Service and Calibration of Imc Devices 2006

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 µ-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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Integrated Quality Management Certified According to ISO 9001:2000 imc possesses DIN-EN-ISO-9001 certification since May, 1995. In June, 2003, the accredited TÜV CERT certification laboratory of TÜV 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 long-term 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, µ-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.



Procedure schematic: Service for imc measurement devices Step Typical “Calibration” work Additional service from imc Other available options

1. Receipt of goods/ administration

2. Performance of safety inspection as per DIN EN 61010-1

3. Calibration upon receipt and test of reproducibility of error messages

4. Repair (if appropriate)

• Update, modification, expansion (if appropriate)

• Software update (if appropriate)

5. inspection/ maintenance of adapter for AC-devices: test of voltage sustaining capability

6. Function test and adjustment (if appropriate). Adjustment of expansion cards (amplifiers, probes, conditioning boards, modem, radio clock, special functions)

7. Adjustment and calibration U, I, ICP,

if appropriate, manual adjustment / calibration of probes (U, I, Q)

8. Temperature calibration and adjustment PT100, Type K thermocouple

9. Inspection of protocol, composition of calibration certificate, archiving

10. Endurance test, e.g. 12 h

11. special tests, climate run, type inspection for customized systems, application

12. Performance of safety inspection as per DIN EN 61010-1

13. Final inspection by QS; in case of error messages: verification of maintenance. Inspection of protocol archiving, clearance for shipping

14. Shipping preparation, visual inspection of device + accessories, packaging, administration, shipping

15. 10 year protocol archiving Longer upon request protocol copies

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.



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 customer-specific 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 system’s 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 device’s 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 imc’s 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 device’s 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.



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 company’s 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 manufacturer’s 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 Meßtechnik - 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, Service_and_calibration_of_imc_devices_2006.doc; MS, 25.01.2006 Page 5 of 16


http://www.ptb.de). The foundation supporting the national standards are the seven basic SI-units and the SI-units 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 other’s 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 Rückführung im Prüfwesen” (“Guidebook on Traceability in Inspection Engineering”), in Section 3, “Instrumente der Rückführung im Prüfwesen – Kompetenznachweis - Messtechnische Rückführung auf SI-Einheiten” (excerpt):

The requirements of DIN EN ISO/IEC 17025 can be fulfilled with a certificate issued by the equipment’s 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

1 “Danach können die entsprechenden Forderungen der DIN EN ISO/IEC 17025 als erfüllt gelten, wenn [...] (3.1.3) ein Kalibrier- oder Prüfschein vom Hersteller der Mess- oder Prüfeinrichtung vorliegt, welcher die Kalibrierung und die Rückführung auf SI-Einheiten mittels dokumentiert rückgeführter Bezugsnormale im Sinne des Punktes 3.1.5 und unter Nutzung allgemein anerkannter Verfahren darlegt bzw. die Kalibrierung und die Rückführung auf SI-Einheiten durch ein kompetentes Kalibrierlaboratorium darlegt;”



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 re-calibration 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.



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 (manufacturer’s 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



Service costs – a comparison2

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

Cost of Ownership

Cost OverviewCost Overviewexample: µexample: µ--MUSYCS per deviceMUSYCS per device

CalibrationCalibration only in conjunction with SI/SRonly in conjunction with SI/SRSystem inspection (flat charge)System inspection (flat charge) € 890.€ 890.-- ((bibi)annual)annualSystem revisionSystem revision (flat charge) (flat charge) € 1290.€ 1290.-- ((tritri--,,bibi--)annual)annual

Repair (basic) Repair (basic) € 80/hr.€ 80/hr. not recommendednot recommendedRepairRepair € 80/hr. plus € 890.€ 80/hr. plus € 890.-- flat feeflat feeincl. system inspection incl. system inspection

System expansionSystem expansion € 1710.€ 1710.--incl. remodeling/system revisionincl. remodeling/system revision plus cost of partsplus cost of parts

Warrantee extension Warrantee extension € 510.€ 510.-- per yearper yearPremium Support incl. SW Premium Support incl. SW updupd.. € 1500.€ 1500.-- per yearper year


Cost of Ownership

Cost Comparison Cost Comparison Industry standard:Industry standard:

System ships with manufacturer’s certificateSystem ships with manufacturer’s certificate(Explicit protocols upon request at extra charge)(Explicit protocols upon request at extra charge)Calibration costs: € 5 to € 20 /measurement point for multiCalibration costs: € 5 to € 20 /measurement point for multi--channel systemschannel systems

µµ--MUSYCS without amplifier = 1502 test pointsMUSYCS without amplifier = 1502 test pointsSPARTANSPARTAN--L 635 test pointsL 635 test points

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

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 manufacturerAdjustment / repair separate billing 97 € / h

Competitor II Basic charge 80 €Setup time / measurement quantity 80 €Measurement point 23 €

