User’s Manual
Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Managing the Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 What FastCalXP Can Do For You . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 1 Introduction Thank you for purchasing FastCalXP. FastCalXP is the cornerstone of a specially designed and easy to use pressure calibration system that helps you calibrate pressure gauges and transmitters (collectively referred to as gauges in this manual) faster than you ever imagined. Whether you calibrate pressure gauges every day or only once in a while, FastCalXP saves you time, while helping you automate record keeping and reduce data entry errors.
Introduction 2 HOW IT WORKS A typical installation of FastCalXP includes a personal computer running Microsoft® Windows®1, a GaugeCalHP comparator and an nVision Reference Recorder, XP2i digital pressure gauge or 30 Series calibrator, used as the reference. The device under test, or gauge, is mounted on the comparator along with the reference and the reference is connected to the computer’s serial or USB port.
Installation and Setup 3 Installation and Setup Included in your FastCalXP box is an installer CD, a USB authorization key, an operation manual as well as various cables and/or adapters. An optional USB foot switch is available. SYSTEM REQUIREMENTS FastCalXP is a Windows application. The USB authorization key is the only additional hardware required to run the software and manage the FastCalXP database.
Installation and Setup 4 HARDWARE SETUP AND CONNECTIONS To set up your work station, position the GaugeCalHP next to the computer monitor and keyboard. Be sure that your serial or USB cable will reach from the reference mounted on the rear comparator position to the serial or USB port of the computer. Also, in some modes of operation, you may need to have one hand on the handle of the comparator and one hand on your computer keyboard or mouse. If you have purchased the optional foot switch (Part no.
Quick Start 5 Quick Start This section provides a summary of the four basic steps needed to complete a calibration using FastCalXP. It is intended to get you quickly up and running upon installation and to provide a guide for the new user of an existing installation. The four basic FastCalXP steps are displayed in the center of the main window and following the steps from left to right will get you through a calibration session.
Quick Start 6 The first time you run FastCalXP after installation, the software will prompt you to locate the database or specify the name and location of a new database. You will also be prompted to select a location for the storage of certificates. 2 Load the Gauge. Lookup existing gauge or create a new gauge using the New Gauge Wizard. The New Gauge Wizard will take you through the addition of a new gauge in the steps listed below.
Quick Start 7 TAKE THE AS RECEIVED DATA Perform a New Calibration. 1 Click the Perform As Received Cal button. 2 The Calibration Wizard will auto-detect the reference as described in the discussion of References. If a new reference is detected, the Calibration Wizard will prompt you to enter the current certificate information for the reference. If using an nVision with two modules you will be prompted to select one of the modules to use for the calibration.
Calibrating Gauges 8 Calibrating Gauges This section describes, in detail, many of the concepts referred to in the Quick Start section above. GAUGES FastCalXP refers to the device under test (DUT) as the gauge. Gauges are the heart of the FastCalXP database. Before beginning a calibration, FastCalXP must load the gauge. Load an existing gauge or use the New Gauge Wizard to create a new gauge.
Calibrating Gauges 9 2 Select a gauge from the list or search for a gauge. If searching for a gauge, select a search type from the dropdown and enter the search criteria. 3 Click OK to load the gauge then connect the gauge as described in the GaugeCalHP manual. New Gauge Wizard To create a new gauge, click on Create New Gauge button from the Select Gauge Step column, choose Create New Gauge from the File menu (Ctrl+N) or use the New Gauge button on the toolbar.
Calibrating Gauges 10 3 Select a model from the pull-down list. If the model of the gauge you are creating has not been previously entered into the database, click on the Add New Model button. The Add New Model Wizard will step you through the creation of a new model in two steps. The initial dialog box allows you to enter the model information. 4 Enter the Model number or name and select the Units of measure from the pull-down list. 5 Enter the Pressure range measured by the model.
Calibrating Gauges 11 8 Select the Accuracy of the gauge from the pull-down list or specify a % of span or Custom accuracy. Refer to the discussion of Models on page 36 in the Managing the Database section. 9 Click Next to select the As Received and As Left calibration Profiles. If the desired profiles are not listed, click on the Create New Profile button to open the Profiles editor. Refer to the discussion of Test Profiles on page 39.
Calibrating Gauges 12 11 Enter gauge information. The Gauge number is your number for this particular gauge – its identifier. This number is required and it must be unique among all gauges stored in the database. Choose the gauge number carefully since the number will be used in the future to identify this specific gauge from, potentially, a large number of gauges stored in the database. The Serial number is that which is provided by the manufacturer.
Calibrating Gauges 13 If the new gauge is a transmitter and Measure HART was selected, the New Gauge Wizard will display a HART Information dialog box. The Manufacturer ID, the Device type ID and the Device ID combined together form the unique ID, defined by the manufacturer, that is used to communicate with a smart transmitter during the calibration session. This ID can be entered manually by consulting the transmitter documentation or determined automatically by FastCalXP.
