Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Service Program for imc Measurement Devices

Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service
Integrated Quality Management Certified According to ISO 9001:2000 ................................................2 Procedure for Calibration, Maintenance, Repair and Adjustment of imc Devices .................................. 2 Flat charge calibration, inspection and revision (maintenance) .............................................................. 4 Protocols and Traceability to National Standards ................................................................................... 4 Some terminology, frequently asked questions ......................................................................................5 Tracing references to national standards (previously: Traceability as per ISO 9000ff) .......................... 5 DKD calibration certificate or manufacturer's calibration certificate?...................................................... 5 What is calibration? Legally secure calibration chains............................................................................ 5 Calibration: Who is qualified? QS 9000, ISO/TS 16949 and ISO 17025 ............................................... 6 How long between calibrations?.............................................................................................................. 7 Calibration procedures and measurement uncertainty ........................................................................... 8 Calibration procedures according to familiar standards.......................................................................... 8 Service costs a comparison ................................................................................................................. 9 Sample inspection plan for SPARTAN (635 test points: 0.93 EUR / test point) ................................ 9 Sample inspection plan for -MUSYCS (1502 test points: 0.72 EUR / test point)........................... 10 Example................................................................................................................................................. 11 Verification of imc CRONOS-PL (CRPL/BR-4) ................................................................................ 11 Sample inspection plan for CANSAS-L-UNI8 (840 test points included in calibration) ................... 13 Synopsis: Maintenance Calibration Inspection Repair System Revision................................. 14 Disposal of obsolete devices .................................................................................................................. 15 Equipment rental service......................................................................................................................... 15 Contacts .................................................................................................................................................... 16 Standards and references ....................................................................................................................... 16

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Integrated Quality Management Certified According to ISO 9001:2000

imc possesses DIN-EN-ISO-9001 certification since May, 1995. In June, 2003, the accredited TV CERT certification laboratory of TV Anlagentechnik GmbH awarded us a certificate attesting to our conformity to the world-wide accepted standard DIN EN 9001:2000. The Certificate Registration Number is 09 100 85 152. The organization of our quality management system, which is intended to provide "integrated product accountability", is established in application of imc Messsysteme Gmbh's accumulated experience and on the basis of DIN EN ISO 9001/9004:2000, and accords with the requirements of TS 16949, QS 9000, VDA Volume 6.1, as well as with the requirements for environmental protection management as per the regulations (EWG) 1836/93 and ISO 14001 as well as with those of European and German law, particularly as regard environmental protection, work safety, equipment safety and product liability. Our goal is to achieve a durable foundation of trust between our company and our customers through continual improvement and progressive development. When organizing calibration, balancing or inspection work, we also give regard to the requirements set out in DIN EN ISO/IEC 17025 (ISO Guide25) and in the EA documents (e.g. DAR-EM6, 9 and 10) published by the DAR; whereby imc's own calibration and balancing system is accredited in regular audits (together with out customers, upon request). Through continuous advancement and improvement of our management system, we hope to establish longterm relationships with our customers based on trust.

Procedure for Calibration, Maintenance, Repair and Adjustment of imc Devices

In addition to our training session and hotline, we offer an extensive range of services for our measurement devices (MUSYCS, -MUSYCS, MKAS, SPARTAN, imc-CRONOS, imc CRONOS-PL) in the form of maintenance, repairs, calibration and adjustment, and a replacement parts service, as well as device rental and consultation. As a standard, all our measurement devices come with manufacturer's calibration certificate, which lists the device modules and serial numbers. When we provide service for devices, we also provide and additional service report detailing all work performed as well as maximum device performance discrepancies detected upon delivery. The calibration reports with measurement values are automatically archived and are optionally available. In the report header, the test equipment employed and the imc-internal test equipment number are indicated. In conjunction with our test equipment management, this ensures traceability to national standards.

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Procedure schematic: Service for imc measurement devices

Step 1. 2. 3. 4. 5. 6. inspection/ maintenance of adapter for AC-devices: test of voltage sustaining capability Function test and adjustment (if appropriate). Adjustment of expansion cards (amplifiers, probes, conditioning boards, modem, radio clock, special functions) Adjustment and calibration U, I, ICP, if appropriate, manual adjustment / calibration of probes (U, I, Q) 8. 9. 10. 11. Temperature calibration and adjustment PT100, Type K thermocouple Inspection of protocol, composition of calibration certificate, archiving Endurance test, e.g. 12 h special tests, climate run, type inspection for customized systems, application Performance of safety inspection as per DIN EN 61010-1 Final inspection by QS; in case of error messages: verification of maintenance. Inspection of protocol archiving, clearance for shipping Shipping preparation, visual inspection of device + accessories, packaging, administration, shipping 10 year protocol archiving Longer upon request protocol copies Calibration upon receipt and test of reproducibility of error messages Repair (if appropriate) Update, modification, expansion (if appropriate) Software update (if appropriate) Typical Calibration work Receipt of goods/ administration Performance of safety inspection as per DIN EN 61010-1 Additional service from imc Other available options

7.

