrument. A

sequential instrument runs the same test on each selected port one after the other,
sequentially, beginning with Port #1. A concurrent instrument runs the same test on
more than one port at the same time or concurrently. For further information on
Concurrent Testing see Appendix A.
The TME SOLUTION Leak and Flow Tester was designed to test devices that pass
liquid or gas at a required flow rate through an intended path. Examples of such
devices include filters, tubing, valves and catheters. These types of devices generally
require a two-part test. The device is first flow tested to verify that flow through the
device is acceptable. Then a leak test is performed to verify that there is no leakage
outside of the intended flow path.
The TME SOLUTION Leak and Flow Tester performs both tests in a single cycle
automatically. The tests can be done in either order: flow followed by leak or leak
followed by flow. Flow tests require the flow path to be open at one end. Leak tests
require a closed path. The TME SOLUTION™ is designed with an optional clamping
device driver, which can activate an external fixture that seals the open end(s) of the
device. Once the clamping is achieved, the leak test can be done.
For applications where occlusions or flow restrictions are the primary concern
and leaks are rare, the TME SOLUTION Leak and Flow Tester can be set-up to perform
only flow tests. If leakage is the main concern and flow is of no consequence, the TME
SOLUTION can be set-up for leak testing.
12
At the completion of a test cycle, the TME SOLUTION indicates whether the
device met the preset test limits. The highlighted "PASS" on the Main Screen Display
and the green “ACCEPT” light on the front panel indicate that the device met the leak
and/or flow specifications. The highlighted "FAIL" on the Main Screen display and the
red “REJECT” light on the front panel indicate that the device did not meet the test
specifications for the indicated test.
In a multi port instrument, the test cycle may include multiple ports. In this case the
status of each port is displayed individually.
13
FEATURES OF THE TME SOLUTION
The TME SOLUTION contains several features and functions that the user should
become familiar with. These features and functions are summarized below.
The pressure transducer provides state-of-the-art sensitivity and temperature

stability. Integrated with the system electronics the TME SOLUTION achieves
resolution as low as 0.0001 PSIG (0.0069 mBar)
The flow transducer is highly responsive to flow changes. The TME SOLUTION
is typically equipped with a flow transducer with a sensitivity of 1 cc/min. For greater
sensitivity, optional transducer models are available.
Self-diagnostics are part of the TME SOLUTION start up program. This feature
assures the operator that the instrument meets its own specifications when powered up.
The 3"x 5" touch screen display consists of white figures on a colored
background. The display size and contrast features provide a wide-angle view in a work
station environment. The user is able to move from one screen to another by touching
the appropriate address on the display screen. The alphanumeric and graphic features
of the display provide ease in viewing menu options as well as visual display of test
results and graphical presentation of data.
The user is able to input up to one hundred (100) programs for individual test
procedures. This feature allows for fast and silent changeover of test programs.
The Key Lockout function assures operation security. Once the key lock is
activated neither test functions nor data can be altered.
The push of one button activates the test cycle once the test parameters have
been programmed. Data from each test is stored automatically and the highlighted test
result tells the operator if the tested part is a "PASS" or "FAIL".
The TME SOLUTION is capable of logging and retaining test results in its Data
Log Memory. This allows for documentation of test results by workstation or shift as
well as trend analysis of the process.
The TME SOLUTION’s statistical capabilities provide the user with immediate
information on process performance. Process control statistics are calculated and
presented in statistical data format on the Main Screen. Process histograms, X-Bar and
Range charts are also available for graphic display. This allows for statistical analysis
for process validation or process control purposes.
14
The TME SOLUTION has multiple output modes. Test results are presented visually on
the touch screen display. Printer capability is available through the instrument’s printer
port. The connection must be made to a compatible printer. The RS232C
communication port allows for computer connection and data transmission in data,
stream or text format.
Some configurations of the TME SOLUTION contain a Bleed Valve Safety

feature. This internal valve allows for air bleeding of a pressurized part prior to
detaching the part from the test port. This safety feature prevents short bursts of air
from escaping as parts are removed from the test port.
15
TME SOLUTION INSTRUMENT CONTROL LOCATIONS
Display Screen
“Accept” Signal Light
“Reject” Signal Light
Solution Start Button
Stop Button
Key Unlock Position

TMElectronics,
Inc.
Test Ports 1 - 4
1 2 3 4
FRONT OF INSTRUMENT BACK OF INSTRUMENT
Fuse
Power Switch
Power Cord Connector
Printer Connection
RS232 Connection
Accessory Connection
Pneumatic Regulator
Air Supply Connection
16
TME SOLUTION INSTRUMENT CONNECTIONS
Refer to "INSTRUMENT CONNECTION LOCATIONS" for location of the

connections mentioned below.
AIR SUPPLY Compressed air inlet to the instrument.

CONNECTION: Connection Type: Instrument air supply fitting is a
(Pneumatic) Female Bulkhead fitting which will accept any male
1/8" NPT fitting or a standard 1/8" NPT
male to 1/4" tube fitting.
WARNING! The air used for the TME SOLUTION must be clean, dry, instrument
quality and at a recommended pressure between 90 and 150 PSIG MAX. A minimum
of 60 PSIG must be supplied for proper operation. For models with a maximum test
pressure higher than 50 PSIG, the inlet pressure must exceed the maximum test
pressure by at least 10 PSIG.
To ensure instrument quality air refer to Appendix F “Filter Drying System”.
TEST PORT CONNECTION: Test air outlet. To be connected to Test Part.

(Pneumatic) Connection Type: Instrument port fitting is a Female
Bulkhead 1/8" NPT that will accept the customer’s
required fitting. See below for information on common
fittings attached directly to the bulkhead connection.
CAUTION! Use caution when testing fluid filled products. Contamination of the
instrument with fluids VOIDS the Warranty.
PRINTER CONNECTION: Printer output connection:

(Electrical) Interface: Centronics
Connection Type: DB-25 Female
Printer cord:
DB25 Male/Centronics 36 (CN36), 25C Mold
17
TME SOLUTION INSTRUMENT CONNECTIONS (continued)
RS232 CONNECTION: Serial port input/output connection:

(Electrical) Interface: RS232-C
Connection Type: DB-9 Female
RS232 Cord:
DB9 M/M Serial
POWER: WARNING! POWER IS FACTORY SET-DO NOT ATTEMPT TO CHANGE
US: 115 Volts, 50-60 Hz @ 1.5 Amps
EUROPEAN: 230 Volts, 50-60 Hz @ 1.25 Amps

POWER CORD: US: 100-125 Volts AC/Grounded Plug
UL E 204241-C, CSA LL2126-C FT2
EUROPEAN: UL/CSA #10W1-11206
UK: UL/CSA to UK with 10 Amp Fuse

#10W1-12206
FUSE (S): For use with US: 2.5 A @ 250 volts, 300 Watts Max
Astrodyne AD-120 Power Type: 5x20 mm Fast-Acting
Supply Quantity Required-1
EUROPEAN: 2.0 A @ 250 Volts, 300 Watts Max

Type: 5x20mm Fast-Acting
Quantity Required-2
CAUTION! Fuse replacement must be with the fuse(s) specified above. Use of
incorrect fuse(s) may result in damage to the instrument and VOIDS THE
WARRANTY!
BULKHEAD CONNECTIONS: ¼” (6 mm) Tube Fitting connects to Bulkhead

Common fittings that attach Male Luer Slip or Luer Lock Connector
directly to the Female Female Luer Lock Connector
Bulkhead 1/8” NPT connection 1/8” Flow Quick Disconnect with O-Ring
CUSTOM FITTINGS: Fittings Face Seal

used on instruments with no Custom Male Luer Slip Fitting
Female Bulkhead 1/8” NPT.
18
TME SOLUTION INSTRUMENT CONTROLS
Refer to "INSTRUMENT CONTROL LOCATIONS" for location of the controls

mentioned below.
POWER SWITCH: Turns instrument On and Off
PNEUMATIC REGULATOR: Controls the pressure or vacuum used in

the test.
START BUTTON: Starts the test sequence.
STOP BUTTON: Stops any test or procedure currently in

progress.
KEYLOCK: Locks the keypad to prevent program and

/or program parameter changes. The
OPEN Lock symbol on the control panel
indicates the key is in the unlocked
position. When the key is in the locked
position, a CLOSED Lock symbol is
displayed in the Status Bar of the <Main
Screen>.
ACCEPT LIGHT: Indicates when the result of a particular

test is a "PASS" or "ACCEPT".
REJECT LIGHT: Indicates when the result of a particular

test is a "FAIL" or "REJECT".
19
TME SOLUTION INSTALLATION AND POWER UP INSTRUCTIONS
UNPACKING:
After taking the system out of its carton, make sure that the following parts are present:
TME SOLUTION Instrument,
Operator’s Manual,
Air hoses, and
Keys.
Contact the factory for missing or damaged parts.
Save all packing material for transport or return to TM Authorized Service Center for
Service or Recalibration.
INSTALLATION:
INSTRUMENT ENVIRONMENT
The TME SOLUTION should be installed in an environment with moderate temperature:
5-40ºC (40-100°F), and humidity (RH<80%, noncondensing). Keep away from strong
electromagnetic interference or machinery that generates large line voltage spikes.
Position the instrument so that the Mains Power Entry Module is easily accessible to
allow the unit to be switched off and the Mains Power Cord to be easily disconnected
from the instrument and/or the power outlet.
CONNECTIONS:
Connect the power cord of the instrument to a properly grounded outlet:
• US Units: Three pronged, properly grounded, 120 Volt (nominal) AC
outlet, or
• European Units: Three pronged, properly grounded 220-240 volt AC.
Connect the air hose from the “AIR SUPPLY” port to a compressed air outlet of
maximum input pressure 150 PSIG. WARNING! DO NOT EXCEED 150 PSIG
MAXIMUM input pressure. Exceeding maximum input pressure could result in a
release of pressure, which could result in death or serious injury and/or instrument
damage.
CAUTION! Instrument air must be free of moisture, oil and dust and at a standard
pressure between 90 and 150 PSIG. Other pressures may be required based on
customer’s special requests.
20
POWER UP:
Turn on the TME SOLUTION by using the power switch in the back of the instrument.
Upon start up the instrument runs three initialization phases and an automatic self-
diagnostic test and displays the Main Screen.
MAIN SCREEN DISPLAY
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
Test Data
21
TME SOLUTION EXPLANATION OF MAIN SCREEN DISPLAY
The Main Screen of the TME SOLUTION is divided into three rows:
1. the top row - the Header,
2. the center row - the Main Screen, and
3. the bottom row - the Footer.
Main Screen Top Row-HEADER ROW

The Main Screen Header Row is divided into three sections:
1. Header Column 1-the Program Bar
2. Header Column 2-the Status Bar, and
3. Header Column 3-the Pneumatic Regulator Control Bar
Header Column 1 Header Column 2 Header Column 2-

Program Bar Status Bar Pneumatic Regulator
Control Bar
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ ▼
Header Column 1-PROGRAM BAR

The left column, Header Column 1, known as the Program Bar, indicates the Program
number and the type of test the program parameters are set to run. In addition, this
section indicates programs that are linked to each other and the type of test each is
programmed to run. For example “Prog: 1►3”, Leak + Flow indicates that Program 1 is
linked to Program 3 and that Program 1 is a Leak Test and Program 3 is a Flow Test.
Header Column 2-STATUS BAR

The middle column, Header Column 2, known as the Status Bar, indicates the status of
the instrument, before, during and after tests are run. As shown above the instrument is
“READY”.
Header Column 3-PNEUMATIC REGULATOR CONTROL BAR

The right column, Header Column 3, known as the Pneumatic Regulator Control Bar,
displays the pressure or vacuum setting of the pneumatic regulator and the units of
measure of the pneumatic regulator.
22
Main Screen Center Row-MAIN SCREEN
The center row of the screen is referred to as the Main Screen. This portion of the
screen is blank prior to running a test. Touching this section of the screen allows the
operator to go to the <Main Menu> Screen.
23
When a test is being run, the Main Screen displays the pressure or vacuum during the
various periods of the cycle. The test result is displayed on the Main Screen after the
test.
Main Screen Bottom Row-FOOTER SCREEN

The bottom row of the Main Screen is referred to as the Footer. The Footer indicates
the type of data displayed. Test specific data as well as statistical analysis data are
displayed in this section of the screen. Test specific data includes the program name,
lot number of parts being tested, and operator identification. Additional data footer
screens include cycle and test counter information. The statistical data presented in the
footer include parameters specific to the statistics selected by the operator. Where
graphic presentations of the data are available the graphs are displayed in the center of
the Main Screen.
For more information on the Main Screen see Chapter 2-entitled “Detailed Explanation
of the TME SOLUTION Screens”.
24
TME SOLUTION EXPLANATION OF MAIN SCREEN FUNCTION KEYS
The Main Screen has four Function Keys indicated by the symbol v. For identification
purposes these keys are referred to as Function Keys 1, 2, 3 and 4 and their location is
shown below:
Function Key 1
Function Key 2
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ ▼
▲
Result ▲
▼ ▼
Test Data
Function Key 3 Function Key 4
Function Key Select Address

Function Key 1 Moves display to Programs List Screen
Function Key 2 Moves display to Test Parameter Screen
for the Program indicated in the Program
Bar.
Function Key 3 While remaining in the Main Screen, the
operator may scroll through the most
recent test result or summarized Test or
Statistical data.
Function Key 4 This function key provides graphical
representation of the most recent test
result or the summarized Test and
Statistical data on the Main Screen.
25
CHAPTER 3 SOLUTION QUICK START GUIDE PAGE
Explanation of the Quick Start Guide 27

TME SOLUTION Quick Start 28
Select Test Type 29
Set Test Parameters 30
Run A Pressure Decay Leak Test 33
26
EXPLANATION OF THE QUICK START GUIDE
The Quick Start Guide is designed to provide instructions on how to set the test
parameters for a pressure decay leak test on a single port SOLUTION. It is a shortened
description of the test set up procedure detailed in Chapter 4. This guide is designed to
teach the operator how select the desired Test Mode and enter:
• the Test Parameters,

• the Test Pressure;
• the Pressure Decay Reject Limit (Pressure Tolerance), and
• the Operator’s Name.
Once the required criteria are entered the guide describes running a pressure decay
leak test and gives a description of the displayed test results.
27
TME SOLUTION QUICK START
Upon completion of the instrument installation and power up the MAIN SCREEN is
displayed as shown below.
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼
▲ Result ▲
▼ ▼
Test Data
Touch the center of the MAIN SCREEN and the <Main Menu> Screen is displayed as
shown below.
<Main Menu>
Pick a Program Printer Reports Alarm
OFF
Set Parameters Statistics and Calib.
Datalog Mode
Set Options MemRef
Store
Lot number: MemRef
*Clear
Operator: Clear test Data
Exit
Touch the “Set Parameters” address and the screen will move to a <LEAK TEST>
Screen.
<LEAK TEST>
CHARGE: 0.0 Progm#
Timer Sec. X
SETTLE: 0.0 Test
Timer Sec. LEAK
TEST : 0.0 Ports
Timer Sec. X
DECAY : 0.00000 Names&
Maximum Psig Option
PRESSR: 0.00 PRESSR 5.00
Specif. Psig ± Toler. % Exit
28
SELECT TEST TYPE
Touch the “Test” address on the test parameter screen.
<LEAK TEST>
CHARGE: 0.0 Progm#
Timer Sec. X
SETTLE: 0.0 Test
Timer Sec. LEAK
TEST : 0.0 Ports
Timer Sec. X
Maximum Psig Option
The test type will be displayed in the “Test” address. Depending on the SOLUTION
model the “Test” address will display some or all of the following test types:
• “LEAK”,
• “FLOW”,
• “LEAK & FLOW”, or
• “FLOW AND LEAK”.
•
NOTE: The test type displayed in the “Test” address is also displayed in the Screen
Address.
<LEAK TEST>
CHARGE: 0.0 Progm#
Timer Sec. X
SETTLE: 0.0 Test
Timer Sec. LEAK
TEST : 0.0 Ports
Timer Sec. X
Maximum Psig Option
Select the LEAK Test mode.
29
SET TEST PARAMETERS
The following test times will be set for the leak test:
Charge Time: 2 seconds,
Settle Time: 2 seconds,
Test Time: 2 seconds,
Decay Maximum Pressure: 0.002 Psig,
Pressure Specified: 10.0 Psig,
Pressure Tolerance: 1.0 Psig.
Touch the “Charge Timer” address on the <Leak Test> Screen and a numeric keypad
will be overlaid on the screen.
<LEAK TEST>
CHARGE: 0.0 2.0 Units

Timer Sec. Sec. Chang
SETTLE: 0.0 1 2 3 Res
Timer Sec.
TEST : 0.0 4 5 6 ±
Timer Sec.
DECAY : 0.00000 7 8 9 Clr
Maximum Psig
PRESSR: 0.00 PRESSR
Specif. Psig ± Toler 0 Enter
Touch the “2”, “.”, and “0” on the keypad and “2.0” will be displayed on the top left box of
the keypad and in the “Charge Timer” address. DO NOT TOUCH ENTER UNTIL ALL
TEST PARAMETERS HAVE BEEN ENTERED.
Touch the “Settle Timer” address. (Note: The selected “Charge Timer” is displayed in
the “Charge Timer” address only after the ‘Settle Timer” address is touched. This
happens for each test parameter selected.) Press “2”, “.” and “0” to enter the Settle
time.
Touch the “Test Timer” address and enter “2.0” for the Test time.
Touch the “Decay Maximum” address and enter “0.002” for the Maximum Decay
Pressure. If necessary, touch the “Units Change” address on the keypad to select
“Psig” for the Maximum Decay Pressure.
Touch “Pressr Specif:” address to set the specified test pressure of 10.0 Psig. If
necessary, select “Psig” for the units.
30
Touch the “Pressr ±Tolerance” address and the keypad will shift to the other side of the
screen. Select “5.0” for the pressure tolerance. This is 5.0% of the 10.0 Psig selected
as the Specified Pressure.
All Test Parameters have been entered. Touch “Enter”.
Upon touching the “Enter” address the <Main Menu> Screen will be displayed.
<Main Menu>
OFF
Datalog Mode
Set Options MemRef
Store
Lot number: MemRef
*Clear
Exit
Touch the “Set Options” address and the <OPTIONS> Screen will be displayed.
< Set Options Screen >

Program name: CLAMP 0.0
Timer Sec.
Lot number: BLEED 0.0
Timer Sec.
Operator: PAUSE 0.0
Timer Sec.
FILL 0.0
Timer Sec.
Memory Mode
OFF Exit
Touch the “Operator” address and an alpha-numeric keypad will be displayed.
31
Touch the “T”, “M” and “E” keys and <TME> will appear in place of <Operator> at the
top of the screen.
<TME>
Clr <-
, @ # % & / | < >

1 2 3 4 5 6 7 8 9 0
A B C D E F G H I J
K L M N O P Q R S T
U V W X Y Z Spc ▲ Exit
Touch the “Exit” address and the display returns to the <Set Options> Screen and
“TME” is displayed in the “Operator" address.