Calibrating Gauges 14 Calibration Schedule FastCalXP keeps track of the calibration schedule for all gauges and references in the database. 1 To view a list of upcoming calibrations, choose Upcoming Calibrations Report from the View menu. 2 Use the radio buttons to view a list of Gauges or a list of References. The time span over which FastCalXP looks for upcoming calibrations is specified under the Config Settings tab of the FastCalXP Options.
Calibrating Gauges 15 Autodetection FastCalXP automatically detects Crystal Engineering’s nVision Reference Recorders, XP2i (XP2) digital pressure gauges and 30 Series calibrators. Once the gauge and the reference have been mounted on the GaugeCalHP and the serial or USB cable has been connected to the reference and the computer’s appropriate port, the autodetection and calibration can proceed.
Calibrating Gauges 16 TEST PROFILES Test profiles are the standardized series of pressure levels used for the calibration of each model. Thus, there is a profile for As Received calibrations and a profile for As Left calibrations associated with each model in the database. To Select a Test Profile Test profiles can be specified within the New Model Wizard (accessed via the New Gauge Wizard).
Calibrating Gauges 17 Associate More Than One Set of Profiles to a Specific Model Imagine, for example, you have a number of Nuova Fima EN837-1 40 Bar gauges and some require a standard nine-point calibration but others, because of the task that they perform, require a finer 17-point calibration. In this case you would create two models, identical except that they would have different names, such as EN837-1 Coarse and EN837-1 Fine, and different calibration profiles associated with them.
Calibrating Gauges 18 To Change the Number of Exercise Cycles Associated with a Profile 1 choose Manage Database from the Tools menu and click on the Profiles button. 2 Select the profile of interest and click on the Edit button. 3 Enter the desired number of exercise cycles in the Number of exercise cycles text box.
Calibrating Gauges 19 To Match the Reference to the Target Pressure 1 Turn the handle of the GaugeCalHP until the Reference matches the Target Pressure. 2 Read the gauge and enter that value in the Gauge box. The number you enter may be modified based on the minor graduation or resolution of the gauge as it is specified.
Calibrating Gauges 20 The Adiabatic Effect Regardless of what fluid is used in the comparator there will always be a small amount of air remaining between the fluid and the gauge sensor. When pressure is increased in the comparator the air is pressurized and this pressurized gas heats up. When the pressure stops increasing, the gas cools and the pressure in the comparator decreases slightly. The reverse is true when the pressure is reduced in the comparator. This is called the adiabatic effect.
Calibrating Gauges 21 ACTUAL MODE CALIBRATION When FastCalXP is operating in Actual Mode, the Reference value that is taken for any point is the pressure reading from the reference at the moment that the keyboard Enter key is pressed, the Next Point button is clicked, or the foot switch is pressed. Actual Mode is the easiest mode of operation for the novice operator. Typically, this is the mode that will be used for calibration of digital gauges and transmitters.
Calibrating Gauges 22 PEAK MODE CALIBRATION Peak Mode calibration uses FastCalXP’s peak detection capability to take advantage of adiabatic pressure changes. In Peak Mode, the Reference reading is the largest (or smallest when descending) value recorded by the reference since the peaks were last cleared. FastCalXP will determine automatically whether you are ascending or descending in order to correctly pick a maximum or minimum for the “Peak.
Creating Certificates 23 Creating Certificates CERTIFICATE BASICS Certificates are meant to be enduring documents that record the calibration of gauges. They are Excel .xls or .xlsx format documents with one or more worksheets each. For the most part, certificate data cannot be edited in the database once the certificate has been created, although the Excel worksheets can be password protected to enhance the security of the data.
Creating Certificates 24 EXCEL TEMPLATES One of FastCalXP’s greatest strengths is the ability to create custom certificates using an Excel template. This allows the certificate to be fully customized, including the use of graphics and foreign languages. Each model in the database can have a different template, allowing for the greatest flexibility in generating certificates.
Creating Certificates 25 VIEWING CERTIFICATE DATA Before creating a certificate, you may wish to look at the data from the current calibrations or from an older certificate. To View Data from a Current or Previous Certificate 1 Open the Excel certificate or load the data into FastCalXP. 2 Load the data for a specific certificate one of two ways. (a) Choose Load Certificate Data from the File menu to select certificate data for the gauge that is currently loaded.
Settings and Options 26 Settings and Options OPTIONS FastCalXP settings can be modified by choosing Options from the Tools menu. By default, this menu item not available when a technician is logged on. Log on as an administrative operator to access Options. The FastCalXP Options dialog box allows configuration in four areas available via four tabs. Config Settings The Config Settings tab provides access to system defaults.