12. 13.

14.

15.

All test equipment used is subject to our test equipment monitoring; the calibrators (KNICK S 252, Wavetek 9100, FLUKE 5500 A, Burster Kelvimat, HBM bridge calibrator et al) regularly undergo external calibration (generally including a manufacturer's calibration certificate). At all times we keep calibrators having a DKD calibration certificate at the ready.

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Flat charge calibration, inspection and revision (maintenance)

We protect your investment! is our proud motto. For this reason, we refer to our service program concerning our measurement devices as System Maintenance. A detailed description of the components of system maintenance is provided in our brochure System Maintenance. Inspection: A function test of the entire device is conducted (e.g. digital input/output, current supply, analog outputs, depending on device configuration). Additionally, each device is subjected to an individual final inspection (function test and a measurement check of individual channels using other calibrators); this final inspection can be made to take account of customerspecific or device-specific prerequisites or conditions (for instance, the characteristic of a special MIC-channel can be checked at this stage). The final inspection is documented internally by imc; the customer receives a calibration certificate, and optionally (for a surcharge) a copy of the complete report (see also Protocols). Calibration: In calibration, the systems measured value is compared against one control value for each channel and in each input range. The results obtained are used to form a correction value which is recorded in the devices memory upon subsequent adjustment. Following the adjustment, the system is re-calibrated. The protocols are (electronically) archived by imc for 10 years. The test equipment used is subject to imcs test equipment monitoring program and is traceable to national standards as per ISO 9001. Which quantities must be calibrated for a specific device depends on the devices hardware configuration; in general, DC voltage calibration (offset and gain over 3 points), calibration of internal reference sources (e.g. PT100 current source), as well as temperature calibration for temperature measuring devices (Type K thermocouples, 1 measurement point with isothermal box) are performed. Revision: Maintenance work, system updating to the latest version, remodeling / expansion, if applicable With each of our systems, we offer affordable flat rates to encourage regular use of our system maintenance services, including calibration, maintenance or remodeling plus calibration. If your last inspection or maintenance work at imc was longer ago than 40 months, we can give you a personalized quote. For devices with custom interconnections, or for cases where devices are to be inspected along with special equipment, there are additional expenses. Please order a personalized quote for your own system.

Protocols and Traceability to National Standards

In general, a manufacturer's calibration certificate from imc for 1 device as per DIN EN ISO 9001 is adequate for our customers. The calibration process entails preliminary calibration (determining actual values; the owner is informed of deviations beyond tolerances), a complete function check, balancing and renewed calibration. The owner receives a manufacturer's calibration certificate without measurement values. The manufacturer's calibration certificate certifies the validity of the calibration in reference to the serial numbers listed (identification of the test object); the serial numbers of the system and of the measurement module are unambiguously correlated to the protocols and measured values; the protocol file headers state the test equipment used along with their imc equipment ID numbers. Optionally, a complete set of protocols with measured values and a list of the measurement equipment used can be ordered (measurement values "as received" + "after balancing"). A complete set of protocols of this type is needed for trend analysis or for determining calibration intervals, or in the framework of QS-audits, but is not required for a traceable calibration certificate according to ISO 9001ff, for example. We do not include this complete protocol set as a standard, thus reducing costs for us and our customers. However, the calibration protocols with the readings are always archived automatically and are available on file for 10 years. We cannot provide DKD calibration for measurement devices we supply. However, upon request we can exclusively use calibrators having DKD calibration certificates. Naturally, such a requirement must be expressed when placing an order.

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Some terminology, frequently asked questions Tracing references to national standards

(previously: Traceability as per ISO 9000ff) Every company desiring or possessing ISO 9000ff certification must demonstrate traceability to national standards. This requirement extends to all measurement and test equipment for all measured quantities which are relevant to quality assurance of the companys own products. The traceability requirement's intent is to ensure "correct" measurement. All imc test equipment used in inspection and calibration is subject to our test equipment monitoring program, certified per ISO 9001: 2000; the references and calibrators used are regularly calibrated externally either by their manufacturer or by an accredited calibration laboratory (generally with a manufacturers calibration certificate). We constantly keep calibrators having DKD calibration certificate at the ready.

DKD calibration certificate or manufacturer's calibration certificate?

Calibration is generally documented by a calibration certificate in which the results of the calibration process are recorded. By virtue of accreditation and continual monitoring by the PTB, DKD calibration certificates are considered valid proof of traceability. A manufacturer's calibration certificate is also proof of traceability if it is awarded by a calibration laboratory which is itself DKD-accredited. Manufacturer's calibration certificates from any other calibration laboratories are referenced to working standards and are not automatically proof of traceability; only if in conjunction with appropriate supplementary information about the calibration of the standards used by the manufacturer. Another distinction is the calibration process. For the DKD, this is laid out in mandatory guidelines while manufacturer's calibrations, referenced to working standards, are usually performed in a simpler (and thus less expensive) manner and on the calibration laboratory's own account.