Timer Sec.
Timer Sec.
Operator: PAUSE 0.0
TME Timer Sec.
FILL 0.0
Timer Sec.
Memory Mode
OFF Exit
Touch the “Exit” address on the <Set Options> Screen and the <Main Menu> Screen is
displayed. Touch the “Exit” address on this screen to return to the MAIN SCREEN.
Use the regulator adjustment handle on the back of the instrument to adjust the Test
Pressure to read 10.00 Psig. The pressure is displayed in the upper hand box of the
MAIN SCREEN. The display will change as the pressure is adjusted.
Prog:26 READY 10.00

LEAK TEST Psig
▲ ▲
32
RUN A PRESSURE DECAY LEAK TEST
Attach a test part to the test port on the front panel of the instrument. To start the test,
press the Green “START” Button. As the test proceeds, the portion of the test
sequence being run-“CHARGE”, “SETTLE”, “TEST”-appears in place of the word
“READY” on the screen,
Prog:26 CHARGE 10.00

LEAK TEST Psig
▲ ▲
When the test is completed the test result will appear in the center of the screen. The
amount of pressure decay that occurred at the end of the specified test time is displayed
numerically in the center of the screen. “PASS” or “FAIL” is displayed below the word
“Decay” on the screen. “PASS” indicates that the pressure decay was less than the
pressure tolerance entered previously (5.0% of 10.00 Psig or 0.5000 Psig). “FAIL”
indicates that the pressure decay was above the entered tolerance. The test result is
logged into the instrument’s Datalog.
For more detailed information on the Leak Test Mode of the SOLUTION refer to
Chapter 4 “LEAK TEST MODE” in this manual.
33
CHAPTER 4 DETAILED EXPLANATION OF THE TME SOLUTION
SCREENS PAGE
Explanation of the TME SOLUTION Main Screen 35

TME SOLUTION Screen Menu Addresses 45
Main Screen 45
Main Menu Screen 47
Programs List Screen 52
Set Parameters Screen 55
Setting Test Parameters 57
Set Options Screen 58
Print Send Screen 61
Statistics & Datalog Screen 65
Calibration Screen 67
Calibration Check 68
Warning Screen 70
34
EXPLANATION OF THE TME SOLUTION MAIN SCREEN
This section describes the sections of the TME SOLUTION’s Main Screen, identifies the
Main Screen function keys, and describes in specific detail the appearance of the
instrument Status Bar and Main Screen before, during and after a test as well as the
specifics on the various screens provided by the Main Screen Footer.
The main screen appears as shown below after the instrument is installed and powered
up.
MAIN SCREEN
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
Test Data
The Main Screen is divided into three sections:

1. Top row - the Header,
2. Center row - the Main Screen, and
3. Bottom row - the Footer.
Main Screen Header

The Main Screen Header is divided into three columns:
1. Header Column 1 is the Program Bar,
2. Header Column 2 is the Status Bar, and
3. Header Column 3 is the Pneumatic Regulator Control Bar.
Program Bar Status Bar Pneumatic Regulator

Control Bar
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ ▼
35
Header Column 1-PROGRAM BAR
The left column, Header Column 1, known as the Program Bar, indicates the Program
number and the type of test the program parameters are set to run. In addition, this
section indicates programs that are linked to each other and the type of test each is
programmed to run. For example “Prog: 1►3”, Leak + Flow indicates that Program 1 is
linked to Program 3 and that Program 1 is a Leak Test and Program 3 is a Flow Test.
Header Column 2-STATUS BAR

The middle column, Header Column 2, known as the Status Bar, indicates the status of
the instrument, before, during and after tests are run. As shown above the instrument is
in the “READY” mode. This bar also indicates the period of the test cycle being run, the
test number, the ACCEPT/REJECT status of the most recent test, indicates when the
Memory Mode is ON, if the instrument is in the LOCK mode and tracks the number of
cycles run. (See more detail below.)
Header Column 3-PNEUMATIC REGULATOR CONTROL BAR

The right column, Header Column 3, known as the Pneumatic Regulator Control Bar,
displays the pressure or vacuum setting of the pneumatic regulator and the units of
measure of the pneumatic regulator setting. This bar also displays the specified
pressure at the start of sampling during each period of the test.
Note: The pneumatic regulator setting is operator set using the pneumatic
regulator control knob in the back of the instrument.
Main Screen Center Row-MAIN SCREEN

The center row of the screen is referred to as the Main Screen. This portion of the
screen is blank prior to running a test. When a test is being run, the Main Screen
displays the pressure or vacuum during the various periods of the cycle. The test
result(s) is(are) displayed on the Main Screen after the test. In addition, the Main
Screen indicates the ACCEPT/REJECT status of the test part(s), the units of test, the
test number and the Memory Mode status of the instrument. The main screen is also
used to display the decay curve of a part, as well as present statistical data numerically
or graphically. The bottom right section of the Main Screen provides information on the
data being presented on the Main Screen-Result or Statistics and the type of data-Plot,
Histogram, X Bar or R Chart.
Main Screen Bottom Row-FOOTER SCREEN

the type of data displayed. Test specific data as well as statistical analysis data is
displayed in this section of the screen. Test specific data includes the program name,
lot number of parts being tested, and operator identification. Additional data footer
screens include cycle and test counter information. The statistical data presented in the
footer include parameters specific to the statistics selected by the operator. Where
graphic representations of the data are available the graphs are displayed in the center
of the Main Screen.
36
Main Screen Function Keys
The Main Screen also has four Function Keys indicated by the symbolv. For
identification purposes these keys are referred to as Function Keys 1, 2, 3 and 4 and
their location is shown below:
Function Key 1
Function Key 2
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
Test Data
Function Key 3 Function Key 4
Function Key Select Address

Function Key 1 Provides a short cut to the Programs List
Screen.
Function Key 2 Moves display to Test Parameter Screen
for the Program indicated in the Program
Bar.
Function Key 3 While remaining in the Main Screen, the
operator may scroll through the most
recent test result or summarized Test or
Statistical data.
Function Key 4 This function key provides graphical
representation of the most recent test
result or the summarized Test and
Statistical data on the Main Screen.
37
Instrument Status Bar
As indicated previously the instrument Status Bar provides specific information relating
to the instrument and the test status.
Status Bar-Power Up
Upon power up of the instrument after installation the Status Bar appears as shown
below:
READY
When the Start button is pressed the Status Bar indicates the time period of the test
cycle being run, the test number, the Memory Mode status, the instrument LOCK mode
and a moving bar indicates the % of the time period of the cycle completed. For
example, the representations pictured below show that Status Bar during the Charge,
Settle and Test Periods of Test 1 with the Memory Mode ON and approximately 50% of
each time period completed.
Status Bar-Instrument Status during Charge, Settle and Time Periods
CHARGE T1-Mem
SETTLE T1-Mem
TEST T1-Mem
Status Bar-Test Complete

When a test is complete the Status Bar appears as below:
READY
#X ACCEPT
“READY” indicates that the instrument is prepared to run the next test. The number and
test result indicate that “X” cycles have been run and that the last test was an
“ACCEPT”.
Note: The cycle number is related to the number of times the start button has
been pressed, not the number of tests. A cycle may consist of more than one
test.
38
Touching the Status Bar provides the operator direct access to the <Test Parameter>
Screen (for the test indicated in the Program Bar), allowing the operator direct access to
the program settings.
Main Screen Header Review

To review and summarize, the appearance of the Main Screen Header prior to the start
of a test, while running a test, and after the completion of a test are shown below:
Main Screen Header-Prior to Test
Prog: 1 READY X.XX

LEAK TEST Psig
▲ ▲
▼ ▼
Main Screen Header during Charge Period of a Test-Memory Mode “Off”-Keylock

“Off”
Prog: 1 CHARGE T1 X.XX

LEAK TEST Psig
▲ ▲
▼ ▼
Main Screen Header after Test Cycle
Prog: 1 READY X.XX

LEAK TEST #1 ACCEPT Psig
▲ ▲
▼ ▼
Main Screen Center

The center row of the screen is referred to as the Main Screen Center. This portion of
the screen is blank prior to running a test. Touching this section of the screen allows
the operator to go to the <Main Menu> Screen.
When a test is being run, the Main Screen displays the pressure during the various time
periods of the cycle. At the end of the test the result is displayed in the center section of
the Main Screen when the system is in the “Result” mode. This mode is indicated in the
bottom right hand corner of the center of the main screen by the word “Result”.
39
The Header and Main Screen Center are pictured below after completion of a test.
Header and Main Screen-After Test Completion-Result Mode-Test Result
Prog: 1 READY X.XXX

LEAK TEST #X ACCEPT Psig
▲ ▲
▼ ▼
Decay
PASS
0.0000 T1
Psig
▲ Result ▲
The test result may also be presented in a plot or decay curve format on the Main
Screen Center as shown below
Header and Main Screen-After Test Completion-Result Mode-Test Plot
Prog: 1 READY X.XXX

LEAK TEST #X ACCEPT Psig
▲ ▲
▼ T1 ▼
0.0000 ---------------------------------- Decay
0.0020 ---------------------------------- 0.0
Sec
0.0040 -----------------------------------
Psig Plot ▲
▲
40
If the screen is in the “Stats” Mode (“Stats” appears in place of “Result”) when the test is
complete and there is insufficient data to complete the statistical analysis, the screen
indicates there is “Insufficient Data”. The informational basis for the statistical data
display is presented in the upper right corner of the center section of the screen under
the word “-Data-“.
Header and Main Screen-After Test Completion-“Stats” Mode-Insufficient

Statistical Data Collected
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ -Data- ▼
Decay
Insufficient Data Pass
▲ Stats ▲
If the system is in the “Stats” Mode and there is sufficient statistical data in memory the
test result is dipayed as shown below.
Header and Main Screen- After Test Completion-“Stats” Mode-Sufficient

Statistical Data Collected
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ -Data- ▼
TEST RESULT
Stats ▲
▲
Each presentation of the Main Screen Center section in the various statistical modes is
displayed below:
STAT MODE SCREENS
The Main Screen center section may be used to view graphical presentations of test
statistics. The operator may choose from histogram, X Bar and R chart formats for data
presentation.
41
Main Screen Footer
the type of data displayed on the Main Screen. The data types include test data and
Statistical Data. In the Test Data Mode the footer displays test information and data.
The Footer displays in the Test Data Mode prior to and after running a test are depicted
below:
Test Data Footer-Prior to running test
▲
Result ▲
▼ Test Data ▼
Test Data Result Footer
▲
PASS ▲
▼ 1 ACCEPT T1 DECAY 0.000 InH20 PASS ▼
The up ( ) and down ( ) arrows on the left side of the footer allow the operator to scroll
through the test information. The following appear in the footer as the operator scrolls
through the test data section of the display
Test Data Name Footer

This footer displays the Program name, lot number and operator identification
information.
▲
Result ▲
▼ Name: ▼
Lot #: Oper:XXXX
Test Data Cycle Counter Footer

This footer displays the results for the number of cycles run. A cycle is one push of the
Start button.
▲
Result ▲
▼ CYCLES ACCEPT REJECT ▼
0 0 0
42
Test Data Test Counter Footer
This data summarized the test data in PASS/FAIL format.
▲
Result ▲
▼ TESTS PASS FAIL ▼
0 0 0
Statistical Data Footer
▲
Stats ▲
▼ X σ Max Min ▼
When the footer displays “Stat data” the up ( ) and down ( ) arrows on the bottom
right of the screen provide Main Screen viewing of the various representations of the
statistical representations of all program test data stored in the memory. See “STAT
MODE SCREENS” above.
Full Main Screen Representations

The following represent the entire Main Screen during the various periods of a cycle
when the screen is in the Result Mode.
Main Screen Prior to Running a Test
Prog: 1 READY xxx.x

LEAK TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
Test Data
43
Main Screen during the Charge period of Test 1 Program 1 Leak Test
Prog: 1 CHARGE T1 0.00

LEAK TEST Psig
▲ ▲
▼ ▼
Psig
Presr 0.00
▲
▲ Result
▼ ▼
Test Data
Main Screen at the Completion of Test 1 Program 1 Leak Test
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ ▼
Decay
PASS
0.0000 T1
Psig
▲
Result ▲
▼ ▼
Test Data
44
TME SOLUTION’s Screen Menu Addresses
The following section of this manual discusses the operator-interactive screens in the
TME SOLUTION. Accompanying each screen is a table that details each address on
that screen, the screen movement after touching the address and the resulting actions
that can be carried out by touching the each address on the new screen.
Main Screen
Prog: 1 READY
LEAK TEST
Psig ▲
▲
▼ ▼
<-------------
--MAIN SCREEN CENTER-- ------------->
▲ Result ▲
▼ ▼
Test Data
Main Screen Addresses

Menu Address Select Address Result Resulting Action
Program Bar/Function Moves Main Screen Allows operator selection
Key 1 directly to <Programs of Program from
List> Screen via shortcut. <Programs List> screen.
Touch “Exit” address
returns operator directly
to Main Screen.
Status Bar Moves operator directly Allows programming or
to the <Test Parameter> reprogramming of a test
Screen for the test parameter. Touch
program indicated in “Enter” address returns
Program Bar operator directly to Main
Screen.
Pneumatic Regulator See Status Bar See Status Bar
Control Bar/Function Key
2
Main Screen Center Moves operator to <Main Allows operator to select
Menu> Screen from the Menu
45
Function Key 3 - Test Allows operator to scroll Test data information is
Data displayed in Footer through Test data displayed in the footer of
information while in the Main Screen as operator
Main Screen. scrolls through footer
Provides access to screens.
Statistical Data when
“Stat data” is displayed in
the footer.
Function Key 3 - Stat. Provides operator access
data displayed in Footer to Statistical Data.
See Function Key 4
below.
Function Key 4 With “Stat. Data” Graphical
displayed in the Left representations of data
footer, the operator can are displayed in center of
scroll through the Main Screen. Operator
statistical representations may scroll and view Plot,
of the test data. Operator Histogram, X-bar chart
must touch Function Key and R Chart as well as
4 to scroll through Result of previous test.
statistical displays in the While in this mode the
Main screen. operator may also scroll
through test data
information by touching
Main Screen Function
Key 3
46
Main Menu Screen
To go to the <Main Menu> Screen touch the center of the Main Screen. The <Main
Menu> Screen below will appear on the screen.
<Main Menu>
OFF
Datalog Mode
Set Options MemRef
Store
Lot number: MemRef
*Clear
Exit