Settings and Options 27 XP2/Model 30 Serial Port The XP2/Model 30 serial port specifies which port FastCalXP will look at to find the Crystal reference. Typically, this is set to ‘Auto’, and FastCalXP will automatically detect the serial port to which the gauge is connected. Change to the specific serial port if your configuration requires it. HART Modem Serial Port The HART modem serial port specifies which port FastCalXP uses to connect to the HART Modem while calibrating transmitters.
Settings and Options 28 Save Certificates To The calibration certificates created by FastCalXP will be saved in the directory specified in Save certificates to. This directory is set the first time the software is run after installation or when a new database is created and can be changed here using the Browse button. Certificate Naming Template The Certificate naming template is used by FastCalXP to name the calibration certificates.
Settings and Options 29 Login Options The Login Options allow the administrator to enable the login feature of FastCalXP. The login feature allows control over who uses the software. In addition, the feature provides a record in the database of which user performed each calibration and of which user created each certificate. The Login Options tab is not available to technicians. No Login Disables the user login feature.
Settings and Options 30 Security Settings The Security Settings allow the administrator to set the privileges of technicians. The Security Settings tab is not available to technicians. Grant Technicians Access to the Options dialog Allows technicians access to the Config Settings and Calibration Settings dialog boxes.
Settings and Options 31 WHERE SETTINGS ARE STORED While most settings and options are stored within the database, some settings, such as the serial port, are stored separate from the database and apply to all databases. If you are only working with a single database, you can ignore this section as it will have no affect on you.
Settings and Options 32 HEAD CORRECTION CALCULATOR The Head Correction Calculator is accessed via a button under the Calibration Settings tab. The calculator uses Fluid density, Gravity and Height change to calculate a correction that is added to the pressure measured by the reference. Four standard fluid densities, for Isopropyl Alcohol at 25°C, Pure Water at 4°C, Pure Water at 20°C and Air at 15°C and sea level, can be applied using the buttons in the Head Correction box.
Managing the Database 33 Managing the Database The FastCalXP database stores all of the information entered into or acquired by the program. The database is a Microsoft Access format database that is accessible from within FastCalXP. All user-entered data related to Gauges, Units, References and Users can be edited by an administrator. Administrator-defined privileges may also permit access to some portions of the database by a technician.
Managing the Database 34 To add to or edit a table Click on the button for that table. Each dialog, or table editor, includes a list of items on the left, item details in the center which can be edited, and action buttons on the right. A checkbox at the bottom left allows you to display hidden items in the list. A checkbox at the bottom center allows you to specify whether or not the current item is hidden.
Managing the Database 35 Gauge number The Gauge number is your number for a particular gauge—its identifier. This number is required and it must be unique among all gauges stored in the database. Choose the gauge number carefully since the number will be used in the future to identify this specific gauge from, potentially, a large number of gauges stored in the database. Manufacturer and Model Use the pull-down lists to select a Manufacturer and Model from those stored in the database.
Managing the Database 36 MODELS The Models editor allows access to the data associated with all models stored in the database. Model The Model name is normally simply the name of the model provided by the manufacturer. However, if you wish use different test profiles on different groups of a single manufacturer’s model, you may need to add a modifier to the model name that will help you recognize which test profiles will be used for calibration.
Managing the Database 37 Use Custom Certificate Template When Use custom certificate template is checked, you can override the default Excel template defined in the Options dialog. This allows different manufacturers or models to have unique certificate formats. Cal Interval Enter the Cal interval (in days) which will be used for calibration scheduling. Transmitter Select Transmitter when you will select which parameters of the transmitter to measure during calibration.
Managing the Database 38 MANUFACTURERS The Manufacturers editor allows access to the information about each manufacturer stored in the database. Only the Name is required. The Address, Phone, Fax and Web address will help with contacting the manufacturer if necessary. In addition there is space to enter any pertinent Notes.
Managing the Database 39 TEST PROFILES The Profiles editor provides access to all test profiles stored in the database. The Profile Details box is also available for creating a new profile when a new model is created using the New Gauge Wizard. Name When creating a new profile, it will help to make the Name descriptive and specific, particularly if you will be using several similar profiles for different models. Units of Measure Use the pull-down list to specify the correct Units of measure.
Managing the Database 40 To Create a Non-Uniform Series of Pressure Points 1 Click to select Custom. Any points that are already listed will remain. 2 Select a point to delete or move or click New to add a point. 3 In the Condition Point dialog box enter a new point, and click OK. The entered pressure value will be added to the list. 4 Click Move Down or Move Up to position the selected point in the profile. 5 Double-click on a point or click on the Delete button to remove the selected point.
Managing the Database 41 LOCATIONS The Locations editor allows access to the information about each location stored in the database. Only the Name is required to store and use a location in the database. The Address, Contact name, Phone, Fax and Email address will help with contacting the location if necessary. There is also a field for any Notes. PRESSURE UNITS Units are specified for each model and that model’s associated profiles.