What is calibration? Legally secure calibration chains

To begin with, it must be noted that there are several related terms to distinguish among concerning measurement (cf DIN 1319-1:1995: Grundlagen der Metechnik - Teil 1: Grundbegriffe). Measurement denotes the quantitative comparison of a measured quantity with a measurement unit. This includes evaluation of the measured values. A test determines to what extent a requirement is satisfied. This usually entails measuring the amount by which limit values are exceeded and evaluating the results. In calibration, the relationship between the measured value of an output quantity and the corresponding value of the measured input quantity is determined under specified conditions. Simply put: comparison with a reference having the same units, which in measurement engineering means determining the measurement deviation returned by measurement equipment. Calibration does not entail technical intervention such as adjustment in the measurement equipment. With indicator measurement equipment, calibration determines the deviation between the measured value indicated and the correct value or the reference value considered correct. Verification denotes quality testing and grading in accordance with verification regulations and is the prerogative of statutory measurement authorities ("verification offices", "verification officials"). In Germany, for instance, it is mandatory for equipment used in pricing (postal scales, gas pumps, etc.) or for dispensing medical products. Unfortunately, the term Verification is also frequently confused with calibration or adjustment. Adjustment refers to the process of adjusting measurement instruments to compensate for known systematic measurement discrepancies. In contrast, then, to calibration, this means manipulating the instrument in a way which produces lasting effects. Note that this renders any previous calibration and its traceability pedigree obsolete! It is then also no longer possible to reconstruct any changes in the instrument's measurement properties. Legally secure calibration chain. The record of how the calibration of an instrument derives its authority from the more authoritative calibration of the instrument by which it was calibrated, and so on, up to the first link in the chain where the measurement equipment is calibrated to the national standard. The purpose of the calibration chain is to ensure traceability of the measurement equipment to national standards. The chain is based on a hierarchy of calibrations. In Germany, the highest authority is wielded by the national standards developed and preserved by the Physikalisch-Technischen Bundesanstalt (PTB,
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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

http://www.ptb.de). The foundation supporting the national standards are the seven basic SI-units and the SIunits derived from these. In Germany the SI-units possess legal status. Thus, liability protection exists for calibration results having a solid traceability chain. The link to the PTB is generally provided by the German Calibration Service (DKD; http://dkd.ptb.de), founded August 25, 1977. International and European cooperation in the filed of accreditation is pursued by a variety of organizations. The main goal of the cooperation is mutual recognition of accreditation in areas not regulated by law. This recognition is encoded in so-called MLAs (Multilateral Agreements). By becoming signatories to the MLA, the accrediting institutions recognize each others accreditations. The DKD is one of currently 34 members within the European cooperation for Accreditation of Laboratories (EAL; http://www.european-accreditation.org), formerly WECC. The MLA ensures a uniform accreditation standard for all accrediting institutions. This reduces or completely obviates the need for multiple appraisals, which means that the vendor only needs one certificate or one report. At the international level, the ILA (International Laboratory Accreditation) was founded already in 1977, with its main goals being international recognition of inspections and close cooperation by experts in the field. In 1996, the ILA became ILACooperation (ILAC http://www.ilac.org). International cooperation in the area of accreditation of certifying institutions for quality management systems, products and personnel is promoted by the IAF (International Accreditation Forum), founded in 1995.

Calibration: Who is qualified? QS 9000, ISO/TS 16949 and ISO 17025

Frequent questions particularly from our customers in the automotive industry concern calibration laboratory accreditation. The QS 9000's requirement of accreditation pertains to inspection and calibration laboratories commissioned by suppliers to the automotive industry. Accreditation of the calibration procedure according to, for example DIN EN 17025 (General Competence Requirements for Inspection and Calibration Laboratories, equal to ISO Guide 25), is considered proof of competence. The QS 9000 alternatively offers the suppliers the possibility of relying on the manufacturers of measurement equipment for calibration. However, it is not necessary for such manufacturers to be accredited if their competence is established by other means, such as quality assurance arrangements or audits. The regulation text itself (QS 9000) makes this explicit (QS 9000 3rd edition, 4.10.6 Requirements for Supplier Laboratories). However, accreditation as a testing and calibration laboratory is not required by the applicable standard DIN EN ISO/IEC 17025. This is stated in greater detail in DAR-4-EM-03, Leitfaden zur Rckfhrung im Prfwesen (Guidebook on Traceability in Inspection Engineering), in Section 3, Instrumente der Rckfhrung im Prfwesen Kompetenznachweis - Messtechnische Rckfhrung auf SI-Einheiten (excerpt): The requirements of DIN EN ISO/IEC 17025 can be fulfilled with a certificate issued by the equipments manufacturer, if it demonstrates traceability to reference standards in accordance with accepted procedures, or that the calibration and its traceability was provided by an authorized calibration laboratory. (Paraphrased)1