Pick a Program Selection will move to <Pick a Program> from
<Programs List> those on the screen, OR
PageUP ( ) or PageDN
( ) to scroll to a higher or
lower number program
OR Copy program
parameters from one
program to another OR
Link/Unlink programs
to/from each other.
Touch “Exit” address to
return to <Main Menu>
Screen.
47
Set Parameters Selection will move to the Select desired test by
<Test Parameter> touching “Test” address,
Screen for the Program set or change test
Selected on the Main parameters by touching
Menu. The <Test each desired parameter
Parameter> Screen title address, OR select the
indicates the type of test- number of ports by
Leak, Flow, Leak&Flow touching the “Ports”
or Flow&Leak. The address,
“Progm#” address OR move to the <Set
indicates the Program Options> Screen by
number selected in the touching the
Main Menu Screen “Names&Options”
address, OR return to the
<Main Menu> Screen by
touching the “Exit”
address.
Set Options Selection will move to the Allows for entering
<Set Options> Screen. program name, lot
number, operator
identification, OR setting
or changing CLAMP,
BLEED, PAUSE, FILL
timers, OR setting
Memory Mode-ON or
OFF by touching
“Memory Mode” address
Lot Number Selection will move to the Allows for entering of a
<Lot number> Screen lot number OR a change
to a lot number NOTE:
With Data present
change to a lot number
moves to a Warning
Screen-See “Clear Test
Data” below
48
Operator Selection will move to Allows for entering of
<Operator> Screen Operator identification.
NOTE: With Data
present a change to
operator identification
moves screen to a
Warning Screen-See
“Clear Test Data”
below.
Printer Reports Selection will move to the Allows output of the last
<Print/Send> Screen test result, Datalog,
Statistics, or Programs
including, if applicable,
User Data to a Printer or
RS232 Output by
touching the appropriate
addresses, OR allows
advancement to a “New
Page” of printed output,
OR allows selection of
“Autoprint” mode, OR
allows selection of
desired Printer Type, i.e.:
Text, HP, EPSON,
Continuous by touching
“Printer Type” address,
OR selection of RS232
Output format i.e.: Data,
Text, or Stream format by
touching “RS232 Output”
address
49
Statistics and Datalog Selection will move to the Operator selects source
<Statistics & Datalog> and type of data to be
Screen used for the selected
statistical analysis, OR
allows for datalog viewing
and output or clearing.
Clear Test Data Selection will move to the Notifies operator “This
WARNING! Screen Action Will Erase all
Test Data”, Operator
must decide to erase
data by touching “YES,
ERASE” address OR
decide to cancel request
by touching “NO,Cancel”
address.
Alarm Selection Turns Alarm In Alarm ON mode a loud
On or Off. Alarm Status is beep will signal a test
indicated in Alarm failure.
address by “ON” “OFF”
indication.
Calib. Mode Selection will move to the
<Calibration> Screen
50
MemRef Stores curve of next When operator returns to
Store device tested as the the Main Screen the
Reference Curve in footer alerts the operator
Memory to “Connect the
When Memory Reference Reference Device(s)
is activated the Block in Press START when
Main screen reads: ready…”
MemReg
*Store
“* Store” indicates that
the Memory Reference
function has been
activated.
NOTE: Memory
Reference is only
available for the first 32
test programs
MemRef Clears Reference Curve
Clear from Memory
When reference curve
has been cleared Main
screen reads:
MemRef
*Clear
“* Clear” indicates that
the instrument Memory
has been cleared of the
Reference curve
Exit Returns operator to Main
Screen
51
Programs List Screen
Touch “Pick a Program” address on the <Main Menu> Screen and the screen will move
to the <Programs list> screen and display 10 program options.
<Programs list>
Program # 1 Program # 6 PageUP
▲
Program # 2 Program # 7 PageDN
▼
Program # 3 Program # 8 Copy
Program # 4 Program # 9 Link

Unlink
Program # 5 Program # 10
Exit
<Pick a Program>

Program # Touch “Program #” Touch “Exit” address on
address to select <Main Menu> Screen to
program to run, and return to Main Screen.
display returns the <Main Program # and type of
Menu> Screen. test selected appear in
Program Bar, OR Touch
“Set Parameter” address
on <Main Menu> screen
and the selected program
number screen appears
with all test parameters
available for verifying or
setting.
52
PageUp (▲) or Scroll to the next or prior Allows operator to select
PageDN (▼) 10 programs in the a unique program
Program List number for programming
The total number of and/or use
available programs is
100.
Copy Copy to? appears in the Allows operator to copy
same location the Highlighted program
to another program #.
Use PageUP(▲) or
PageDN(▼) to scroll to
desired Program number
if it is not on the screen.
Touch desired “Program
Number” address to copy
highlighted program
parameters to the new
program. After touching
the new “Program
Number” address the
screen returns to the
<Main Menu> Screen.
53
Link Unlink appears in the Touch “Unlink” and the
Unlink Copy location and Link highlighted program is
to? appears in the unlinked from the
original location. program it is linked to.
Both positions are Touch “Link to?” and
highlighted and blink. touch the program the
highlighted program
should be linked to and
the two programs are
linked. The screen
returns to the <Main
Menu> screen. To verify
linking is complete return
to Main Screen and
confirm that Program Bar
indicates the first
program number followed
by an arrow and the
program number of the
linked program. For
example: Prog:1►3
indicates Program 1 is
linked to Program 3.
When unlinking verify
previously linked program
and arrow and linked
program number have
been deleted from the
Program Bar on the Main
Screen.
Exit Returns operator to
<Main Menu> Screen
54
Set Parameters Screen
Touch the Set Parameters address on the <Main Menu> Screen and the screen will
move to the <LEAK TEST> screen.
<LEAK TEST>
CHARGE: 0.0 Progm#
Timer Sec. X
SETTLE: 0.0 Test
Timer Sec. LEAK
TEST : 0.0 Ports
Timer Sec. X
Maximum Psig Option
Menu Address Select Address Resulting Action

Result
Title Block Indicates type of test Title Block should agree
with Test indicated in
“Test” Address on this
screen
Program # Indicates program Touching this screen
number highlighted and address returns operator
selected by operator from to <Programs list> where
Program List the program # is
highlighted
Test Indicates the type of test Touching this screen
selected. Operator location changes the type
selects Leak, Flow, Leak of test to be
and Flow, or Flow and programmed. The
Leak test. screen’s title block and
the test parameters
displayed change to
coincide with the test
selected by the operator.
55
Result
Ports Touching this address The number of ports can
block allows the operator be set at 1, 2, 3 and 4 (or
to select the desired any combination thereof)
number of ports that will depending on the number
be used to run the test. of ports in the instrument.
Names and Options This address is a short Allows operator to name
cut to the <Set Options> program, assign lot
Screen number and operator
identification. Allows
setting parameters for
external devices. See
<Set Options> Screen
below.
Exit Returns to <Main Menu>
screen
Test parameter Touch desired test Allows operator to select,
addresses for selected parameter address, change or clear timers,
test address is highlighted pressure and units for
and keypad for number each test parameter.
and unit selections is Allows operator to view
displayed. resolution of each
See “Setting Test parameter.
Parameters” section
below.
56
Setting Test Parameters
While in the <LEAK TEST> screen touch a test parameter address and a keypad
comes up on the screen and allows the operator to set or change timers or pressure
and the units of test.
<LEAK TEST>
Timer Sec.
TEST : 0.0 4 5 6 ±
Timer Sec.
DECAY : 0.00000 7 8 9 Clr
Maximum Psig
PRESSR: 0.00 PRESSR
<PROGRAM NAME>
To select Charge timer touch “Charge timer” address. Enter the desired time and units
and touch “SETTLE Timer” address. Touch the desired time and units. Touch the
“TEST Timer” address and proceed as above for each of the remaining parameters that
need to be set. Once all parameters are set return to the <Main Menu> Screen and
proceed to <Set Options>screen.
57
Set Options Screen
Touch the “Set Options” address on the <Main Menu> screen and the <SET
OPTIONS> screen will appear on the display:
<SET OPTIONS>
Timer Sec.
Timer Sec.
Operator: PAUSE 0.0
Timer Sec.
FILL 0.0
Timer Sec.
Memory Mode
OFF Exit
Each of these addresses allows the operator to enter specific information for the test
being programmed. The following details how to enter the desired information.
Entering Program Name, Lot Number and Operator Information

To enter Program name, Lot number, or Operator information touch the desired
address on the screen. An alphanumeric keypad comes up on the screen with the item
being entered. For example when creating the program name the following screen
appears:
<Program Name>
Clr <-
L
, @ # % & / | < >
1 2 3 4 5 6 7 8 9 0
A B C D E F G H I J
K L M N O P Q R S T
To create a program name touch the first letter of the name, the letter appears in the
center box in the top row. Up to fifteen (15) characters may be used for a program
name. Touch “Clr” to clear the entire entry. Touch “ <- “ to back space and delete one
symbol. Touch “Spc” to enter a space in the program name. Touch “▲ ” and this key
is highlighted indicating that it is locked “ON”. When “▲” is locked “ON” the symbols
above the numbers in the second row are entered when a number key is touched.
58
Lower case letters are entered with the “▲” key in the “ON” position when a letter is
touched. When the entire program name is entered, touch “Exit” and the screen
returns to the <Set Option> Screen and the Program name appears in that block on the
screen.
NOTE: When a Program is given a name that name will appear in the bottom of
the <Test Parameters> Screen.
The same sequence is followed to enter the Lot number and the Operator identification.
Memory Mode-ON/OFF Selection

The Memory Mode can be turned “ON” or “OFF” by touching the “Memory Mode”
address block.
Memory Mode ON-When the Memory Mode “ON” is activated the instrument will
memorize and store the test curve produced by the next item tested. This curve is
stored for reference and the curve from each subsequent test is compared to the
reference curve. The fact that the Memory Mode is “ON” is indicated on the Main
Screen as shown below.
Main Screen Indicating Memory Mode is “On” and Instrument is prepared to

memorize reference curve(s)
Prog: 1 READY
LEAK TEST Psig
▲ ▲
▼ ▼
▲
Result ▲
▼ Connect the Reference Device(s)
Press START when ready…
59
Prior to running any tests the operator must run a test on the memory device(s) in order
to record the reference curve. When a reference device test is being run the Main
screen indicates this as shown below:
Main Screen during Charge Period of Testing of Reference Device(s)
Prog: 1 Charge T1-Mem

LEAK TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
. . .Recording Memory Reference . . . .
Memory Mode OFF-The memory reference curve is cleared from instrument memory.
Clamp, Bleed, Pause and Fill times are set in the same way as the test parameters are
set. Touch the time to be set and the numeric keypad will appear on the screen. For
further detail see the “Set Test Parameters” section. See Clamp, Bleed sections of this
manual for more information.
When all required information has been entered in the <Set Options> screen touch the
“Exit” address and the screen returns to the Main Menu Screen. The Lot number and
Operator information appear in those addresses on the Main Menu screen.
60
Print/Send Screen
The TME SOLUTION can send data to a printer* or to a computer. The printer and the
RS232 connections are located on the back of the instrument. If the printer and /or the
RS232 is/are connected and ready the TME SOLUTION will send and print the selected
data with a touch of the screen. The <Print/Send> screen is pictured below:
*
<Print/Send>
Last test Autoprint: Test
ON Plot
Datalog User Data:
ON x &R
Charts
Statistics Print to: Histog
PRINTER
Programs Printer Type: All
TEXT Report
New Page RS232 Output
STREAM Exit
The table below details the result of touching each of the indicated Menu addresses on
the <Print/Send> Screen.

Result
Last test, Datalog, These addresses indicate Data is output to the
Statistics, Programs, the type of data that will printer or computer
Test Plot, x-Bar & R be output to the selection screen. If data is printed
Charts, Histogram, All displayed in the “Print to” the word <Printing>
Report address appears at the bottom of
the screen
New Page Moves page currently in
printer to be released and
printing will begin on a
new page.
Autoprint, User Data Allows for “ON”/”OFF”
selection of “Autoprint”
mode and “User Data”
Print to Allows selection of device Allows operator to select
data is output to and Printer or RS232 output.
printed from. Selection appears in the
“Print to” address
*
Printer-Parallel interface (Centronics), 80 column.
61
Result
Printer Type Allows selection of mode Allows operator to select
of printer output “HP”, ”EPSON”, “TEXT”,
or Continuous print out.
Selection appears in the
“Printer Type:” address
RS232 Output Allows selection of mode Allows operator to select
of RS232 output “TEXT”, “STREAM” or
“DATA” output format
Exit Returns to Main Screen
The operator connects the desired output device to the TME SOLUTION™ and enters
the required input in the “Autoprint”, “User Data” “Print to”, “Printer Type” and if
applicable the “RS232” addresses on the <Print/Send> screen. To send and print the
operator touches the desired selection address on the “Print/Send” screen.
Printer output will be as it appears on the TME SOLUTION’s display.
V2.3 RS232 Input/Output Functions
The SOLUTION™ RS232 Port is configured as tabulated below:
Item Setting Remarks

Baud 9600 Not adjustable
Bits 8N1 8 data, No parity, 1 stop
Handshake Null modem No flow control
The RS232 Input Commands and Output Formats are detailed below for Text, Stream
and Data Modes.
Input Commands
When a Single character command is received, it is interpreted immediately. All other

characters are buffered until a <CR> character is entered. The buffer is then converted
to a number to be used for program selection. The table below details the RS 232
commands.
Item Code Actions

Select Pgm# ‘NN+CR’ Selects the ‘NN’ Program Number
Redraws the Screen to Show New Number
Start ‘S’ Starts a Test
Reset ‘R’ Resets the Current Test
Program ‘P’ Sends the Current Program Settings
Datalog ‘D’ Sends the Contents of the Datalog
Statistics ‘X’ Send the Statistics
62
Output Format
To set the RS232 Mode touch the middle of the “READY” Screen. When the <Main
Menu> Screen is displayed touch the “Printer Reports” address to display the
<Print/Send> Screen. Touching the “RS232” address allows selection of TEXT,
STREAM or DATA mode output format.
Text Mode
Selection of this mode results in test data being sent in a printable format, including
tabs, spaces, etc. This mode formats and prints the data in the same format as the
“Last Test Report” format.
Stream Mode
The STREAM Mode Format sends test data in a comma-separated format. This mode
is used when easily separated output is required.
Field Bytes Description Example

Cycle# 5 Test cycle number “15” : Cycle #15
Cycle Result 6 Overall result for the cycle “ACCEPT” or “REJECT”
Test # 3 Test number “T2”: Second test in the
cycle
Stats Tag 1 Marks the statistical tests with an “*” Test included in
Datalog only asterisk (*). Used only with statistics
datalog “ “ Test excluded from
statistics
Test Mode 5 Type of test (Decay, Flow…etc.) “Decay”
Data 7 Measurement “0.0001”: Decay value
Units 5 Units of measure “Psig”
Test result 4 Result of the test “PASS” : Test #2 PASS
Time 6 Time 12:34a” : Time of test
End of line 1 New line marker <CR>
Repeated “n” When sending a multi-test cycle, When sending the

times Repeat for every test in the cycle. datalog,
Repeat for every test in
the datalog.
End of block 1 New block marker <LF>
63
Data Mode Format
The DATA Mode Format sends only measurement data and therefore should be
selected when the test result is the only significant information required.
Field Bytes Description Example

Data 7 Measurement “0.0001” :Decay value
End of line 1 New line marker <CR>
64
Statistics and Datalog Screen
<Statistics& Datalog>
Data Datalg
X-UCL Source View
Data Datalg
X-LCL Type Print
Data Datalg
R-UCL Port RS232
Datalg
R-LCL Clear
Calc: UCL, LCL Sample Size
Min: n [N]: x

Result
Data Source Allows operator to select Operator selects
the source of the data to Test Type - Decay,
be presented or Test #’s, etc.
analyzed.
Data Type Allows operator to select
all “PASS” results, all
“FAIL” results or both
Data Port Allows operator to select
the ports from which the
data source and type are
to be selected. ALL
ports, Port 1, &/or 2, &/or
3, &/or 4 etc.
Datalg View Displays the <Datalog> This screen displays
screen individual test information
and results for all tests in
the Datalog
Datalg Print Sends the Datalog view
to the printer for printing
Datalg RS232 Sends the Datalog view
to a computer screen for
viewing.
Datalg Clear Clears all data in the
Datalog
Sample Size Allows operator to select
subgroup sample size for
process control
applications.
65
Result
Calc: UCL ,LCL Allows for automatic
Min: calculation of the Upper
and Lower Control Limits
for the Process X Bar
and R Charts
X Bar upper control limit
X-UCL
X Bar lower control limit