Managing the Database 42 REFERENCES The References editor provides access to all references stored in the database. References are Crystal digital pressure gauges or calibrators automatically detected by FastCalXP. Refer to the Autodetection on page 15. Any instrument used to measure ambient conditions in the calibration laboratory, such as temperature, humidity and barometric pressure, can also be considered a reference.
Managing the Database 43 USERS The Users editor provides the administrator access to the login information for all users of the FastCalXP software. The Login name and Password are used in the login dialog box. The Full name of the user is attached to the saved calibrations and certificates completed by the user. The Authorization of Technician or Administrator defines the privileges of the user. There is also a field for any Notes.
Managing the Database 44 If multiple database support is enabled, when the Change button is clicked in the Manage Database dialog, the following dialog appears: To Add a Database to the List of Available Databases 1 Click the Add Existing Database button. 2 Browse to the database and click Open. After selecting the database, you will be asked for a name, which will be displayed along with the database file name.
Menus and Windows 45 Menus and Windows COMMAND SUMMARY Following is a list of all commands available in the FastCalXP menu structure. File Create New Gauge. . . . . . . . . . . . . . . . . . . . . . . . . Use the New Gauge Wizard to create a new gauge. Lookup Existing Gauge . . . . . . . . . . . . . . . . . . . . Load a gauge. Load Previous Data . . . . . . . . . . . . . . . . . . . . . . . . Load existing calibration data for the loaded gauge. Load Certificate Data . . . . . . . . . . . . . . . . .
Menus and Windows 46 MAIN WINDOW The FastCalXP Main Window provides a graphical representation of the program flow and the current status of the program and the calibration process.
Menus and Windows 47 CALIBRATION WINDOW The FastCalXP Calibration Window provides a straightforward user interface for proceeding with a single calibration.
Frequently Asked Questions 48 Frequently Asked Questions GAUGES Why doesn’t the gauge that I am looking for show up on the list in the Load Gauge window? It is marked as hidden. Click the box that says Show hidden gauges. To un-hide the gauge edit the gauge with the Database Manager.
Frequently Asked Questions 49 REFERENCES Why doesn’t the Calibration Wizard detect my reference? Be sure that the serial cable connectors are properly seated and that the reference has been turned on. If the software still does not detect the reference, check the number of the serial port on the computer. Choose Options from the Tools menu. On the Config Settings tab, verify that the XP2/Model 30 serial port is the same as that to which the serial cable is connected.
Pressure Calibration Terms 50 Pressure Calibration Terms Actual Mode . . . . . . . . The data acquisition mode that takes the current reading from the reference at the desired moment of measurement. As Left . . . . . . . . . . . . . . The state of the gauge after it has had calibration adjustments made. As Received . . . . . . . . . The state of the gauge when it is initially measured. Comparator . . . . . . . . A device used to apply equal pressure to the gauge and reference. Gauge . . . . . . . . . . .
Appendix 51 Appendix APPENDIX A: FASTCALXP PRESSURE UNITS FastCalXP uses the following standard units and associated conversion factors from PSI. All conversion factors use a gravity constant of 9.80665 m/sec2. 1 PSI = 27.6806 inches of water column (water at 4° C [39.2° F]) 27.7070 inches of water column (water at 15.6° C [60° F]) 27.7292 inches of water column (water at 20° C [68° F]) 2.03602 inches of mercury (mercury at 0° C [32° F]) 51.7149 millimeters of mercury (mercury at 0° C [32° F]) 703.
Appendix 52 Tag Name Description Saved in Cert As Left Profile 0 = active, 1 = inactive (hidden) Number of exercises Maximum pressure in profile Minimum pressure in profile Database ID number of profile Name of profile Yes Yes As Received Profile 0 = active, 1 =
Appendix 53 Tag Name Description Location 0 = active, 1 = inactive (hidden) Location address Location contact Location email Location FAX Location database ID Location name Location notes Location phone Manufacturer 0 = active, 1 = inactive (hidden) Manufacturer address Manufac
Appendix 54 Tag Name Description Operator The Operator User is the account that is logged in when the cert was created.
Appendix 55 Tag Name Description Saved in Cert Conditions As Left pressure set point As Received pressure set point Yes Yes Data
Support 56 Support CONTACT US Phone . . . . . . . . . . . . . . . . . . . . . . . . . . (805) 595-5477 Toll-Free . . . . . . . . . . . . . . . . . . . . . . . . (800) 444-1850 Fax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (805) 595-5466 Email . . . . . . . . . . . . . . . . . . . . . . . . . . . service@crystalengineering.net Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . crystalengineering.net Send your comments to: sales@crystalengineering.
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