Danach knnen die entsprechenden Forderungen der DIN EN ISO/IEC 17025 als erfllt gelten, wenn [...] (3.1.3) ein Kalibrier- oder Prfschein vom Hersteller der Mess- oder Prfeinrichtung vorliegt, welcher die Kalibrierung und die Rckfhrung auf SI-Einheiten mittels dokumentiert rckgefhrter Bezugsnormale im Sinne des Punktes 3.1.5 und unter Nutzung allgemein anerkannter Verfahren darlegt bzw. die Kalibrierung und die Rckfhrung auf SI-Einheiten durch ein kompetentes Kalibrierlaboratorium darlegt;
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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

How long between calibrations?

To get correct measurements in the long term, the test equipment used has to be monitored regularly and calibrated, if appropriate. The time between such calibration treatments is called the calibration interval. We frequently receive questions about the necessary calibration interval for measurement and test equipment. However, there is no unambiguous answer to this question, since a device's state of calibration is dynamic and depends upon the following factors, to name a few: the input quantity and its permissible tolerances, wear and tear on the equipment, stability of previous calibration procedures, measurement precision required and last but not least a company's quality assurance system policies. As a matter of principle, a calibration is valid only at the moment it is performed. Setting deadlines for recalibration is the responsibility of the equipment user. As a rule, the calibration interval should be designed to optimize the balance between risks and costs. This means that the calibration interval is ultimately the user's own responsibility to determine and monitor. Our recommendation is from 1 up to 3 years. In order to support our customers in determining the calibration interval, we offer consultation from our employees. Our standard statement in our spec sheets is for 1 year. However, some equipment users are able to calibrate measurement channels themselves by virtue of their own calibration laboratory, or in some cases, calibration of the entire measuring sequence is carried out prior to each measurement. In such cases we recommend maintenance checkup of the measurement systems every 24 to 60 months, depending on the model and the application. Note, however, that we offer an inexpensive flat charge for calibrations where the last calibration was carried out by imc not longer than 40 months ago.

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Calibration procedures and measurement uncertainty

At the moment, adjustment and calibration operations by imc are steps within an overall production process or a service; this means we have no separate inspection laboratory but rather so-called adjustment and inspection stations. The processes and procedures are set out in a protocol in the test instructions and test planning as elements of our Integrated Management System. All the processes are procedures developed by imc itself, and for this reason we make conservative claims for the measurement uncertainty, typically 0.01 % to 0.05 % (absolute over total) of the input range. For typical specified accuracy of 0.1 %, this already characterizes our systems as perfectly adequate. However, in most cases we are much better than that. We are gradually investigating all the procedures and will specify the uncertainty levels and process descriptions more precisely in future, as suggested in DIN V ENV 13005, for instance. Since we are manufacturers and developers and not a calibration laboratory, the standards DIN 45001 / DIN EN ISO/IEC 17025 and QS 9000 / TS 16949 are means we employ to promote our QM-system and technical systems. By May, 2004, we plan to revise complete the orientation stage for implementing DIN EN ISO/IEC 17025 (general competence requirements for inspection and calibration laboratories) in our system. For instance, we plan to describe the inspection and calibration methods used by imc in a manual, with reference to individual products. A comparison of the performance of our QM-system with the requirements of QS 9000, VDA 6.1, TS 16949, ISO 9001:2000 and DIN EN ISO/IEC 17025 is to appear in the future QM-manual. At this time, we perceive it to be an important goal to make the imc inspection and calibration management system transparent for our customers, and to demonstrate our expertise in this area.

Calibration procedures according to familiar standards

Calibration procedure: Calibration at imc is performed by comparing the value indicated by the measurement standard with the value indicated by the calibrated object. All calibration and adjustment procedures used at imc in the framework of our type testing are developed, validated and optimized for serial inspection with the goal of achieving the greatest precision economically justifiable. In this context, the protocols of measurement values are at the same time a certificate and an inspection plan (manufacturers specification). It is easy to develop customer-specific inspection plans on this basis; imc is happy to provide support in doing so. In our Calibration type test, we use the following standards, among others: The series of standards VDI/VDE/DGQ/DKD 2622: Calibration of measurement equipment for electrical quantities, describes fundamental calibration procedures. DKD 2622 Blatt 5 describes calibration of function generators DKD 2622 Blatt 11: Calibration guidelines for spectrum analyzers DKD 2622 Blatt 20 describes the calibration of DC voltage measuring amplifiers Additional standards and guidelines: DKD-R 5-5 regulates the calibration of temperature indicator devices DKD-R 6-1 regulates the calibration of pressure measurement modules Power network quality, voltage quality: EN 50160 and DIN 61000-4-30