X–LCL
R chart upper control limit
R-UCL
R chart lower control limit
R-LCL
66
Calibration Screen
To display the <Calibration> Screen move to the <Main Menu> Screen and touch the
“Calib Mode” address. This will move the display to the <Calibration Screen> as shown
below.
Calibration Screen
< Calibration >
LTA XX.XX 0% Set
<0-100> Psig 0.0 Psig ▲
25% Set
25.0 Psig ▼
50% Screen
50.0 Psig Contr.
Supply: ON 75% Time &
(Span) 75.0 Psig Date
Bleed: OFF 100%
(Zero) 100.0 Psig Exit
The table below details the result of touching each of the indicated Menu addresses:
Result
▲T XX.X Allows selection of TA selects internal
<0-100> Psig internal or port transducer for calibration
transducers for check, T1 the port 1
calibration check. transducer, T2 the port 2
Displays monitored transducer, etc.
pressure of transducer
being checked.
Indicates full range of
indicated transducer and
units of measure.
Supply: ON Allows opening and “ON” opens air supply
(Span) closing of air supply valve and allows
valve. pressure from regulator
to reach transducers,
“OFF” closes air supply
valve.
Bleed: OFF Allows selection of “ON” In “ON” mode opens
(Zero) or “OFF” bleed valve to allow
transducers to “see”
atmospheric pressure,
“OFF” closes the bleed
valve.
67
Result
Screen Contrast Allows operator to adjust Touch “Set ▲” and “Set
contrast on screen. ▼” addresses to set
desired screen
appearance.
Time & Date Allows operator to input Touch “Set ▲” and Set
date and time. ▼” addresses to set time,
AM or PM, and date
MM/DD/YY
Exit Returns display to Main
Screen
0%, 25%, 50%, 100% No operator access. For
operator reference only.
These addresses indicate
normal calibration points
as a % of the
transducer’s full scale.
Calibration Check
The following example demonstrates the procedure for checking the calibration of the
transducers in the TME SOLUTION.
Example:
The transducer for Port 1 will be checked for its calibration using a pressure gage with a
full scale of 10.000 Psig. The instrument range is 0 to 10.00 Psig.
Procedure Overview
1.) Select Port 1 Transducer to check
2.) Attach gage to Port 1
3.) Check Zero
4.) Turn Supply “ON”
5.) Adjust regulator to 10.00 Psig using pneumatic regulator control knob in the back
of the instrument.
6.) Check the instrument at 2.5, 5.0 and 7.5 Psig.
Step 1-Select transducer(s) to be check

Touch the “▲T” address to select the port number to be checked. ▲T1 indicates that
the Port 1 transducer is selected. The <0-10> under ▲T1 indicates the full range of this
transducer.
Step 2-Attach gage to Test Port 1

Connect the gage to Test Port 1
68
Step 3-Check Zero
Touch the “Bleed” address. With the Bleed valve “ON” verify that the instrument
displays a Psig of 0±½% of the test gage’s full scale in the “LT1” address.
< Calibration >

▲T1 0.0 0% Set
<0-10> Psig 0.0 Psig ▲
25% Set
25.0 Psig ▼
50% Screen
50.0 Psig Contr.
Supply: OFF 75% Time &
Bleed: ON 100%
Step 4-Turn Supply “ON”

Touch the “Supply” address and verify that the Supply is “ON”.
< Calibration >

▲T1 0.00 0% Set
<0-10> Psig 0.0 Psig ▲
25% Set
25.0 Psig ▼
50% Screen
50.0 Psig Contr.
Supply: ON 75% Time &
Bleed: OFF 100%
Step 5-Check Full Scale

Adjust the pneumatic pressure regulator until gage reads the full range of the transducer
being checked. Full scale of Transducer 1 is 10.00 Psig. Verify that transducer #1’s
pressure displayed in the “LT1” address is within the range 10.00±½% of the test
gage’s full scale.
Step 6-Check Set Points
Adjust the pneumatic pressure regulator to 25%, 50% and 75% of the transducer’s full
range-i.e.: 2.5, 5.0 and 7.5 respectively. Verify that the “▲T1” address displays a
pressure at each set point that is within ±½% of the gage’s full scale.
If any of the readings are outside of the tolerance range the instrument should be
returned to the factory for Calibration.
69
WARNING SCREEN
The <Warning Screen> on the display when an address is touched that could result in a
change in a parameter or data stored in memory.
WARNING!
ANY CHANGES WILL ERASE ALL TEST DATA
DO YOU WISH TO CONTINUE?
YES. NO.
ERASE CANCEL
Touch “NO” address returns operator to previous screen.
Touch “YES” address and all data in memory is cleared. Display shows “Data Erased”
and beeps as this is done.
70
CHAPTER 5 LEAK TEST MODE PAGE
Introduction to Leak Testing 72

Delta P Curve Memorization 74
Typical Decay Curves 75
Establishing Test Specifications 76
Setting the TME SOLUTION Parameters 77
TME SOLUTION Normal Leak Test Cycle 79
Programming a Normal Leak Test (Vacuum or Pressure) 81
Running a Leak Test 86
Using the Set Options Mode 90
71
INTRODUCTION TO LEAK TESTING
Leaks can be detected in several different ways. Test methods range all the way from
looking for a bubble (Bubble Testing) to testing for a few molecules of a tracer gas
(Mass Spectrometer testing). The Bubble Test method seems efficient at first but its
faults of high per unit cost due to handling, potential bacterial contamination of product,
and operator “judgment” calls soon become apparent. The Mass Spectrometer Test
method, on the other hand, carries a very high price tag as well as a high per unit cost.
This method is more useful in testing for permeability than actual leaks.
A third test method known as the Pressure Decay Test method provides sensitive
testing with simplified methods. A Pressure Decay Tester is must less costly than a
Mass Spectrometer and has a lower per unit cost when compared to both the Bubble
Test and the Mass Spectrometer Test. Pressure Decay testers monitor a gas
pressurized part, or parts, for a decrease (or decay) in pressure during the test period.
This decay is attributed to a leak in the part.
There are two types of pressure decay testers-the Differential Pressure Decay tester
and the Single Ended Pressure Decay tester. As the term Differential implies, the
Differential Pressure Decay test is looking for a difference in pressure decay between at
least two volumes. One of these volumes should be a reference-a known non-leaker. If
there is no known leak-free volume, it is difficult to determine if both units are leaking,
with one leaking more than the other, or if only one unit is leaking. The Single End
Tester is engineered to avoid the problems associated with reference part quality. Its
simple air handling system pressurizes one unit and watches for a decay in the test
pressure.
Both of these testers pressurize a gas and must deal with the physical effects of gas
pressurization. When a gas is pressurized its temperature increases. This is known as
“Adiabatic Heating”. As this heat dissipates, the gas temperature and pressure
decrease. Additionally, if the item being tested is flexible, its walls will expand during
and immediately after pressurization. This expansion will also cause a pressure
decrease.
The Differential Pressure Decay tester tests two or more units at the same time in order
to cancel out the non-leak decay. The Single Ended tester will either compensate for
the decay, (using mechanical, electrical or mathematical compensation), or incorporate
the decay into the test by utilizing long stabilization periods or curve memorization-“∆P”.
“∆P” is equivalent to “Delta P” and refers to changes in pressure. In this Manual “∆P”
refers to Pressure Decay.
The TME SOLUTION is a Single End Pressure Decay System. As the term “pressure
decay” implies, the tester is looking for a minute decrease (decay) in pressure in the
tested part. The TME SOLUTION’s air handling system pressurizes the test volume
72
and monitors this pressure over time. Any decrease in the monitored pressure is known
as “Pressure Decay” and is attributed to a leak.
Since the TME SOLUTION pressurizes a gas to perform the test, it must deal with
pressure decay due to “Adiabatic Heating” and test part flexibility. The TME SOLUTION
uses a “Settle” or equilibration period to accommodate the cooling and expansion of the
gas and the test part. After the “Settle” period is completed the test cycle begins and
the instrument then monitors pressure changes due to leakage from the test part.
73
DELTA P CURVE MEMORIZATION
The pressure decay due to adiabatic heat dissipation and expansion are factors that
can influence the sensitivity of any Pressure Decay Leak Tester. The Single Ended
testers have either compensated for the decay or excluded it from the test by using
long, pre-test stabilization periods. This gives the Differential testers an advantage in
sensitivity and speed. However, improved electronic technology has decreased this
advantage.
Testers using a computer to analyze and record the pressure decay due to adiabatic
heat dissipation and expansion have shown that pressure decay (Delta P) is the same
for comparable parts. When pressure decay is plotted versus time a Pressure Decay
Curve is created. The Pressure Decay Curve varies with the introduction of a leak into
the test part. The curve changes from a characteristic round shape (exponential decay
curve) to a straight line. See Typical Decay Curves below.
A microprocessor based leak tester, such as the TME SOLUTION is capable of

evaluating and storing in memory the pressure decay curve of a leak free reference
part. Once the reference part’s pressure decay curve is stored in the leak tester
memory, the decay curve of each subsequent unit tested can be compared to the
reference unit’s curve on a point by point basis at a rate of several thousands times a
second. This allows the test to begin almost immediately after the unit is fully
pressurized, eliminating the need for long stabilization times. Also, since the unit leak
rate is being compared against the memorized ∆P curve, there is no need for the
compensation mechanisms that are built into non-microprocessor based Single Ended
Leak Testers. There is also no need to run test parts at the same time as the reference
part as is required by Differential Pressure Decay Testers.
The TME SOLUTION being a microprocessor based Leak tester combines the simplicity
of a Single Ended leak tester with the sensitivity and speed of a Differential Tester.
MODES OF OPERATION
The SOLUTION can be used in two different modes of operation:

• Normal, or
• Memory Mode.
The Normal Mode is a straight pressure decay measurement used for parts that exhibit
low heat absorption and/or low elasticity. Normal Mode in the SOLUTION is run with
the Memory Mode OFF.
The Memory Mode or Delta P Reference Mode is used for improved speed in parts that
exhibit high heat absorption and/or high elasticity. The reference mode is run with the
Memory Mode ON.
74
TYPICAL DECAY CURVES
CHARGE SETTLE TEST
NONLEAKER
PRESSURE
Leak Limit
LEAKER
Load Unload
TIME
75
ESTABLISHING TEST SPECIFICATIONS
Prior to setting the SOLUTION controls the following information needs to be

established for the item to be tested.
Product Description
The following items will influence the design of the test program.
How will the item be used? Will it contain air or liquid? What pressures will the item be
subjected and for what period of time? What is the elasticity of the item? What are the
heat absorption properties of the item - material, temperature, volume?
Production Requirements
What test time will fit with the production process? What is the desired sampling rate or
frequency?
Define the Leak Test Specifications

In determining the test specifications consider the system’s internal volume, the test
temperature, the test time and the density of air versus liquid. Establish the minimum
leak rate to be detected by the test.
Establish Test Parameters

Identify the test time and test pressure that will detect leaks that correlate with the
results of previous test methods.
76
SETTING THE TME SOLUTION TEST PARAMETERS
SET CHARGE TIMER

This timer controls the amount of time that the SOLUTION will use to pressurize the part
to be tested. Allow sufficient time for the pressure inside the part to reach the required
test pressure. Use short charge times for small parts/volumes and long charge times
for larger parts/volume items.
SET SETTLE TIMER

This timer controls the amount of time that the SOLUTION will allow the part to stabilize
after pressurization. When setting this timer set sufficient time for the pressurized part
to stabilize (equilibrate) to account for adiabatic cooling and elastic expansion.
Metallic devices, devices with large surface areas or devices that are colder than normal
tend to absorb large amounts of heat from the pressurizing gas. The heat loss due to
dissipation of heat to the walls of the device will show up as pressure decay during test.
Soft, flexible or otherwise compliant devices will expand when pressurized increasing
the volume of the part. This volume increase will also show up as pressure decay
during test. Some devices are so flexible that restraining by means of a fixture may be
necessary to stop the expansion.
The settle time should be set long enough to allow the part to reach 90 to 100% of its
equilibrium state. The equilibrium state is reached when the part no longer expands
and the temperature of the device is the same as that of the test gas. There is no
universal settle time that can be used since the time required to reach equilibrium
depends on the volume of the part, its material of construction, its thickness, the test
pressure and the test temperature. Settle time can only be determined through actual
tests.
When the memory mode is used, shorter settle times can be set because the expansion
and cooling are already part of the reference curve (∆P), again actual tests are the only
way to determining the timer settings.
SET TEST TIMER

The test timer controls the amount of time that the SOLUTION will check the decay of
the test device. The Test Timer should be set for the time required to detect a leak. Set
a short test time when detecting large leaks and a long test time to detect small leaks.
To increase reliability the test timer should be set for the time required to see a
minimum difference of 3 to 4 decay steps between good and bad parts. Five or more
steps is most desirable. A “Decay Step” is the smallest amount of pressure decay that
the instrument can detect, i.e.: resolution of the instrument.
77
TEST PRESSURE
Test pressure is the pressure to be used during testing. It is also known as the
Specified Pressure. This pressure is set by manually turning the regulator knob at the
back of the instrument until the desired pressure is displayed on the Main Screen
Display in the Pneumatic Regulator Control Bar.
TEST PRESSURE TOLERANCE (+ % OF TEST PRESSURE)

The selected test pressure tolerance is the amount that the regulator can vary and not
stop a test.
If the pressure of the regulator varies outside of the tolerance range, the instrument will
not allow the test to begin.
DECAY LIMIT
The decay limit is the pressure decay threshold used to determine a REJECT or
FAILURE. Typically, the decay limit is set 3 to 5 decay steps above the maximum
decay of an acceptable part. For example, if the maximum decay of an acceptable part
is 1.0 InH2O at a resolution of 0.2 InH2O, the decay limit must be set at least at 1.6 or
2.0 InH2O in order to allow a clear distinction between an acceptable and rejectable
part.
NOTE: Settings of below 3 decay steps are not recommended unless the leaks
are large.
GROSS LEAK
This setting is used to detect parts with large leaks during the CHARGE and SETTLE
periods. The TME SOLUTION compares the pressure inside the part to the preset
standard test pressure. If the pressure drops by an amount equivalent to the Minus
tolerance on the pressure of the part then the part will be rejected
Small or rigid parts can work with a smaller + % tolerance of standard test pressure
setting. Large or flexible parts will need a larger + % tolerance of the standard test
pressure to allow for variations from part to part and pressure drops due to normal
expansion of the part.
NOTE: A gross leak on one test port of a multichannel instrument may cause a
Gross Leak failure to be indicated on all ports. A Maximum Leak Rate may need
to be determined during test set up and is dependent on test application.
78
TME SOLUTION NORMAL LEAK TEST CYCLE
The TME SOLUTION Leak Test consists of three periods: CHARGE, SETTLE and
TEST. The leak test begins when the START button is pressed. The part is
pressurized to the specified pressure. This part of the cycle is called the CHARGE
portion of the cycle or pressurization period.
If at the end of the CHARGE the pressure inside the part is less than the % tolerance
setting, the device being tested is considered a “REJECT” and the result is a Gross leak
failure and the cycle stops. If the pressure inside the part is within the selected
pressure tolerance range the instrument will move to the “SETTLE” portion of the cycle.
The “SETTLE” portion of the cycle allows the part to expand and cool before it goes into
the “TEST” portion of the cycle. If the pressure detected is below the standard pressure
tolerance during the “SETTLE” time the part is rejected as a “GROSS” leaker. The
standard pressure range (+ % Tolerance) should be set high enough so that good parts
are not rejected due to their normal expansion and cooling. A “Gross” leaker decays far
more than a good part, therefore, it can be detected before the actual “TEST” portion of
the cycle begins. If the pressure is within the set tolerance range during the “SETTLE”
time the TME SOLUTION™ will initiate the “TEST” portion of the cycle.
During the “TEST” portion of the cycle the pressure decay of the part is monitored and
compared to the preset Decay Limit. If the Decay exceeds the preset limit then the
device is “REJECTED” and the result is displayed on the screen as “LEAK - FAIL” and
the Red “Reject” light is lit up. If the decay is less than the decay limit the part is
“ACCEPTED” and the display reads “LEAK - PASS” and the green “ACCEPT” light is lit
up.
79
TME SOLUTION NORMAL LEAK TEST CYCLE
START TEST END TEST
PASS
CHARGE SETTLE TEST or
TIME TIME TIME FAIL
CHARGE SETTLE TEST
NONLEAKER
PRESSURE
Leak Limit
LEAKER
TIME
80
PROGRAMMING A NORMAL LEAK TEST (VACUUM OR PRESSURE)
The following example demonstrates the procedure for programming the TME
SOLUTION to run a Normal Pressure Decay Leak Test.
NOTE: The TME SOLUTION configuration must be a pressure instrument to

program a pressure decay leak test. If the instrument’s configuration is a vacuum
instrument, then a vacuum decay leak test must be programmed.
Program #25 will be programmed for testing a part at 10.0 psi ± 10% for 4 seconds with
a charge time of 2 seconds allowing 3 seconds for settle, and having a Decay pressure
limit of 0.5 inches of water.
Procedure overview
1.) Select Program #25
2.) Set Leak Test Program Parameters:
Charge time: 10.0 seconds
Settle time: 3 seconds
Test time: 4 seconds
Decay pressure: 0.5 Psig
Pressure: 10 psi
Pressure tolerance: ±10%
3.) Adjust Pressure Regulator to Programmed Pressure
4.) Run the test.
Step 1-Select Program #25-

