The final leak reading was less than the set limit 

Common Causes:

• Leak in reference part
  • Block reference port and retry test
• Invalid calibration
  • Previous calibration was performed with a leak in the system

When entering into the READ phase a positive slope was detected.  In direct flow models this indicates being over filled.

Common Causes:

• Too much time given during 'Fast Fill'
• 'Fast Fill' regulator set too high​
  • Pressure drop to part is too great to effectively stop fill cycle before being over pressure

Unit received the abort signal

Common Causes:

• A voltage bias across pins 9 and 12 of 12-pin connector

At the end of test the block test was performed.  The pressure reading was not lower than the pressure limit after the set amount of time

Common Causes:

• Part is blocked
  • Confirm with known good part
• Blockage in seal
  • Add roll-pin or some means to avoid 'folding over'
• Crimped air line from tester to part
  • Known good part will also fail

During the calibration the SystemZero could not be calculated with confidence as the sensor input varied too greatly

Common Causes:

• Seal movement
  • Add a hard stop for seals
  • Change seal durometer
  • Add a wait before sending the start signal after sealing
• External air source
  • Ensure that process air is not leaking through a valve into the test circuit
• Part still exhausting from previous test
  • Try again after waiting

During the READ phase of the test, the slope was too large in the negative direction

Common Causes:

• Insufficient time for accurate test
  • Extend times for STAB or READ
• Movement of seals
  • Add hard stops for seals
• Temperature effects
  • Add more cooling time or active cooling

After 1 minute the pressure sensor is reviewed and is expected to be close to the programmed zero.  If not, the unit will not permit a test to start unless the pressure has been brought to zero or the unit has been tared.

Common Causes:

• Part still clamped
• Pressure sensor zero calibration has floated too high
  • The unit must be zero'd either by a tare or pot adjustment

The flow reading was much larger than expected during the STABilization state

Common Causes:

• Gross leak
  • Check seals for debris or damage
  • Check the tubing from the test part to the leak tester for damage
• External air source causing flow
  • ​Ensure control air is not leaking through a valve

The raw flow before a test has started was too far away from SysZero

Common Causes:

• An external air source
  • Ensure a valve controlling test air paths isn't leaking control air
• Part still exhausting from previous test
  • Wait and try again

The test failed the secondary pressure decay check

Common Causes:

• Leak in part, seals, or test lines

Calibration Zero Error

This happens when F Zero is much different than SysZero
  F Zero: "Flow Zero" is calculated during a calibration and is the average of the final two 'Zero' readings
  SysZero: "System Zero" is sensor zero when the leak tester is unpressurized 

For versions 7 and earlier the difference cannot be larger than 500.  For versions 8 and later the difference cannot be larger than 8000

Possible Causes

Typically this is caused by invalid 'Zero' readings due to a leakage.  Possible root causes include:

• Hole in reference part
• Loose fittings or connections to either reference or test part
• A valve (internal or external) leaking control air into the test circuit
• Seal movement during the READ phase
• Leaking seal
• Bad part used during calibration

The pressure decay reading during calibration was much larger than allowable

Common Causes:

• Leak in part, seals, or test lines
  • Ensure that the part is a good part
  • Ensure seals are okay, free of debris or damage

The two pressure decay readings were too different from each other 

Common Causes:

• Seal movement
  • Ensure stand air is isolated from 'hungry' air consumers
  • Use hard stops for seals
• External air source
  • Usually observed in raw flow readings as well as a large leak 
• Part still exhausting from previous test
  • ​Check exhaust path to ensure air exits quickly

The reading taken during COMPensation time was too negative to perform a valid test (Only with 'Temp Comp')

Common Causes:

• Part temperature too cold for unit to compensate
  • Allow more time for part to climatize or add active cooling

The reading taken during COMPensation time was too large to perform a valid test (Only with 'Temp Comp')

Common Causes:

• Part temperature too hot for unit to compensate
  • Add cooling time or active cooling
• Seal creep during COMP reading
  • Extend COMP time

Pressure halfway through STABilization was outside the bounds set by PRESSURE HI and PRESSURE LO in the part SETUP

Common Causes:

• Gross leak usually in seals, part, or test lines
  • Check seals and part for large leak
• Wrong test program selected
  • External program selection may not be enabled if the stand normally changes part number.  Check setting in SYSTEM SETTINGS
• Incorrect settings
  • Verify that settings for upper and lower limits are correct for test pressure
• Upstream pressure is insufficient
  • Ensure pressure to leak tester is greater than required test pressure
  • Check tubing from tester to pressure source for kinks or significant holes

The initial flow test was completed and failed.  Sufficient flow was not read after a set amount of time

Common Causes:

• A blockage exists in the tested part
  • Verify system with known good part
• A blockage or kink exists in the tubing between the leak tester and part
  • Examine tubing leading from fixture to tester
• A blockage or kink exists in the tubing between the pressure source and leak tester
  • Examine tubing leading from tester to supply port
• If initially setting up, parameters may be too stringent
  • Change limits to reflect nominal part response

The span readings (CAL1 & CAL2) were too close to the zero readings (ZERO1 & ZERO2) in relation to the difference in zero readings

Common Causes:

• Insufficient time for accurate test without a drain valve
  • Add a drain valve
  • Control a seal cylinder from the leak tester EXH port
  • Add time to STAB or READ

During the READ phase of the test the slope was too large in the positive direction

Common Causes:

• Insufficient time for accurate test
  • Increase READ or STAB timers
  • Ensure no kinks in line from leak tester to parts
• Movement of seals
  • Add hard stops for seals
  • Increase sealing pressure
  • Try another seal durometer
• Temperature effects
  • Wait for part to climatize
  • Add temperature compensation
  • Add active cooling

Vacuum pressure was not achieved to the set level after the VAC1 state

Common Causes:

• A gross leak either in the part or seal
  • Ensure seals are clean and not damaged.  Replace as required.
• Insuffient seal pressure
  • Increase sealing pressure

The 24V power supply has dropped below acceptable limits

Common Causes:

• Insufficient supply voltage 
  • Ensure power supply rating is correct for application
• External source drawing high current
  • Disconnect external loads to see if condition persists

A cross cooler test was completed and the flow or pressure was greater than the set limit after the set amount of time

Common Causes:

• A leak exists connecting two separate cavities within a test part
  • Check manufacturing process

During a calibration the zero readings (ZERO1 & ZERO2) were too far apart

Common Causes:

• Insufficient time for accurate test without a drain valve
  • Add a drain valve or control a seal motion using EXH port of leak tester
  • Increase STAB or READ timers