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Service costs a comparison2

Cost of Ownership Cost of Ownership

Cost Overview
example: -MUSYCS per device -

Cost Comparison
Industry standard: System ships with manufacturers certificate (Explicit protocols upon request at extra charge) Calibration costs: 5 to 20 /measurement point for multimultichannel systems
-MUSYCS without amplifier = 1502 test points SPARTAN-L 635 test points SPARTAN-

Calibration System inspection (flat charge) System revision (flat charge) Repair (basic) Repair incl. system inspection

only in conjunction with SI/SR 890.(bi)annual 890.bi)annual 1290.(tri-,bi-)annual 1290.tri- bi 80/hr. not recommended 80/hr. plus 890.- flat fee 890.-

System expansion 1710.1710.incl. remodeling/system revision plus cost of parts Warrantee extension Premium Support incl. SW upd. upd. 510.- per year 510. 1500.- per year 1500.-

Its worth asking for the calibration instructions. Are really all ranges and measurement points checked?

www.additive-net.de www.imc-berlin.de

www.additive-net.de www.imc-berlin.de

Sample inspection plan for SPARTAN (635 test points: 0.93 EUR / test point)

Competitor I

5 / Measurement point for additional measurement points over and above those specified by manufacturer Adjustment / repair separate billing 97 / h Basic charge Setup time / measurement quantity Measurement point 80 80 23

Competitor II

(16 channels, voltage x 4 input ranges x 3 points, PT 100 x 2 input ranges at 2 points Example: SPARTAN measuremeapiece temperature) 272 nt 1,360 (Basis 5 ) points ,256 (Basis 23 ) 6 Price incl.minor maintenance: 620.00 (403.00 ) These are the prices to expect from a calibration lab. Adjustment, protocols cost extra

Example: SPARTAN-L 2 x 2 current sources / bay 16 digital inputs 4 alarm outputs (closing relay) Function test instructions UPS test Display Long-term test run with data recording Data recording Stand-alone mode

Calibration, adjustment, inspection of SPARTAN-L

8 32 8 36 3 1 1 1 1 91 272 272 635

Measurement points Measurement points Measurement points Test steps Function tests Function test final inspection Function test final inspection Function test final inspection Function test final inspection Test points function test Adjustment Calibration => approx. 0.98 / Test point

The price examples base on the price list for Germany.

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Sample inspection plan for -MUSYCS (1502 test points: 0.72 EUR / test point)
Example: calibration, adjustment/calibration, inspection -MUSYCS-S (RJ45, AC, C32, list price 8310 ) Device safety test upon receipt Supply voltages Vcc, +/-15 V, +/-5 V, +12 V Function test Calibration: TE Type K Calibration: 16 x diff 4 input ranges at 3 points apiece Calibration: 3 x ICP 2 input ranges at 3 points apiece Calibration: 2 reference channels at 12 points apiece Calibration: current source Calibration: 32 x single end 4 input ranges at 3 points apiece Adjustment / calibration: 32 x single end 4 input ranges at 3 points apiece Adjustment / calibration: 16 x diff 4 input ranges at 3 points apiece Adjustment / calibration: 3 x ICP 2 input ranges at 3 points apiece Adjustment / calibration: 2 reference channels at 12 points apiece Adjustment / calibration: current source Adjustment / calibration: TE Type K Calibration: 8 x DAC at 3 points apiece Test: 32 x digital input Test: 32 x digital output Test: incremental encoder interface 4 channels dual-signal, trigger bit Device safety test: Final test Supply voltages Vcc, +/-15 V, +/-5 V, +12 V Sync-Signal Long-term test run with data recording Final test instructions, All channels are meassured 1 function test 6 1 function test 16 192 18 24 1 384 384 192 18 24 1 16 24 64 64 12 3 6 2 1 48 232 635 635 1502 => points points points points points points points points points points points points points points points points Test points function test Test points function test Test points function test Function test Test steps Test points function test Adjustment/calibration Calibration upon receipt points

Calibration, adjustment, inspection -MUSYCS-S Basis 890

< 0.60 per test point

Cost of Ownership

Cost of Ownership

Low operating costs, long operating life

Operating costs = System inspection System revision SW update System training Usage (hrs. of operation) (hrs. Life span = Operating system compatibility Technical applicability State-of-the-art functionality State- of- theReplacement part guarantee Repair warrantee
* -MUSYCS mit Anschaffungspreis 15.000.-

Our Global Advantages Today

Innovation
Continuing development of existing products Special applications using standard systems No special software version we avoid one-of-a-kind solutions but one-ofstill provide solutions to one-of-a-kind applications one- of-

every 12 - 24 months every 12 - 36 months as required one-time oneMaximized due to reliability

5.9 % of purchase price* 8.6 % of purchase price * 2.7 % of purchase price * per user

Responsibility
Updates ensure long life span Device software for all Windows versions Old, new, different devices can run in concert

all Windows versions unlimited due to unchanged measurement methods for years to come (innovation leader) 10 years 10 years