Touch the center of the Main Screen to display the Main Menu Screen. Touch “Pick a
Program” address to display the Program list screen. Touch the PageUP(▲) address
or PageDN (▼) to move to the Program list that contains Program 25. Touch “Program
# 25” address to bring up the Main Menu display.
Step 2-Set Leak Test Program Parameters

Touch the “Set Parameters” address on the Main Menu display to get the Program 25
Leak Test Display: < LEAK TEST>
CHARGE: 0.0 Progm#

Timer Sec. 25
SETTLE: 0.0 Test
Timer Sec. LEAK
TEST : 0.0 Ports
Timer Sec. X
Maximum Psig Option
81
Note: The test to be programmed is a “Leak Test” as indicated by the screen’s title
block and the word “LEAK” displayed in the test address box. If the Screen’s title block
does not indicate Leak Test, touch the “Test” address until “LEAK” is displayed in the
title block and the “Test” address.
Step 2.1-Program Charge Timer

Touch the “Charge Timer” address to bring up the keypad on the display:
<LEAK TEST>

Timer Sec.
TEST : 0.0 4 5 6 ±
Timer Sec.
DECAY : 0.00000 7 8 9 Clr
Maximum Psig
PRESSR: 0.00 PRESSR
Touch the keypads “1”, “0”, “”, and “0”. As the keypads are touched the number or
symbol selected is displayed in the box next to the “Units Chang” address. For
example, the “10.0” seconds selected for the Charge Timer appear as shown above.
NOTE: Do not touch the “Enter” address until all program parameters have been
selected. Touching the “Enter” address after selecting any of parameters will
return the screen to the <Main Menu> Screen. To return to the <Leak Test>
Screen touch the “Set Parameters” address.
Step 2.2-Program Settle Timer

Touch the “SETTLE Timer” address.
Verify the “CHARGE” and “SETTLE” timer addresses appear as pictured below:
CHARGE: 10.0
Timer Sec.
SETTLE: 0.0
Timer Sec.
Touch keypads “3”, “”, and “0”.
82
Step 2.3-Program Test Timer
Touch the “TEST Timer” address and verify that the Timer addresses appear as
pictured below:
CHARGE: 10.0
Timer Sec.
SETTLE: 3.0
Timer Sec.
TEST : 0.0
Timer Sec.
Touch keypads “4”, “”, and “0”.
STEP 2.4-Program Decay Pressure

Touch the “DECAY” address and verify that the addresses appear as pictured below:
CHARGE: 10.0
Timer Sec.
SETTLE: 3.0
Timer Sec.
TEST : 4.0
Timer Sec.
DECAY : 0.0000
Maximum Psig
Touch keypads “0”, “”, and “5”. Touch “Units Chang” key to change units from Psig to
any of the following desired units-InH20, kPa, mBar,Kgcm2, cmH20, mmH20, InHg,
mmHg, or Bar.
STEP 2.5-Program Specified Pressure

Touch the “PRESSR Specif” address and verify the “Timers”, the “Decay” and
“Pressure” addresses display the following on the screen:
CHARGE: 10.0
Timer Sec.
SETTLE: 3.0
Timer Sec.
TEST : 4.0
Timer Sec.
DECAY : 0.5000
Maximum Psig
PRESSR: 0.00
Specif. Psig
83
Touch keypads “1”, “0”, “” and “0”. If necessary, touch the “Units Chang” address to
select the desired pressure units. Touch the “PRESSR, Specif.” address box and verify
the “Flow”, “Timer” and “Specified Pressure” addresses appear as below:
CHARGE: 10.0
Timer Sec.
SETTLE: 3.0
Timer Sec.
TEST : 4.0
Timer Sec.
DECAY : 0.5000
Maximum Psig
PRESSR: 10.00
Specif. Psig
STEP 2.6-Program Pressure Tolerance

Touch the address location “PRESSR ± Toler.” and the entire display should appear as
below:
LEAK>
0.00 Units Progm#
% Chang 25
1 2 3 Res Test
LEAK
4 5 6 ± Ports
X
7 8 9 Clr Names&
Option
PRESSR 0.00
0 Enter ± Toler. % Exit
Touch Keypads “1”, “0” and “”. Touch the “PRESSR ± Toler” address on the screen
and this should appear as below on the screen:
PRESSR 10.00
± Toler. %
Step 2.7-Enter Selected Program Parameters

Touch “Enter” and the display will return to the Main Menu Screen.
Step 2.8-View Selected Program Parameters

To view the Leak Test Screen touch the “Set Parameters” address and verify the test
parameter settings.
84
Step 2.9-Return to Main Screen
Touch “Exit” and return to the Main Screen.
Step 3-Adjust Pressure Regulator to Programmed Pressure

While in Main Screen, turn the pressure regulator at the back of the instrument until the
programmed pressure of 10.00 Psig appears in the Pneumatic Regulator Control Bar
address of the Main Screen as shown below:
Prog:25 READY 10.00

LEAK TEST Psig
▲ ▲
Step 4-Run Leak Test

See the section on Running a Leak Test.
85
RUNNING A LEAK TEST
The following example explains the procedure for running a Normal Leak Test and
continues with the example detailed in the section entitled “Programming a Normal Leak
Test”.
Procedure Overview
1.) Put the instrument in “READY” Mode.
2.) Select program to run.
3.) Connect test part.
4.) Run the Test.
5.) Read the result.
Step 1-Put Instrument in “READY” Mode

With the instrument in the “READY” mode the Main Screen Display is shown below:
READY 10.00
Prog: 1 Psig
LEAK TEST
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
Test Data
Step 2-Select Program to Run

Verify that the program selected is that for the program to be run. In the
“PROGRAMMING A NORMAL LEAK TEST” section the program selected for the
normal leak test was Program #25. Program #1 is displayed on the Main Screen above.
Program #25 must be selected before the leak test is run. Touch the Program Bar on
the Main Screen and the <Programs List> screen will be displayed. Touch the
“PageUP L” address box to scroll to the screen that includes Program #25. Touch
“Program #25” address box and it should appear as shown below:
Program # 25
Touch the “Exit” address to return to the Main Screen.

The Main Screen should indicate Prog: 25 in the Program Bar as indicated below:
86
Main Screen Prior to Running Program #25
Prog: 25 READY 10.00
LEAK TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
Test Data
Step 3-Connect Test Part

For this example the part to be tested is a stopcock in it “OFF” position.
Connect the part to the test port.
Step 4-Run the Test

Press the “START” Button.
The Main Screen will automatically display the following sequence of messages as the
part is being tested.
Main Screen during the Charge period of Test 1 Program #25 Leak Test
Prog: 25 CHARGE T1 10.00
LEAK TEST Psig
▲ ▲
▼ ▼
Presr
10.00
Psig
▲ Result ▲
▼ ▼
Test Data
Program #25 is in the Charge portion of the Leak Test. The current pressure is 10.00
Psig.
87
Main Screen during the Settle period of Test 1 Program #25 Leak Test
Prog: 25 SETTLE T1 10.00
LEAK TEST Psig
▲ ▲
▼ ▼
Presr 10.00 Psig
Result ▲
▲
▼ ▼
Test Data
Program #25 is in the Settle portion of the Leak Test. The current pressure is 10.00
Psig.
Main Screen during the Test period of Test 1 Program #25 Leak Test
Prog:25 TEST T1 10.00
LEAK TEST Psig
▲ ▲
▼ ▼
Presr 0.0000 Psig
Result ▲
▲
▼ ▼
Test Data
Program #25 is in the Test portion of the Leak Test. The current pressure decay is
0.000 Psig.
Step 5-Read the Result

The following are the possible outcomes of the test.
Main Screen at the Completion of Test 1 Program 25 Leak Test-PASS
LEAK TEST Psig
▲ ▲
▼ ▼
Decay
PASS
0.3000 T1
Psig
▲
Result ▲
▼ ▼
Test Data
The Test 1 result was a “PASS”. The final decay pressure was 0.3000 Psig units. The
pressure decay in the specified Test Time was less than the allowable decay of 0.500
Psig.
NOTE: This decision was not made until the test time was completed.
88
Main Screen at the Completion of Test 1 Program 25 Leak Test-FAIL
LEAK TEST Psig
▲ ▲
▼ ▼
Decay
FAIL
1.000 T1
Psig
▲
Result ▲
▼ ▼
Test Data
The Test 1 result was a “FAIL”. The final decay pressure was 1.000 Psig. The
pressure decay in the part exceeded the allowable limit of 0.5000 Psig.
.
NOTE: This decision is made as soon as the limit is exceeded.
GROSS LEAK DURING CHARGE

Main Screen after test halted due to Gross Leak
LEAK TEST Psig
▲ ▲
▼ ▼
TEST HALTED >>> REQUIRED TEST PRESSURE:
0.10 Psig
… Press any key to continue…
▲ ▲
Result
▼ ▼
Test Data
89
USING THE SET OPTIONS MODE
The following example will demonstrate the steps to follow to set the TME SOLUTION
Options and Memory Mode.
This example will use the same Leak test program parameters as the example used in
“PROGRAMMING A NORMAL LEAK TEST” with the following exceptions:
The Program number will be #26 instead of #25 as in the previous example.
The following additional information will be included in this example:

The instrument will be run with the MEMORY MODE-ON, the program will be named
“LTMemory”, Lot number “2030” will be assigned to the part and the Operator’s
identification will be “TME”.
Procedure overview
1.) Select Program #26.
2.) Set Leak Test Program Parameters:
Charge time: 10.0 seconds
Settle time: 3 seconds
Test time: 4 seconds
Decay pressure: 0.5 Psig
Pressure: 10 psi
Pressure tolerance: ±10%
3.) Adjust Pressure Regulator to Programmed Pressure.
4.) Set Options.
5.) Run a test using the Memory reference.
6.) Run a test in the Memory Mode.
7.) Cancel Memory Mode.
8.) Restore Memory Mode.
Step 1-Select Program #26-

Touch the center of the Main Screen to display the <Main Menu> Screen. Touch the
“Pick a Program” address to display the <Programs list> screen. Touch the “PageUP
(▲)” or “PageDN (▼)” address to move to the Program list that contains Program 26.
Touch Program # 26 address to bring up the <Main Menu> display.
Step 2-Set Leak Test Program Parameters

Touch the “Set Parameters” address on the <Main Menu> display to get the Program
26 <Leak Test> Display. Follow Steps 2.1 through 2.8 under “PROGRAMMING A
NORMAL LEAK TEST” to select and enter the test parameters for Program #26, and
Step 2.9 to return to the Main Screen.
90
While in Main Screen, turn the pressure regulator knob at the back of the instrument
until the programmed pressure-10.00 Psig-appears in the Pneumatic Regulator Control
Bar address as shown below:
Prog:26 READY 10.00

LEAK TEST Psig
▲ ▲
Step 4-Set Options
Step 4-Set Options

While in Main Screen, touch the center of the Main Screen to go to the <Main Menu>
Screen. Touch the “Set Options” address in the <Main Menu> and the <Set Options>
screen will be displayed as shown below:

Timer Sec.
Timer Sec.
Operator: PAUSE 0.0
Timer Sec.
FILL 0.0
Timer Sec.
Memory Mode
OFF Exit
To enter Program name, Lot number, or Operator touch the desired address on the
screen. An alphanumeric keypad comes up on the screen with the screen title that of
the item being entered. For example, when creating the program name the <Program
Name> screen appears as shown below:
< Program Name>
Clr <-
, @ # % & / | < >

1 2 3 4 5 6 7 8 9 0
A B C D E F G H I J
K L M N O P Q R S T
91
To enter the program name “LTMemory” touch the “L” key and “L” appears in the
center box in the top row as shown below:
< Program Name>

Clr <-
L
, @ # % & / | < >
1 2 3 4 5 6 7 8 9 0
A B C D E F G H I J
K L M N O P Q R S T
Continue entering each letter until the entire program name is entered. The screen will
appear as shown below:
< Program Name>
Clr <-
LTMemory
, @ # % & / | < >
1 2 3 4 5 6 7 8 9 0
A B C D E F G H I J
K L M N O P Q R S T
Touch the “Exit” address and the “Program name” address in the <Set Options> Screen
will be displayed as shown below:
Program name:
LTMEMORY
92
Touch the Lot number address on the <Set Options> Screen and the <Lot number>
Screen will appear as shown below:
< Lot number >

Clr <-
, @ # % & / | < >

1 2 3 4 5 6 7 8 9 0
A B C D E F G H I J
K L M N O P Q R S T
Enter the lot number “2030” by touching the numbers “2”, “0”, ”3”,and “0”. These
numbers will appear in the same location as the program name did in the prior example.
< Lot number >

Clr <-
2030
, @ # % & / | < >
1 2 3 4 5 6 7 8 9 0
A B C D E F G H I J
K L M N O P Q R S T
Touch the “Exit” address and the lot number will appear in the “Lot number” address
of the Set Options Screen as shown below:
Lot number:
2030
Touch the “Operator” address on the <Set Options> Screen and follow the same steps
detailed in entering the Program name to enter the Operator identification “TME”. The
“Operator” address in the <Set Options> Screen will appear as shown below:
Operator:
TME
93
To set the “Memory Mode ON” touch the “Memory Mode” address on in the <Set
Options> Screen until the “ON” indicator appears in the “Memory Mode” address box as
shown below:
Memory Mode
ON
The <Set Options> Screen will appear as shown below after the above options have
been set:

LTMEMORY Timer Sec.
2030 Timer Sec.
Operator: PAUSE 0.0
TME Timer Sec.
FILL 0.0
Timer Sec.
Memory Mode
ON Exit
Touch the “Exit” address to return to the <Main Menu> Screen. The entered
information will appear in the <Main Menu> Screen as shown below:
< Main >

LTMEMORY OFF
Datalog Mode
Set Options MemRef
*Store
Lot number: MemRef
2030 .Clear
TME Exit
Note the “MemRef” address contains an “*” indicating that the Memory Mode is
“ON”.
Touch the “Exit” address and the Main Screen will appear as shown below for Program
#26, Leak Test in Memory Mode.
94
Main Screen indicating Memory Mode is On and instrument is prepared to
memorize reference curve(s)

LEAK TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ Connect the Reference Device(s) ▼
Note: Footer of Main Screen indicates Memory Mode has been turned on.
Step 5-Run a Test using the Memory Reference

Prior to running the test connect the reference device-a good, known non-leaker to the
test port in order to record its characteristic reference decay curve. For this example a
stopcock in the “OFF” position will be the reference device. Connect the device to the
test port. Press the “START” button. The Main Screen will appear as shown below:
Main Screen During Charge Period of Testing of Reference Device(s)
Prog: 26 CHARGE T1-Mem 10.00

LEAK TEST Psig
▲ ▲
▼ ▼
Presr
X.XXXX Psig
Result
▲ ▲
▼ ▼
. . .Recording Memory Reference . . . .
Note: The footer indicates that the Memory Reference curve is being memorized
for the device being tested. This is Test 1 in the Memory Mode as indicated in the
Status bar.
95
The words “SETTLE” and “TEST” will appear in place of “CHARGE” as the test
proceeds. The number of decimal places on the display will change as the test portion
of the cycle changes. Upon completion of the test the words
“MEMORY REFERENCE READY”
appear on the screen along with a long beep. The Main Screen then appears in the
“READY” mode.
Step 6-Run a Test in the Memory Mode

After connecting the test part to the port and pressing the “READY” button the
instrument will run Program # 26 Leak Test and internally compare the test part’s
pressure decay to that of the reference part. During the test the fact that the test is
being run in the Memory Mode is indicated in the Status bar as shown below for each
portion of the test:
CHARGE T1-Mem
SETTLE T1-Mem
TEST T1-Mem
To verify that the Memory Mode is “ON” move to the <Set Options> Screen and note
the Memory Mode in that address.
Main Screen at the Completion of Test 1 Program 26 Leak Test in Memory Mode
LEAK TEST Psig
▲ ▲
▼ ▼
Decay
PASS 0.3000 T1-Mem
Psig
▲ Result ▲
▼ ▼
Test Data
Step 7-Cancel Memory Mode

To cancel or turn off the Memory Mode move to the <Set Options> Screen and touch
the Memory Mode address. If the Mode was “ON” and a reference was stored in
memory the screen will go to the <Warning Screen> and the operator will have to
decide to erase all test data or not. If the decision is to “Clear All Data” the Screen will
96
indicate “Data Erased” with a long beep as the data is being erased. The next screen
will indicate “MEMORY REFERENCE CLEARED” with a long beep indicating that the
memory is being cleared. The screen returns to the <Set Options> screen and the
Memory Mode address indicates that the Memory Mode is “OFF”.
Step 8-Restore Memory Mode