Affordability (through integrated measurement engineering)

Multiple devices but one software (IMC Devices, IMC COM) High reliability through widespread installation
www.additive-net.de www.imc-berlin.de

www.additive-net.de www.imc-berlin.de

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Example
Verification of imc CRONOS-PL (CRPL/BR-4) CRPL-BR-4 is a plug-in measurement module for the imc CRONOS-PL family of measurement devices. The user can set the following basic functions (for each channel): + Bridge CF: 9 x 3 input ranges @ 5V, 2,5 V, 1 V + Bridge DC: 9 x 3 input ranges @ 5V, 2,5 V, 1 V + 4 mode options (full bridge, half bridge, quarter bridge: 120 Ohm, 350 Ohm) (= 216 bridge measurement ranges) + DC-amplifier: 13 DC-voltage measurement input ranges 5 mV .. 50 V = 229 basic input ranges (also possible: current measurement, ICP-measurement) DKD 2622 Part 20 describes the calibration of DC-voltage measuring amplifiers. Among other things, this guideline recommends calibration of preferably 10 points per polarity and input range, and repeated preferably 6 times3 = 6 x 4.580 input ranges per channel. By complying with this recommendation to the extent of measuring 5 points per input range, (no repeat measurements), then calibrating the entire measurement functionality of the 4-channel measurement amplifier would entail calibrating 4.580 measurement points. Important note! Even then, that would be calibrating only at one sampling rate and one filter setting! For a complete and manual inspection, assuming a test duration of 1 min per measured point (transient subsidence, data recording in Excel, for instance), the overall test duration comes to more than 70 h or approx. 10 days labor. Estimating an hourly wage rate of 95 EUR, this would come to more than 7000 EUR calculating on a T&L basis; some calibration labs calculate the price per measurement point... This manner of proceeding is uneconomical, not suitable for serial inspection and therefore employed only in exceptional cases as verification of calibration. An alternative for obtaining the conformity rating Usable measurement functionality was calibrated is calibration according to imc manufacturers specifications: Ee the example "T5311353.prt" (text file - excerpt of adjustment protocol for a CRPL/BR-4) In the Internet at www.imc-berlin.de or www.additive-net.de => Instrumentation => Search for 99999 (registration for download area required) In designing the measuring amplifier, the procedures for its adjustment and calibration are also developed at the same time and verified in the type inspection. One part of the procedure is to adjust various parameters due to their dependence on properties of components and on the running temperature; additional parameters such as the sampling rate selected or the selected filtering may not affect the measurement precision according to design targets. The resulting acceptance tests include procedures for the serial production and servicing, which reflect an optimum balance of test precision, standards conformity and economic viability In accordance with imc manufacturers specifications, the following measurement points are adjusted and calibrated for the BR-4 (on each of 4 channels): + DC 5 mV ... 50 V: Gain: 13 input ranges * 3 measurement points, + Offset: 13 measurement points (208 measurement points) + internal reference quantities (not externally accessible): 18 measurement points + CF-mode full bridge, 5 V power supply, low-pass 10 Hz in the input ranges 1 mV/V, 10 mV/V, 50 mV/V, 200 mV/V: 16 measurement points + DC mode full bridge 9 input ranges: 108 measurement points = in total 350 measurement points

3 DKD2622, Part 20 (Draft 09/2003) quote from Section 3.2.3: To characterize the response of measuring amplifiers for a defined input signal range, measurement of the output signal of the measuring amplifier at equidistant input values (preferably at 10 points per polarity) is repeated preferably six times... ... Service_and_calibration_of_imc_devices_2006.doc; MS, 25.01.2006 Page 11 of 16

Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

In order to be able to test according to these specifications, the condition for calibrating must be met; this is checked in a function test prior to calibration, in which additional measurement points are tested according to imc inspection plans with a pass/fail rating:
-

Offset measurement and noise test shorted directly at the device, with a high sampling rate and no filter Background: If either the offset or the noise is too high, there is a defect which may violate the calibration conditions. Too much noise, in conjunction with averaging of the signal, can lead to an apparent offset or apparent non-linearities. Testing of reference voltages, supply voltages Calibration signals emitted by the test object (e.g. shunt calibration of bridges) Test of basic functions such as auto bridge balancing Test of power consumption

These tests are generally conducted during the warm-up phase. The inspection plan for confirming the calibration conditions is modified by the Service department in adaptation to emerging experience. If the function test indicating fulfillment of the calibration conditions according to the imc inspection plan is passed, and the subsequent calibration according to imc manufacturers specifications carried out successfully, the conformity declaration "Calibrated according to manufacturers specifications traceable to national standards". Any additional measurement points specially ordered by the customer must be calibrated subsequently.

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Sample inspection plan for CANSAS-L-UNI8 (840 test points included in calibration)
only calibration Item Remarks

Calibration / Adjustment

1 2 3 4 5 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 8 9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 10 11 12 13 x x x x x x x x

x x x x

x x

Option

Admin

Designation

Description

Goods Received Administration Service standard Function test (IN) Temperature calibration (IN)

intake, unpacking, recording, device intake printout records, oder clarification, record service order, check history, assign to P, order confirmation to customer determine SW, in case of repairs: replicate error (see 4) manually with ISO-thermal box, Type K thermocouple 1 MP * 1 input range * 8 channels (room temperature) verify faults, clarify automated (no input needed), 840 MP 1 MP * 13 input ranges * 8 channels = 104 MP 1 MP * 13 input ranges * 8 channels = 104 measurement points 3 MP * 13 input ranges * 8 channels = 312 MP 11 MP * 8 channels = 88 MP 4 MP 4 MP * 8 channels = 32 MP 4 MP * input ranges * 8 channels = 192 MP 4 MP automated (no input needed), 840 MP 1 MP * 13 input ranges * 8 channels = 104 MP 1 MP * 13 input ranges * 8 channels = 104 MP 3 MP * 13 input ranges * 8 channels = 312 MP 11 MP * 8 channels = 88 MP 4 MP 4 MP * 8 channels = 32 MP 4 MP * input ranges * 8 channels = 192 MP 4 MP plausibility, check validity on server manually upon instruction

x x

x Administration Service Reparatur (IN) Calibration (IN) Noise test 1 (RMS) Noise test 2 (peak-peak) Voltage measurement PT100 measurement internal reference PT1000 Bridge Sense Current measurement Bridge Supply Adjustment / calibration (OUT) Noise test 1 (RMS) Noise test 2 (peak-peak) Voltage measurement PT100 measurement internal reference PT1000 Bridge Sense Current measurement Bridge Supply Check protocol, generate certificate electronically

Final inspection (OUT) Module measurement Test PT100 @ 50 C Sensorflash Robustness test 1 Sensor info Test Divider test Robustness test 2 Sensor info Test Test shunt calibration Temperature calibration (OUT)

disconnect power supply 3 times, connect, test reproducibility of measurement

disconnect power supply 3 times, connect, test reproducibility of measurement

manually with ISO-thermal box, Type K thermocouple 1 MP * 1 input range * 8 channels (room temperature) File service documents, print certificate, inspection markrt on the module optional

Document results, label module x Print protocol and certificate per ISO17025 x Recording of time and materials, file and edit device intake document

14 15 16 17 18

Complete service documents x Extended protocol set

Inspect documents, file in inforunder Service, edit device intake document Inspect plausibility, adaptation to customer wishes Shipping documents, packaging, shipping Conclude procedures, statistics Statistics, reports, archiving

x x x

Shipping preparation / shipping Wrap-up Data administration

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Synopsis: Maintenance Calibration Inspection Repair System Revision

Cost of Ownership Cost of Ownership

Maintenance Work
Definitions 1.) Calibration: 2.) Inspection 3.) Revision 4.) Repair, Remodeling, Update To date: IMC calibration = 1 + 2 +(sometimes) 3 Now: System-inspection or Revision System1 can be done by anybody, 2 4 only the manufacturer imc

System Calibration
Comparison with a reference having the same units Calibration means certificate of traceability Only valid at the time performed Re-calibration appointment the users responsibility ReUser must monitor interval between calibrations We recommend: Calibration interval of 1-2 years 1Who can perform calibration? Any calibration laboratory
Usually in accordance with DIN EN ISO/IEC 17025

www.additive-net.de www.imc-berlin.de

www.additive-net.de www.imc-berlin.de

Cost of Ownership

Cost of Ownership

System Inspection
Calibration of inputs Maintenance (repair if appropriate) Adjustment Function test Final inspection incl. Calibration of outputs Shipping with manufacturers calibration certificate and service report
Protocol of data for each channel and input range offered for extra charge extra

System Revision
Inspection plus System Update

Bringing systems up to date Benefits of further developments Extends system life span Revision only performed by imc Recommended at 12 - 36 month intervals

Inspection only performed by imc Recommended at 12 - 24 month intervals

www.additive-net.de www.imc-berlin.de

www.additive-net.de www.imc-berlin.de

Cost of Ownership

Cost of Ownership

Repairs
Repair (basic)
Test for reproducibility of error message and repair Function test of overall system (incomplete) Calibration history is lost

Why perform a system inspection (former calibration) with every repair order
The device returns to the user in reliable working condition Calibration history not lost Best, most reliable 100% function test (even finds hidden errors) errors) Fault remedy/ component replacement often necessitates readjustment, anyway readjustment, Example: an adapter defect is reported. Error profile: defective input channels strain the adapter. Also: DAC (analog outputs) Channel 2 defective.