To restore the Memory Mode to “ON” touch the Memory Mode Address. The <Warning
Screen> will appear and the operator will need to decide to erase all data. All data must
be erased prior to the Memory Mode being returned to “ ON” and the reference device
must be rerun as done in Step 5.
97
Chapter 6 LEAK TEST WITH FLOW RATE READOUT PAGE
Introduction to Leak Testing with Flow Rate Readout 99

Pressure Decay Test Mode 100
Setting Leak Test with Flow Rate Readout Test Parameters 101
Leak Test with Flow Rate Readout Calibration 102
Running a Leak Test with Flow Rate Readout 105
98
INTRODUCTION TO LEAK TESTING WITH FLOW RATE READOUT
The TME SOLUTION with Flow Rate Readout capability is a pressure decay leak tester
customized to display leaks in both pressure and flow units. In the Pressure Decay
Mode the SOLUTION detects leaks by measuring the decay in pressure during the
selected test time. The pressure decay is displayed in pressure units-PSI, In H2O, kPa
etc.
In the Flow Rate Mode the instrument detects leaks by measuring the decay in pressure
in a known volume during the test time and reports the pressure decay in flow units-
CCM, etc. The Flow Rate Mode requires that the instrument be calibrated with a
Certified Flow Reference Standard and a “known good part”.
99
PRESSURE DECAY TEST MODE
The Pressure Decay Test Mode is the standard Leak Test Mode described in Chapter 4
of this manual. To select the Pressure Decay Test Mode the operator must touch the
“Test” address of the <Test Parameter> Screen until the “Test” address displays
LK-PRS. The <Test Parameter> Screen title also displays LK-PRS as the selected
test. Select the required test parameters and pressure units for the test. Once the
parameters are selected, touch “Enter”, touch “Exit” and return to the Main Screen.
When the Main Screen is displayed LEAK (PRS) appears in the Program section of the
screen. Attach the part to be tested and press the “START” button. The result will be
displayed on the Main Screen as shown below:
Prog: 1 READY 10.00

LEAK (PRS) Psig
▲ ▲
▼ ▼
Decay
PASS
0.001 T1
Psi Result
▲ ▲
▼ ▼
Test Data
No calibration is required in the Pressure Decay Mode.
100
SETTING LEAK TEST WITH FLOW RATE READOUT TEST PARAMETERS
In the Flow Rate Test Mode the SOLUTION detects leaks by measuring the decay in
pressure of a known volume during the test time. The measured pressure decay is then
converted to and displayed in flow units such as “ccm”. To select the Leak Test with
Flow Rate Readout Test Mode move to the <Test Parameter> Screen. Touch the
“Test” address until the “Test” address displays “LK-FLW”. The screen title displays
<LEAK(FLW)>.
Test parameters need be set prior to running the calibration cycle for the Leak Test with
Flow Rate Readout.
Select and enter the following test parameters:
• Charge Time,
• Settle Time,
• Test Time,
• LEAKRT Maximum-Flow value considered the maximum allowable flow rate.
A test result above this value will be a REJECT, a test result below this value
will be an ACCEPT,
• LEAKRT Standard-Certified Flow Reference Standard’s Nominal Value,
• Pressure-Full Scale of Certified Flow Reference Standard,
• Pressure Tolerance-±5.0% or ±10.0%,
• Program name (if needed),
• Lot Number (if needed,
• Operator (if needed),
• CLAMP Timer-0.0 Sec.,
• BLEED Timer-0.0 Sec.,
• PAUSE Timer-0.0 Sec., and
• FILL Timer-0.0 Sec.
Touch “Enter” and all of the selected test parameters will be displayed on the
<LEAK(FLW)> Screen. Touch “Exit” to return to the Main Screen.
101
LEAK TEST WITH FLOW RATE READOUT CALIBRATION
In order to convert pressure decay to flow rate, the instrument must be calibrated with a
certified flow standard and a known-good part. Calibration is done using only Port
#1. If the Solution has more than one port, touch the “Ports” address. Move to the
<Select ports> screen. Touch the “Clear” address and then select all ports by touching
each port address. The selected port addresses are highlighted. Once the ports are
selected touch “Exit” to return to the<LEAK (FLW)> screen. The selected port number
should be displayed in the “Ports “address in the order they were selected. Return to
the MAIN SCREEN. The screen will appear as shown below indicating that the unit is
ready to run a calibration cycle.
Prog: 1 READY
LEAK (FLW) Psig
▲ ▲
▼ ▼
▲ ▲
▼ Connect Test Part and Flow Standard ▼
Adjust the regulator knob in the back of the instrument to maximum pressure of the flow
orifice entered as the test pressure.
Attach a “Tee” fitting to the quick disconnect fitting on the test port. Connect the
Certified Flow Reference Standard to the “Tee” outlet of the fitting and the Known-Good
Part to “thru” outlet to the quick disconnect fitting as shown below. Note the part MUST
BE connected to the “thru” outlet of the “Tee” fitting since the calibration of the
system is based on the total system volume.
102
Calibration Test Set-up
SOLUTION Test Port
Calibrated Flow Orifice
Known-good Part
Quick Disconnect “Tee Connector”

Fitting Fitting
Use Dead End Plugs to cap off other ports if the instrument is a multi-port configuration.
Press the “START” button to run calibration cycle. While the calibration is being done
the screen will display:
Prog: 1 READY
LEAK (FLW)
▲ Psig ▲
▼ ▼
▲ ▲
▼ Calibration Flow (Leak Rate) ▼
Upon successful completion of the calibration cycle appears on the screen as shown
below and a long beep sounds.
Prog: 1 READY
LEAK (FLW)
▲ Psig ▲
▼ ▼
CALIBRATION COMPLETED
▲ ▲
▼ ▼
103
When a successful flow rate calibration cycle is completed, the calibration data is stored
in the program currently selected. Whenever the program is recalled, the calibration
data is also recalled and the instrument is ready to test the same type of part without
recalibration.
Using a different program number for each type of test part provides a means of storing
test parameters and calibration data for each part under its specific program number.
This allows recall of a particular program without recalibration being necessary every
time the program is selected.
When recalibration is necessary attach the test set up to the instrument test port and
touch the “Calibrate Flow” address in the <Main Menu> screen and the instrument will
run a Flow Rate Calibration cycle.
Invalid Calibration Run
If the screen displays
“INVALID CALIBRATION RUN”
at the end of a flow rate calibration cycle it means that the pressure decay was close to
zero. This could be due to:
• a Known-good part with too large a volume,
• too short a test time,
• too small a leak rate, or
• a gross leak detected during the calibration cycle.
104
RUNNING A LEAK TEST WITH FLOW RATE READOUT
Once a successful Flow Rate Read Out Calibration Cycle is completed the MAIN
Screen is displayed and the SOLUTION is ready to run Flow Rate Read Out Test Cycle
on the same type of part. Disconnect the “Tee” connector with the calibrated Flow Rate
Standard and the Known-good part from the instrument’s test port prior to running a test
part.
Connect the test part to the instrument “Test Port” using the quick disconnect fitting.
Press the green “START” button to run a test. The instrument will cycle through the
normal test sequence of CHARGE, SETTLE AND TEST. The test result will be
displayed on the MAIN Screen as shown below:
Prog: 1 READY
LEAK (FLW)
▲ Psig ▲
▼ ▼
Flwrt T1
PASS
5.000 Psig
CCM
▲ ▲
▼ ▼
NOTE
The calibrated Leak Test with Flow Rate Readout is only valid for the same test
parts as the one used during the Flow Calibration Cycle.
If a different part is to be tested then the instrument must be calibrated with a new
Known-good test part. New test parameters may also be required
If a part with a different volume than the part used during calibration is tested the
flow readings will not be accurate.
105
CHAPTER 7 TME SOLUTION-C CHAMBER TEST MODE PAGE
Introduction to Chamber Leak Testing 107

Setting Chamber Leak Test Mode Parameters 109
Finding the Correct Overpressure 111
Running a Chamber Leak Test 112
106
INTRODUCTION TO CHAMBER LEAK TESTING
The TME SOLUTION-C Leak Tester has all the features of the standard SOLUTION
Leak Test instrument with the added capability of running a chamber leak test. The
chamber leak test provides for leak testing of sealed packages or parts. In the
Chamber Leak Test Mode the sealed test part is placed in a chamber, the chamber is
pressurized to a selected test pressure and the pressure decay in the chamber is
measured during the test period. The measured pressure decay is an indirect
measurement of leakage into the test part.
The Chamber Leak Tester consists of an Accumulator and a port valve contained within
the instrument and an external test chamber designed to contain the test part.
SOLUTION-C Chamber Tester Setup
Accumulator & Port Valve
Test Port Test Chamber Test Part
The volume of the Accumulator is designated VA and during test setup it is pressurized
to an initial pressure of PA. The volume and test pressure of the empty test chamber
are designated VC and PC and those of the test part are designated VP and PP.
With the instrument in the Ready Mode, the port valve is in the “closed” position and the
Accumulator is pressurized to a pressure higher than the actual test pressure-
Overpressure. With the port valve in the closed position the Accumulator is sealed off
from the test chamber and the test part, which are at atmospheric pressure.
As the test proceeds through the Charge portion of the test cycle the port valve opens
and connects the Accumulator to the Test Chamber. The initial pressure of the
Accumulator-PA, drops to a lower pressure as the initial volume of air (VA) expands from
the Accumulator into the larger volume of the Accumulator and the Test Chamber less
the volume of the test part in the chamber. The final volume is (VA+VC-VP). The final
test pressure, designated PF, is defined by the formula:
PF=PA (VA/VA+VC-VP)
107
©2009 T.M. Electronics, Inc.
The Overpressure setting is required to account for this pressure change during the test
period. The correct Overpressure is the pressure that results in the correct test
pressure with the port valve open.
An airtight test part reduces the test chamber volume by its volume (VP) and the final
pressure is higher than that observed if the test part leaks. The volume of the test
chamber with a leaky part is larger resulting in a lower final pressure in the test
chamber. This difference in final pressures is used to determine Gross Leaks in the
SOLUTION Chamber Test. By setting a test pressure drop limit, known as the
Maximum Pressure Drop Limit, the instrument is able to discriminate between parts that
leak and parts that are airtight.
Maximum Pressure Drop Setting

Different chamber sizes, tubing and part volumes result in different pressure drops. To
account for this variation the SOLUTION has a setting for the maximum amount that the
overpressure is allowed to drop when it is applied to a sealed test chamber containing
an airtight part. This pressure is the Maximum Pressure Drop and characterized as a
percentage of the Overpressure (initial pressure-PA). When a test part causes the
pressure to drop below the Maximum Pressure Drop setting the instrument will display
“GROSS LEAK”.
As an example, if the chamber test requires an Overpressure of 15 Psig to drop to a test

pressure of 10 Psig, the pressure drop is 5 Psig or 33.3% of the 15 Psig Overpressure.
The Maximum Pressure Drop should be set slightly higher than 33.3% to allow for minor
volume differences in the test parts.
The Maximum Pressure Drop is also used to select the Standard Leak or Chamber
Leak Test Mode. To run a Standard Leak Test the Maximum Pressure Drop must
be set to 0.00%. To run a Chamber Leak Test the Maximum Pressure Drop value must
be set to a value other than 0.00%.
108
SETTING CHAMBER LEAK TEST MODE PARAMETERS
While in the MAIN Screen set the Overpressure by adjusting the regulator to the desired
pressure. The pressure will be displayed on the screen as shown below:
Prog: 1 READY 15.00

LEAK TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
Test Data
Touch the center of the screen to display the <Main> Screen. Touch the “Set
Parameters” address and the <LEAK TEST> Screen is displayed.
<LEAK TEST>
CHARGE: 0.0 PRESSR 0.00 Progm#

Timer Sec. MaxDrop % 25
SETTLE: 0.0 PRESSR -0.00 Test
Timer Sec. MaxDrop Psig LEAK
TEST : 0.0 Ports
Timer Sec. X
Maximum Psig Option
Enter the following test parameters:

• Charge,
• Settle,
• Test,
• Decay Maximum,
• Pressure Specified, and
• Pressure Tolerance.
To turn the Chamber Leak Test Mode ON a % Maximum Pressure Drop value greater
than “0.00” must be entered as the test parameter setting. Touch the address and enter
the desired Maximum Pressure Drop %. The Maximum Pressure Drop Psig displayed
109
is a calculated value based on the previously entered Maximum Pressure Drop %. The
Maximum Pressure Drop Psig address cannot set by the operator.
Touch the “Name&Option” address and the <Names & Options> screen is displayed.
Enter the desired Bleed Time in the “BLEED Timer” address. The Bleed time will open
the chamber to relieve any residual pressure between tests. For further information on
the Bleed Cycle reference Chapter 8.
Touch the “Exit” address three times to return to the MAIN SCREEN.
NOTE:
In order for the SOLUTION-C Leak Test Instrument to run a Standard Leak Test
the Maximum Pressure Drop % setting must be set to 0.00. When the Maximum
Pressure Drop % is set to 0.00% the Maximum Pressure Drop is set to 0.00 Psig
automatically. When these parameters are set to Zero the Chamber Leak Test
Mode is turned OFF and a Standard Leak Test can be run.
110
FINDING THE CORRECT OVERPRESSURE
Once the test parameters have been entered place an airtight part or a filled part in the
test chamber. Press the START button and observe the pressure reading during the
CHARGE portion of the test cycle.
If the observed pressure was less than the required test pressure, increase the
Overpressure by turning the regulator knob on the back of the instrument.
If the observed pressure was greater than the required test pressure, decrease the
Overpressure.
If the observed pressure was equal to the required test pressure then the correct
Overpressure was set prior to the test.
Disregard PASS/FAIL/GROSS results reported during setup.
111
RUNNING A CHAMBER LEAK TEST
Once the correct Overpressure has been found and set, the instrument is ready to run
test samples. Place the test part in the chamber and press the “START” button. When
the test is complete the instrument will display the result on the screen as shown below:
Prog: 1 READY 15.00

LEAK TEST Psig
▲ ▲
▼ ▼
Decay
PASS
0.3000 T1
▲
Psig ▲
Result
▼ ▼
Tests PASS FAIL
1 1 0
112
Chapter 8 CLAMP DRIVER OPTION AND BLEED CYCLE PAGE
Using the Clamp Driver Option 114

Using the Bleed Cycle 115
113
USING THE CLAMP DRIVER OPTION
NOTE: The Clamp Driver is a separate option, which is ordered at the time of
purchase.
Clamp delay is the time from the beginning of the test that the instrument allows for the
holding clamp (or fixture) to actuate fully on the test part before applying the test
pressure. The clamp driver is a feature that allows the TME SOLUTION to control
pneumatic fixtures that are used to restrain or seal the device being tested. When
enabled the clamp driver energizes an external low power valve** or solenoid for the
duration of the test cycle. After the test is over the valve remains de-energized until the
next test.
To enable the clamp driver, set the clamp delay timer to a value higher than zero,
typically between 0.5 and 1.0 seconds. The Clamp Driver Timer address appears in the
<Set Options> screen.
*
-CLAMP DRIVER OPTION: Low power valve, solenoid or relay=12 VDC @ 200mA. Clippard ET-3M-12V or
equivalent.
114
USING THE BLEED CYCLE
The bleed cycle is a function of the TME SOLUTION that allows the release of the
pressure inside the device under test after the test is done. Bleed time is useful when
parts are tested at high pressures and/or restrained by a fixture. In these cases the part
will be difficult or dangerous to remove from the fixture unless the pressure is exhausted
or bled internally in the instrument.
In order to enable the bleed cycle set the BLEED TIMER to a value higher than zero
typically between 0.5 and 1.0 seconds for small parts. The BLEED TIMER address is in
the <Set Options> Screen. A typical Clamp + Bleed Test Cycle is diagrammed below:
TME SOLUTION CLAMP + BLEED TEST CYCLE DIAGRAM
START END
 →PASS
 CLAMPING CHARGE SETTLE TEST BLEED
 →FAIL
NOTE: When the bleed function is used the air inside the part flows back into the
instrument carrying any loose debris or dust from inside the part. To prevent
contamination of the internal pneumatics of the TME SOLUTION the use of a filter at the
front port is recommended.
115
CHAPTER 9 FLOW TEST MODE PAGE
Leak and Flow Test Model Only
Flow Testing in the TME SOLUTION LEAK AND FLOW TESTER 117
Establishing Flow Test Parameters 118
Programming a Normal Flow Test 119
Running a Flow Test 124
116
FLOW TESTING IN THE TME SOLUTION LEAK AND FLOW TESTER
In manufacturing and quality control, one of the most important parameters to be