(not recommended)

Repair incl. System Inspection (recommended)

Input calibration (documentation of all measurement channels and ranges actual values) Test for reproducibility of error message and repair Adjustment of all measurement channels and ranges Overall system inspection Maintenance work (if appropriate) Function test of overall system Final inspection and calibration protocol composition Shipping with manufacturers calibration certificate and service report www.additive-net.de www.imc-berlin.de

www.additive-net.de www.imc-berlin.de

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Disposal of obsolete devices

Sooner or later, the time will come. Your measurement device will be beyond repair or will simply no longer meet requirements. Send back your old product (only one-piece systems!) labeled scrap, and we will dispose of it for a flat charge (of 5% of original price!!), or will salvage components if applicable. You will automatically receive from us a quote for a unit of the corresponding successor product. When you buy a new product the price of disposal will be deducted. Any questions? Please contact us to let us know of any special wishes you may have!

Equipment rental service

Below are our charges for providing rental equipment (with calibration certificate). We regret that we cannot guarantee the availability of appropriate rental equipment in absence of prior arrangement: Flat rate rental: Devices such as test equipment generally fail just when you need them most, meaning that the repair time is too long, by definition. For such cases, we offer a flat rental rate for the duration of repair work. Contact us with your special requests! Example of rental devices as backup during repairs: + Fixed fee 105 + 2.5 % of system price / week + shipping and handling Example of other rental devices: + Processing fee (e.g. system inspection + calibration) (to cover the cost of calibration before and after customer use) + 2.5 % of system price / week + shipping and handling. Please feel free to contact us for a customized quote.

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Service Program for imc Measurement Devices Calibration, Adjustment, Maintenance, Repair and Miscellaneous Service

Contacts
Youre welcome @ http://www.imc-berlin.de/en imc Mesysteme GmbH integrated measurement & control Quality Assurance Voltastrae 5 D-13355 Berlin Additive GmbH hotline Tel.: +49-(0)30-467090-26 Fax: +49-(0)30-467090-22 email: hotline@imc-berlin.de Internet: http://www.imc-berlin.de Tel.: +49 (0) 641 5905-0 email: hotline@additive-net.de Internet: http://www.additive-net.de

Standards and references

We have collected the most frequent questions regarding calibration in an article on our homepage: http://www.imc-berlin.de/support/messtechnik/qualitaetssicherung.shtml In case youre interested, we can send you our quality management manual (on CD). See also: http://www.imc-berlin.de/support/messtechnik/supportpdfs.shtml Management systems, test equipment monitoring, terms (see also www.beuth.de) DIN EN ISO 9000 ff: 2000: Quality management systems QS 9000 3rd edition (1994): Quality Systems Requirements QS 9000 (Chrysler Corp., FORD Motor Corp., General Motors Corp.) ISO/TS 16949 (2002) Requirements for a quality management system VDA 6.1: Forderungen an ein Qualittsmanagementsystem VDA Band 6 Teil 1 (Verein der Deutschen Automobilindustrie e. V.) DIN 55350-11 (1987): Begriffe der Qualittssicherung und Statistik; Grundbegriffe der Qualittssicherung DIN: Internationales Wrterbuch der Metrologie (1994) DIN 1319-1:1995: Grundlagen der Metechnik - Teil 1: Grundbegriffe DIN EN ISO 10012 (2004): Measurement management systems Requirements for measurement processes and measurement equipment

DIN EN ISO/IEC 17025:2005 General requirements for the competence of testing and calibration laboratories (replaces EN 45000, implements ISO Guide 25) Calibration guidelines for electrical measurement equipment DIN ISO 10012-1: Measurement monitoring systems ISO 8402 (1986): Quality terminology also: DIN 55350 T 11-15, 17, 18, 21-24, 31 (Terminology) + DIN Taschenbuch 223 DKD Guidelines, miscellaneous (see also http://www.dkd.ptb.de) VDI/VDE/DGQ/DKD 2622 (draft): Kalibrieren von Messmitteln fr elektrische Gren (describes calibration procedures generally) Blatt 3: Kalibrierrichtlinien fr Digitalmultimeter Blatt 4: Kalibrierrichtlinien fr Oszilloskope Blatt 5: Funktionsgeneratoren Blatt 11: Kalibrierrichtlinien fr Spektrumanalysatoren Blatt 20: Kalibrierung von Gleichspannungsmessverstrkern DKD-R 5-5 regulates calibration of temperature indication devices DKD-R 6-1 regulates calibration of pressure measurement modules DKD-3: Specifies measurement uncertainty in calibrations DKD-4 (1991) Traceability of test equipment to national standards EA Richtlinien (European cooperation for Accreditation of Laboratories): Overview: DAR-INF2, e.g. DAR-EM6: Interne Audits und QM-Bewertung in Laboratorien DAR-EM32: Anleitung zur Akkreditierung nach ISO/IEC 17025 DAR-EM23: Sammlung von Begriffen DIN V ENV 13005: Leitfaden zur Angabe der Messunsicherheit beim Messen (identical to Guide to the expression of uncertainty in measurement = GUM)

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