measured is flow. The airflow through a part can indicate whether the part is within the
acceptable dimensional, seal or density tolerances.
For example, a smaller than normal flow rate in a particular section of tubing might
indicate a reduction in the Internal Diameter (I.D.) of the tubing. An unusually high flow
rate in a filter element might indicate lower fiber density or membrane perforation. In
the extreme case, a very low or zero flow rate would indicate a partial or total occlusion
of the part which might be the result of manufacturing flaws or poor bonding - welding,
assembly operations, etc.
The TME SOLUTION uses a mass flow meter that is the state of the art in flow
measurement technology to perform its flow tests. This allows accurate measurement
of the flow through a part regardless of pressure or temperature.
117
ESTABLISHING FLOW TEST PARAMETERS
The flow test, as performed by the TME SOLUTION, requires the setting of the
maximum and minimum acceptable flow rate limits.
• The Maximum Flow Rate limit is highest flow rate that the instrument will consider
acceptable, if a part has a flow rate higher than this limit a FAIL result is displayed.
• The Minimum Flow Rate limit is lowest flow rate that the instrument will consider
acceptable, if a part has a flow rate lower than this limit a FAIL result is displayed.
• The Nominal Flow Rate is not used by the instrument, but it is provided as a way to
record the expected nominal value. This is intended for users who want to print
reports stating Maximum, Minimum and nominal values.
• The Flow Timer is used to control the duration of the flow test. Typically, the flows
rate value settles to 98% of its final value in 2 seconds. However, if the flowmeter is
exposed to flowrates beyond its full scale, longer settle times are required to allow
the flow meter to recover. This is particularly important with low flowmeters (10-50
ccm).
Once the flow rate of a particular part is known, the TME SOLUTION will compare the
measured value to limits set by the operator. If the measured flow rate is within the
acceptable range, the part will PASS the flow test. If the measured flow rate is outside
the acceptable tolerance range the part will fail the test.
For example: If a part is to be tested using Minimum=750 ccm and Maximum=1250

ccm. Parts with flow rates BETWEEN 750 and 1250 would PASS the Flow test.
118
PROGRAMMING A NORMAL FLOW TEST
The following example demonstrates the procedure for programming the TME
SOLUTION™ to run a Normal Flow Test.
EXAMPLE
Program 7 will be programmed to test a part with a flow range of 750-1250 ccm. The
specified (test) pressure will be 2.6 psi to produce a flow of approximately 1000 ccm.
The test pressure tolerance will be ±25%. The flow test time will be 2.0 seconds.
Procedure Overview
1.) Select Program #7.
2.) Set Flow Test Program Parameters:
Maximum Flow: 1250 ccm
Nominal Flow: 1000 cc(* Optional)
Minimum Flow: 750 ccm
Flow Timer: 2.0 seconds
Specified Pressure: 2.6 Psi
Pressure tolerance: ±25 %.
3.) Adjust Pressure Regulator to Programmed Pressure.
4.) Run the test.
Step 1-Select Program #7

Touch the center of the Main Screen to display the <Main Menu Screen>. Touch “Pick
a Program” address to display the <Programs List screen>. Touch the “PageUP (▲)”
or “PageDN(▼)” address to move to the Program list page containing Program #7.
Touch the “Program # 7” address to bring up the <Main Menu> display.
Step 2-Set Flow Test Program Parameters

Touch the “Set Parameters” address on the Main Menu display to get the Program #7
Test Display. If Program #7 has not been programmed before the screen will display
the <LEAK TEST> parameter screen. To display the <FLOW TEST> screen touch the
“Test” address box until the word “FLOW” is displayed. The <FLOW TEST> screen will
be displayed as shown: < FLOW TEST>
FLOW : 0.00 Progm#
Maximum CCM 7
FLOW : 0.00 Test
Nominal CCM FLOW
FLOW : 0.00 Ports
Minimum CCM X
FLOW : 0.0 Names&
Timer Sec. Option
119
Step 2.1-Program Maximum Flow
Touch the “Flow Maximum” address to bring up the keypad on the display:
< FLOW TEST>
FLOW : 0.00 1250.00 Units
Maximum CCM CCM Chang
FLOW : 0.00 1 2 3 Res
Nominal CCM
FLOW : 0.00 4 5 6 ±
Minimum CCM
FLOW : 0.0 7 8 9 Clr
Timer Sec.
PRESSR: 0.00 PRESSR
Specif. Psig ± Toler. . 0 Enter
Touch the keypads “1”, “2”, “5” and “0”. The selected units will appear in the address
next to the “Unit Chang” box as shown above. The units displayed in box next to the
“Unit Chang” address and the Flow addresses are those required for this example. To
change units when programming an actual test parameter, touch the “Units Chang”
address until the required units are displayed in the address next to the “Units Chang”
address. In addition to cubic centimeters per minute (ccm), the operator may select
from the following units for leak testing:
• LPM-Liters per minute,
• CFM-Cubic feet per minute,
• CFH-Cubic feet per hour,
• GPM-Gallons per minute, or
• CIM-Cubic inches per minute.
NOTE: Do not touch the “Enter” address at this point. Touching this address will
return the screen to the Main Menu Screen.
Step 2.2-Program Nominal Flow

Touch the Nominal Flow address.
Verify the “Maximum Flow” and the “Nominal Flow” addresses appear as pictured
below:
FLOW : 1250.00
Maximum CCM
FLOW : 0.00
Nominal CCM
Touch keypads “1”, “0”, “0” and “0”.
120
Step 2.3-Program Minimum Flow
Touch the “Minimum Flow” address.
Verify the “Maximum”, “Nominal” and “Minimum” Flow addresses appear as pictured
below:
FLOW : 1250.00
Maximum CCM
FLOW : 1000.00
Nominal CCM
FLOW : 0.00
Minimum CCM
Touch keypads “7”, “5” and “0”.
Step 2.4-Program Flow Timer

Touch the “FLOW Timer” address and verify that all the “Flow” and “Flow Timer”
addresses appear as pictured below:
FLOW : 1250.00
Maximum CCM
FLOW : 1000.00
Nominal CCM
FLOW : 750.00
Minimum CCM
FLOW : 0.0
Timer Sec.
Touch Keypads “2”, “.” and “0”.
Step 2.5-Specified Pressure

Touch the “Specified Pressure” address and verify that all the “Flow”, “Flow Timer” and
“Specified Pressure” addresses appear as pictured below:
FLOW : 1250.00
Maximum CCM
FLOW : 1000.00
Nominal CCM
FLOW : 750.00
Minimum CCM
FLOW : 2.0
Timer Sec.
PRESSR: 0.00
Specif. Psig
121
Touch keypads “2”, “•” and “6”. If necessary, touch the “Units Chang” address to select
the desired pressure units. Touch the “PRESSR, Specif.” address box and verify the
“Flow”, “Timer” and “Specified Pressure” addresses appear as below:
FLOW : 1250.00
Maximum CCM
FLOW : 1000.00
Nominal CCM
FLOW : 750.00
Minimum CCM
FLOW : 2.0
Timer Sec.
PRESSR: 2.60
Specif. Psig
Step 2.6-Program Pressure Tolerance

Touch the address location “PRESSR ± Toler.” and the entire display should appear as
below:
<FLOW TEST>
0.00 Units Progm#
% Chang 7
1 2 3 Res Test
FLOW
4 5 6 ± Ports
X
7 8 9 Clr Names&
Option
PRESSR 25.00
. 0 Enter " Toler. % Exit
Touch Keypads “2” and “5” . Touch the “PRESSR ± Toler” address on the screen and
this should appear as below on the screen:
PRESSR 25.00
" Toler. %
Step 2.7-Enter Selected Program Parameters

Touch “Enter” and the display will return to the <Main Menu> Screen.
Step 2.8-View Selected Program Parameters

To view the Flow Test Screen touch the “Set Parameters” address and verify the test
parameter settings.
122
Step 2.9-Return to Main Screen
Touch “Exit” and return to the Main Screen.

While in Main Screen, turn the pressure regulator at the back of the instrument until the
programmed pressure of 2.6 Psig appears in the Pneumatic Regulator Control Bar
address of the Main Screen as shown below:
Prog: 7 READY 2.60

FLOW TEST Psig
▲ ▲
Step 4-Run the test

See the section on Running a Flow Test.
123
RUNNING A FLOW TEST
The following example explains the procedure for running a Normal Flow Test and
continues with the example detailed in the section entitled Programming a Normal Flow
Test.
Procedure Overview:
1.) Put the instrument in the “READY” Mode.
2.) Select Program to run.
3.) Connect the test part.
4.) Run the Test.
5.) Read the Results.
Step 1-Put Instrument in “READY” Mode

With the instrument in the “READY” mode the Main Screen Display is shown below:
Prog: 1 READY 2.60

FLOW TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
Test Data
Step 2-Select Program to Run

Verify that the program selected is that for the program to be run. In the
“PROGRAMMING A NORMAL FLOW TEST” section the program selected for the
normal flow test was Program #7. Program #1 is displayed on the Main Screen above.
Program #7 must be selected before the flow test is run. Touch the Program Bar on
the Main Screen and the Program List screen will be displayed. If necessary, touch the
“PageUP L” address box to scroll to the Program List screen that includes Program #7.
Touch “Program #7” address box and it should appear as shown below:
Program # 7
Touch the “Exit” address to return to the Main Screen.

The Main Screen should indicate Prog: 7 in the Program Bar as indicated below:
124
Main Screen Prior to Running Program #7
Prog: 7 READY 2.60
FLOW TEST Psig
▲ ▲
▼ ▼
▲ Result ▲
▼ ▼
Test Data
Step 3-Connect the Test Part.

For this example the part to be tested is a stopcock in its “ON” position.
Connect the part to the test port.
Step 4-Run the Test

Press the “START” Button, The Main Screen will show the progress of the flow test.
Main Screen During Test 1 Program #7 Flow Test

Prog: 7 FLOW T1 2.60
FLOW TEST Psig
▲ ▲
▼ ▼
1023 CCM
▲ Result ▲
▼ ▼
Test Data
125
Step 5-Read the Results
When the test is completed, the unit will display the test result in a screen like this:
Main Screen at the Completion of Test 1 Program 7 Flow Test-FAIL

Prog: 7 READY 2.61
FLOW TEST # 1 ACCEPT Psig
▲ ▲
▼ ▼
FLOW CCM
PASS
1034
▲ Result ▲
▼ ▼
Test Data
The Test #1 result was a “PASS”. The final flow value was 1034 CCM.
126
APPENDIX A-CONCURRENT TESTING
Concurrent testing consists of running the same test on more than one port at the same
time or concurrently. Multiport instruments have this capability. This allows the
operator to test multiple parts at the same time. To do concurrent testing in the TME
SOLUTION the operator must determine which ports will be used.
Example:
Reference the example in “Programming a Normal Leak Test (Vacuum or Pressure)” in
the Leak Test Chapter.
Leak Test Program #25 is programmed with the following parameters:
Charge time: 10.0 seconds,
Settle time: 3 seconds,
Test Time: 4 seconds,
Decay Pressure: 0.5 Psig,
Pressure: 10 psi, and
Pressure tolerance: ±10% .
The operator determines that Ports 1, 3 and 4 will be used to test the parts. To enter
this information the operator must display the <LEAK TEST> screen and touch the
“PORT” address. The <Port> screen is then displayed. The operator touches the Port
1, Port 3 and Port 4 addresses on this screen. These addresses will be highlighted
indicating that they have been selected. Test port 2 is not selected and will not be used
for leak testing in Program #25. The operator touches the “Exit” address on the <Port>
screen and returns to the <LEAK TEST> screen to proceed as described in the
referenced example.
The operator must connect a test part to each of the three test ports prior to running a
test. If all three ports do not have test parts attached a Gross Leak Failure will occur.
127
APPENDIX B: STATISTICS REFERENCE
The following formulas are used for calculating the LCL and UCL for the X Bar and R
charts
X-Bar Chart: UCL = X + (A2)R LCL = X - (A2)R
R Chart: UCL = (D4)R LCL = (D3)R
Where X = the Average of all X values

R = the Average of the Ranges of all Subgroups
A2 = Factor from Table 1
D3 = Factor from Table 1
D4 = Factor from Table 1
TABLE 1: Factors for Determining 3 Sigma Control Limits of X-Bar and R Charts
N A2 D3 D4
2 1.880 0 3.27
3 1.023 0 2.57
4 0.729 0 2.28
5 0.577 0 2.11
6 0.483 0 2.00
7 0.419 0.08 1.92
8 0.373 0.14 1.86
9 0.337 0.18 1.82
10 0.308 0.22 1.78
11 0.285 0.26 1.74
12 0.266 0.28 1.72
13 0.249 0.31 1.69
14 0.235 0.33 1.67
15 0.223 0.35 1.65
16 0.212 0.36 1.64
17 0.203 0.36 1.62
18 0.194 0.39 1.61
19 0.187 0.40 1.60
20 0.180 0.41 1.59
NOTE: The accuracy of the statistics routines is 2 minor digits.
128
APPENDIX C: TME SOLUTION PLC INTERFACE
Cycle-based Input/Outputs (Standard for: Single channel, Sequential, Concurrent)

These signals refer to the outcome of the test(s) when only one ACCEPT/REJECT
criteria is needed to describe the result of the tests performed by the instrument in one
test cycle. Thus in the Single channel unit the ACCEPT/REJECT refers to the one
outcome of the test. In the Sequential or concurrent units these outputs refer to the
Overall ACCEPT (all channels passed) or REJECT (at least one channel failed). These
signals are intended for parts that must be accepted or rejected based on the results of
all the channels. For example parts with multiple ports to be tested. The connections to
these signals are as follows:
ACC Type Signal name Description

Pin#
1 Output-Sinking CYCLE-ACCEPT Output Active when ALL channels
PASS
2 Output-Sinking CYCLE-REJECT Output Active when ANY channels
FAIL
3 Output-Sinking TEST Output Active during the test cycle
4 Output-Sinking NEXT Output Active during the second test
of a two-part test sequence
5 Common input Common for sinking Should be connected to the
Outputs PLC’s 24V GND (-)
9 Input-Sinking START test input. Actuate to START a test
(t>0.25s)
6 Input-Sinking RESET test input. Actuate to RESET a test
(t>0.25s)
10 Common-Inputs Common for sinking Inputs Should be connected to the
PLC’s 24V GND (-)
• Sinking Inputs are rated for 30V max./ 20mA
• Sinking Outputs are rated for 30Vmax. / 20mA
129
APPENDIX C: TME SOLUTION PLC INTERFACE (continued)
SOLUTION Sinking-Output PLC (Sink/Source input) PLC’s 24V

Power Supply
+ -
ACCEPT
1
SOLUTION Sinking-Input PLC (Sink/Source Output)
START
9
10
130
APPENDIX C: TME SOLUTION PLC INTERFACE (continued)
Port-based Outputs (Optional for : Sequential, Concurrent)

These signals refer to the outcome of the individual test ports in the Sequential or
Concurrent units.
These signals are intended for individual 1-port-parts tested by the instrument in one
test cycle yielding multiple PASS/FAIL outputs. The connections to these signals are as
follows:
ACC Type Signal name Description

Pin#
17 Supply input +24V supply for all Should be connected to the
sourcing outputs. PLC’s 24V Supply (+)
18 Output- PASS Output channel #1 Active when Channel #1
Sourcing PASSed.
19 Output- FAIL Output channel #1 Active when Channel #1
Sourcing FAILed.
Sourcing PASSed.
Sourcing FAILed.
Sourcing PASSed.
Sourcing FAILed.
Sourcing PASSed.
Sourcing FAILed.
• Sourcing Outputs are rated 60V max / 1A
131
APPENDIX D: USE OF FLOW STANDARD or CALIBRATED ORIFICE
The Flow Standard or Calibrated Orifice may be used to perform a functional test of a
leak or flow instrument or simulate a leak in a test part.
The following instructions assume that test parameters for the orifice being used have
been programmed into the instrument.
Instrument Functional Check

These instructions assume that test parameters have been established on known good
and bad parts and that these parameters have been programmed into the instrument
Remove all fixture and test lines and items attached to the instrument. Attach the Flow
Standard to the instrument with its connector line or quick disconnect fitting. Be sure
nothing blocks the flow standard. Run the test.
Test Port Connection Line
Flow Standard
A Flow Reading will be displayed for instruments with Mass Flow Meters. Consult the
Calibration Report for the expected Flow reading.
The Flow Standard can also yield a specific Pressure Decay result related to instrument
test parameters and the flow specifications of the calibrated orifice. Consult T.M.
Electronics, Inc. for the expected Pressure Decay Reading.
132
APPENDIX D: USE OF FLOW STANDARD OR CALIBRATED ORIFICE (continued)
Leak Simulation
These instructions assume that test parameters have been established on known good
and bad parts and that these parameters have been programmed into the instrument
To simulate a leak in a test part the Flow standard must “Tee” into the pneumatic test
circuit. This configuration will simulate the volume leak of a complete system, which
includes the test part, the instrument and all connection lines. Install a “Tee” fitting on
the instrument Test Port. Connect the Flow Standard to one of the “Tee” connections
and a known good test part to the other connection. Run the test.
Test Port
Tee Connector Flow Standard
Test Part
The test result will be a leak result on a good test part with a simulated leak rate
equivalent to that of the flow standard. Consult the Calibration Report for the indicated
leak rate.
133
APPENDIX E: TAL SOFTWARE
This Appendix details the configuration of TAL 3.2 Software for use with the TME
SOLUTION. These directions provide a Quick Start Guide as well as more detailed
directions. All directions are specific to a single port SOLUTION. SEE the TAL 3.2
Software Manual to set up the software for a multi-channel SOLUTION.
The TAL 3.2 Software allows for the ASCI output of the SOLUTION to be converted into
keystroke data which is then presented in a spreadsheet format, such as Excel.
QUICK START FOR THE TAL WinWedge® FOR THE SINGLE CHANNEL SOLUTION
Port Setting:
Baud: 9600
Data: 8 bits
Stop: 1 bit
Parity: None
Flow: None
Select the following:

1. “DEFINE”
2. “INPUT DATA STRUCTURE”
3. “ANY CHARACTER RECEIVED” and “FIXED NUMBER OF BYTES RECEIVED”
4. Enter “42”
5. Define the data structure as follows:
Field Bytes Description TAL Filter Example

Cycle# 5 Test cycle number NONE “15”: Cycle #15
Cycle result 6 Overall result NONE “ACCEPT” or “REJECT”
Test# 2 Test number NONE “T2”: Test NUMBER
Test mode 5 Type of test NONE “Decay”
Data 7 Measurement NONE “0.0001”: Decay value
Units 5 Units of measure NONE “Psig”
Test result 4 Result of test NONE “PASS”: Test #2 PASS
Time 6 Time NONE “2:34a”: Time of test
End of line 2 New line marker IGNORE <CRLF>
Select:
1. “MODE:
2. “SEND KEYSTROKES TO”
3. Enter the path to “Excell.exe”.
Typically: C:\WINDOWS\PROGRAM_FILES\OFFICE\EXCEL.EXE
134
APPENDIX E: TAL SOFTWARE (continued)
SET STREAM MODE OUTPUT FORMAT
The SOLUTION RS232 Mode must be set to the STREAM Mode for use with the TAL
3.2 Software. To set the RS232 Mode touch the middle of the “READY” Screen. When
the <Main Menu> Screen is displayed touch the “Printer Reports” address to display the
<Print/Send> Screen. Touch the “RS232” address to select the STREAM mode output
format.
COMPUTER CONFIGURATION
Load the TAL 3.2 program into the computer.

A small task bar will show on the screen with titles “File”, “Mode”, “Port”, “Define”,
“Activate”, and “Help”.
1. Click on “File”, select New
2. Click on “Mode”, select “Send Keystrokes to…”

On Title Bar select Application… Excel
Command Line…Enter the exact command path to Excel in the computer.
For example, c:\msoffice\excel\excel.exe
Click “OK”
3. Click on “Port”, select Settings
Select Connector port #,
Select Parity=even, Data bits = 7, Stop Bits=1, Flow Control = none,
Select Baud rate = 9600,
Select Output Buffer size = 1024,
Select Input Buffer size = 512.
Click “OK”
4. Click on “Define”, select Input Data Record Structure

Select “Any Character Received”,
Select “Fixed Number of Bytes Received” and
Select “Continue”
Enter the number 42 into the box for the complete Record Length
Click “Continue”
135
APPENDIX E: TAL SOFTWARE (continued)
Use the table below for each of the “Field” settings. Move the cursor to
the desired field and enter the Filter and Length data presented for that
field. For the “postamble” field, go to the “Keystroke” list to click on the
correct input. Note the drop down “Keystroke” button to find added
commands
Field Filter Length Field Postamble

1 None 5 Tab
2 None 6 Tab
3 None 2 Tab
4 None 5 Tab
5 None 7 Tab
6 None 5 Tab
7 None 4 Tab
8 None 6 Tab
9 Ignore 2 Home; Down
4. Click “OK”
5. Return to “Files” and select “Save As” and give the program a Name
6. Click “Activate” and select “Normal Mode” to engage the program for use.
SOLUTION/TAL OPERATION
When the SOLUTION initially sends data to TAL, the program should activate Excel and
start putting data in the columns.
136
APPENDIX F: FILTER DRYING SYSTEM
A Filter Drying System is recommended to ensure that only instrument quality air is
used in the TME SOLUTION™. An LA-05, Filter Drying System may be purchased
directly from TM Electronics, Inc. and consists of the following components:
• Coalescing Filter - 16 CFM, 150 Psig maximum at 125° F or Wilkerson M16-02-

000 or ASCO #34203468,
• Desiccant Drying Filter – 10 CFM at 100 Psig; 150 Psig maximum at 125° F, or
Wilkerson X03-02-000, and
• After Filter – 40 CFM, 5µ, 150 Psig maximum at 125° F or Wilkerson F08-02-
SK00 or ASCO #34204018.
Installation Responsibility and Recommendations
The customer is responsible for properly mounting the components to a wall or an

adjacent surface.
It is recommended that the filter assembly be mounted within 10 feet from the
instrument location.
It is recommended that a shut off valve be placed in line between the main air supply
and the coalescing filter.
Installation
Connect the three (3) components as shown in the drawing below. Use the ¼” NPT
fittings supplied with the system.
5µ
Shut off Valve After Filter
Plant
Air Supply Air out to
instrument
Coalescing
Filter Desiccant
Drying Filter
137
APPENDIX F: FILTER DRYING SYSTEM (continued)
After connecting the components, mount the filter assembly in its permanent position.
Open the desiccant filter bowl and fill it with silica gel supplied with the system. Fill the
filter bowl with silica gel up to 1/8” below the bowl’s inner shoulder. Shake and/or tap
the bowl while filling to settle the gel.
Connect the plant air supply line to the input side of the shut off valve. Connect a line
from the output side of the shut off valve to the input side of the coalescing filter. If
there is no shut off valve, connect the plant air supply line to the input side of the
coalescing filter.
Connect an air line from the outlet of the 5 µ After Filter to the air supply connection on
the back of the instrument.
Maintenance
CAUTION-The instrument Warranty does not cover water, water vapor, oil vapor or oil
damage to the instrument. It is the customer’s responsibility to maintain dry, clean
instrument quality air.
The filter assembly should be checked on a periodic basis to assure that no water is
found in the drain bowls of in any of the components. Frequency of checks should be
based on the air supply quality and the frequency of use.
The coalescing filter prevents oil vapors from contaminating the desiccant drying resin.
Oil contamination of the resin decreases its absorption capacity. The coalescing filter
should be replaced when it appears gray, damp from contamination or when the
indicator requires.
The desiccant drying material is silica gel with an indicating color. When the color is
PINK the silica gel must be replaced or recharged. See the manufacturer’s instructions
on the insert provided for recharging directions.
The After Filter is a 5µ particulate filter that prevents dust from the desiccant drying
cartridge from entering the instrument. The filter should be monitored for discoloration
or visible particulate. The 5µ filter element can be washed and blown dry and reused.
138
APPENDIX F: FILTER DRYING SYSTEM (continued)
Order/Reorder Numbers for Filter Drying System Components
Filter Type ASCO Wilkerson

Coalescing Filter 34203468 M16-02-000
Coalescing Filter Replacement 97801005 MTP95548
Desiccant Drying Filter N/A X03-02-000

Desiccant Drying Filter Replacement N/A DRP-85-059
(2 packs/unit)
5µ After Filter 34204018 F08-02-SK00

5µ After Filter Replacement Element 97802070 FRP96729
139
APPENDIX G: TME SOLUTION SPECIFICATIONS
Dimensions ….……………………………………………8 ½”W x 16”D x 10”H

Power ….………………………..US: 115 Volts, 50-60 Hz @ 1.5 Amps
………………EUROPEAN: 230 Volts, 50-60 Hz @ 1.25 Amps
Storage Environment …………………………………………………5-40°C (40-100°F),
…………………………………………RH<80%, non-condensing
Operating Environment ………………………………………………….5-40°C (40-100°F)
…………………………………………RH<80%, non-condensing
Controls …..Push Buttons, Touch Pad, Keylock, Power ON/OFF Switch
Test Channels ………………………………1,2,3 or 4;Concurrent or Sequential
Test Mode ………………………Pressure or Vacuum, Single or Differential
Single Tests ………………………Pressure or Vacuum; Single or Differential
Dual Tests ………………………………………………Leak/Flow; Flow Leak
Displays ……………………Backlit colored LCD, 40 character x 16 line
……………………………………Alphanumeric/Graphic Display
Units …………...PSI, Inches of H2O,kPa, mbar, Others are available
DATALOG Memory ……………………………………………………Up to 5000 Tests
PROGRAM Memory ……………………………….Up to 100 Linkable Test Programs
Statistics ……………………..Mean & Range Charts, Histograms, Mean,
………………………Standard Deviation, Min/Max, UCL & LCL
Manual Output ……………Test Setup Parameters, Test Results, Datalog and
………………………………………………Statistics on Demand
Automatic Output ……………………….Current Test Results to Preset up Printer
Auxiliary Output 24 V Opto Isolated PLC Interface for Single and Multiport
Configurations
Communications Port ………………………..RS232 Connector
Program Input/Data Output
Calibration ……………………………………………………..NIST Traceable
Timer Ranges ……………………………………………….0.1 to 1000 Seconds
PRESSURE RANGES …………………………….0.5-15, 1.0-50, 2.0-100, 5.0-250 Psig
VACUUM RANGE …………………………………………………………0.2-28 In Hg
RESOLUTION: Decay ………………………..Maximum 0.0001 PSI (0.001mBAR/Sec)
FLOW RANGE (sccm) ………………………………………….Standard-250-5000 sccm
…………………………………………Available-10sccm-75 LPM
FLOW RESOLUTION ……………………………………………………Standard-1 sccm
…………………………………..Available-0.01 sccm to 1.5 LPM
Cleaning ………Soft cloth wetted with a glass cleaner such as Windex®
140
ADDENDUM: CUSTOM DESIGN INSTRUMENTS
This manual does not cover Custom Models of the TME SOLUTION. Please reference
the Addendum shipped with the instrument for specific information related to a Custom
instrument. This Operator’s Manual should be reviewed prior to reviewing the
Addendum as it contains information pertinent to features common to all models of the
SOLUTION.
141
INSTRUMENT MAINTENANCE
WARNING! Do Not open or remove the instrument cover. There is hazardous

voltage inside the instrument. Opening or removing the cover will expose the operator
to a potential shock hazard and WILL VOID THE WARRANTY. There are no user
serviceable parts inside the instrument. Refer all servicing to authorized
TMElectronics, Inc. Service Centers
INSTRUMENT MAINTENANCE
Note WARNINGS and CAUTIONS detailed throughout this manual to prevent any
damage to the instrument.
Use only a soft cloth wetted with a glass clean such as Windex® to clean the outside of
the instrument.
FUSE REPLACEMENT
CAUTION! Fuse replacement must be done with the fuse(s) specified under
Instrument Connections. Use of an unspecified fuse(s) may result in damage to
the instrument and WILL VOID THE WARRANTY!
To replace the fuse(s), unplug the power cord from the wall outlet and from the
instrument. Insert a small flat head screw driver in the opening on the top of the fuse
holder cover. Twist the screw driver gently to flip the cover open. Insert the blade of
the screw driver between the top of the fuse holder and its outer housing and gently
twist the screw driver to release the fuse holder. Remove the holder and replace the
fuse(s). Reinsert the fuse holder ensuring that the proper instrument power
configuration will be visible through the opening in the cover. Replace the fuse holder
cover. Plug the power cord back into the instrument and the wall outlet.
142
INSTRUMENT SERVICE
TM Electronics, Inc. recommends that the SOLUTION be recalibrated at least annually.

The customer should establish an appropriate recalibration interval for the instrument.
The following are some of the factors to consider when establishing a recalibration
interval:
• characteristics, specifications and tolerances of the product being tested,
• frequency of use of the SOLUTION, and
• work environment.
Before returning any SOLUTION to the T.M. Electronics, Inc. for Service or Calibration
contact TM’s Customer Service Department at 1-508-869-6400 to obtain a Return
Material Authorization Number.
143
WARRANTY
T.M. Electronics, Inc. warrants to the original use purchaser that it will repair or
replace, at its option, any product under normal use and service that proves
defective in material or workmanship, as determined by TM Electronics’ inspection,
within one year from the date of purchase when promptly returned to the TM
Electronics factory. This warranty does not extend to damage caused by dirty air,
water or water vapor, oil or oil vapor intrusion from the air supply source or from
the product tested.
If TM Electronics’ inspection discloses no defect in material or workmanship, repair

or replacement will be made at customary charges. Freight charges are the
customer’s responsibility.
The foregoing warranty supersedes, voids and is in lieu of all or any other
warranties, expressed or implied, and no warranty of merchantability or fitness for
particular purposes is intended or made. TM Electronics’ sole obligation and the
original use purchaser’s sole remedy is as stated above and in no event shall TM
Electronics be liable for any special, direct, indirect, incidental, consequential or
other damages or expenses of any nature including, without limitations, loss of
profits of production time incurred by the original use purchaser or any other party.
DO NOT ATTEMPT TO OPEN THE INSTRUMENT. There are no user

serviceable parts inside and opening or removing the cover WILL VOID THIS
WARRANTY. Refer all servicing to authorized T.M. Electronics, Inc. Service
Centers.
T.M. Electronics, Inc.

45 Main Street
Boylston, MA 01505
508-869-6400
144

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TME

Leak and Flow Tester

CHAPTER 1 IMPORTANT INSTRUMENT SAFETY INFORMATION 4

CHAPTER 3 SOLUTION QUICK START GUIDE 26

CHAPTER 4 DETAILED EXPLANATION OF THE SOLUTION

CHAPTER 6 LEAK TEST WITH FLOW RATE READOUT 98

CHAPTER 7 TME SOLUTION-C CHAMBER TEST MODE 106

CHAPTER 8 CLAMP DRIVE OPTION AND BLEED CYCLE 113

CHAPTER 9 FLOW TEST MODE-Leak and Flow Model Only 116

APPENDIX A: Concurrent Testing 127

• to keep this manual for future use, and

SAFETY LABEL DESIGN

Hazard Severity Section

ISO General Warning Symbol

A black triangle with a black exclamation point on a yellow

DANGER is used to indicate an imminently hazardous situation, which, if

CAUTION indicates a potentially hazardous situation, which, if not avoided

Safety Symbol Panel

Word Message Panel

INSTRUMENT SAFETY LABELS

Hazardous Voltage Warning

Compressed Air Warning

The safety symbol conveys the explosion/release of pressure as the potential

The safety symbol conveys the explosion/release of pressure as the potential

Custom Compressed Air Warning

The safety symbol conveys the explosion/release of pressure as the potential

Fuse Safety Alert-Non-CE Configured Instruments

Fuse Safety Alert-CE Configured Instruments

RECOMMENDED SAFETY PRACTICES

DO NOT OPEN OR REMOVE THE INSTRUMENT COVER. There is hazardous

Introduction to the TME SOLUTION 12

A multi-port SOLUTION will be either a sequential or a concurrent instrument. A

The pressure transducer provides state-of-the-art sensitivity and temperature

Some configurations of the TME SOLUTION contain a Bleed Valve Safety

“Accept” Signal Light

“Reject” Signal Light

Solution Start Button

Key Unlock Position

FRONT OF INSTRUMENT BACK OF INSTRUMENT

Air Supply Connection

Refer to "INSTRUMENT CONNECTION LOCATIONS" for location of the

AIR SUPPLY Compressed air inlet to the instrument.

To ensure instrument quality air refer to Appendix F “Filter Drying System”.

TEST PORT CONNECTION: Test air outlet. To be connected to Test Part.

PRINTER CONNECTION: Printer output connection:

RS232 CONNECTION: Serial port input/output connection:

EUROPEAN: 230 Volts, 50-60 Hz @ 1.25 Amps

EUROPEAN: UL/CSA #10W1-11206

UK: UL/CSA to UK with 10 Amp Fuse

EUROPEAN: 2.0 A @ 250 Volts, 300 Watts Max

BULKHEAD CONNECTIONS: ¼” (6 mm) Tube Fitting connects to Bulkhead

CUSTOM FITTINGS: Fittings Face Seal

Refer to "INSTRUMENT CONTROL LOCATIONS" for location of the controls

POWER SWITCH: Turns instrument On and Off

PNEUMATIC REGULATOR: Controls the pressure or vacuum used in

START BUTTON: Starts the test sequence.

STOP BUTTON: Stops any test or procedure currently in

KEYLOCK: Locks the keypad to prevent program and

ACCEPT LIGHT: Indicates when the result of a particular

REJECT LIGHT: Indicates when the result of a particular