Example: SPARTAN272 measuremepoints

nt (16 channels, voltage x 4 input ranges x 3 points, PT 100 x 2 input ranges at 2 pointsapiece temperature) 1,360

€6,256 €

(Basis 5 €)(Basis 23 €)

Price incl.minor maintenance: 620.00

€ €)These are the prices to expect from a calibration lab. Adjustment, protocols costextra

(403.00

Example: SPARTAN-L 2 x 2 current sources / bay 816 digital inputs 324 alarm outputs (closing relay) Function test instructions UPS te stDisplay Long-term test run with data recording Data recording Stand-alone mode

836

31111

91272272

Measurement pointsMeasurement pointsMeasurement pointsTest stepsFunction testsFunction test final inspection Function test final inspection Function test final inspection Function test final inspection Test points function testAdjustmentCalibration=> approx. 0.98 € / Test point Calibration, adjustment, inspection of SPARTAN-L 635

2 The price examples base on the price list for Germany.



Sample inspection plan for µ-MUSYCS (1502 test points: 0.72 EUR / test point)

ExamExamExam

DevSupply DevSupply DevSupply

FuncFuncFunc

CaliCaliCaliCaliCaliCali

CaliCaliCaliCaliCaliCali CaliCaliCaliCaliCaliCali AdjAdjAdj

AdjAdjAdj

AdjAdjAdj

TesTesTes

TesTesTes

DDD Supply SyncSupply SyncSupply Sync

LoFiLoFiLoFi

AlAlAl

CaliCaliCali

BasBasBas

ple: calibration, adjustment/calibration, inspection µ-MUSYCS-S (RJ45, AC, C32, list price 8310 €)

ice safety test upon receipt 1 function testvoltages Vcc, +/-15 V, +/-5 V, +12 V 6

tion test 1 function test

bration: TE Type K 16 pointsbration: 16 x diff 4 input ranges at 3 points apiece 192 pointsbration: 3 x ICP 2 input ranges at 3 points apiece 18 pointsbration: 2 reference channels at 12 points apiece 24 pointsbration: current source 1 pointsbration: 32 x single end 4 input ranges at 3 points apiece 384 pointsustment / calibration: 32 x single end 4 input ranges at 3 points apiece 384 points

Adjustment / calibration: 16 x diff 4 input ranges at 3 points apiece 192 pointsustment / calibration: 3 x ICP 2 input ranges at 3 points apiece 18 points

Adjustment / calibration: 2 reference channels at 12 points apiece 24 pointsustment / calibration: current source 1 points

Adjustment / calibration: TE Type K 16 points

Calibration: 8 x DAC at 3 points apiece 24 pointst: 32 x digital input 64 points

Test: 32 x digital output 64 pointst: incremental encoder interface 4 channels dual-signal, trigger bit 12 points

evice safety test: Final test 3 Test points function testvoltages Vcc, +/-15 V, +/-5 V, +12 V 6 Test points function test

-Signal 2 Test points function testng-term test run with data recording 1 Function testnal test instructions, 48 Test stepsl channels are meassured 232 Test points function test

635 Adjustment/calibration635 Calibration upon receipt

bration, adjustment, inspection µ-MUSYCS-S 1502 points

is 890 € => < 0.60 € per test point






























Cost of Ownership

Low operating costs, Low operating costs, long operating lifelong operating life

Operating costs =Operating costs =System inspectionSystem inspection every 12 every 12 -- 24 months24 months 5.9 % of purchase price*5.9 % of purchase price*System revisionSystem revision every 12 every 12 -- 36 months36 months 8.6 % of purchase price *8.6 % of purchase price *SW updateSW update as requiredas required 2.7 % of purchase price *2.7 % of purchase price *System trainingSystem training oneone--time time per userper user

Usage (Usage (hrshrs. of operation). of operation) Maximized due to reliabilityMaximized due to reliability

Life span =Life span =Operating system compatibilityOperating system compatibility all Windows versionsall Windows versionsTechnical applicabilityTechnical applicability unlimited due to unchanged measurement methodsunlimited due to unchanged measurement methodsStateState--ofof--thethe--art functionalityart functionality for years to come (innovation leader)for years to come (innovation leader)Replacement part guaranteeReplacement part guarantee 10 years 10 years Repair warranteeRepair warrantee 10 years10 years

* µ-MUSYCS mit Anschaffungspreis € 15.000.-


Cost of Ownership

Our Global Advantages TodayOur Global Advantages TodayInnovationInnovation

Continuing development of existing productsContinuing development of existing productsSpecial applications using standard systemsSpecial applications using standard systemsNo special software version No special software version –– we avoid onewe avoid one--ofof--aa--kind solutions but kind solutions but still provide solutions to onestill provide solutions to one--ofof--aa--kind applications kind applications

ResponsibilityResponsibilityUpdates ensure long life spanUpdates ensure long life spanDevice software for Device software for allall Windows versionsWindows versionsOld, new, different devices can run in concert Old, new, different devices can run in concert

Affordability (through integrated measurement engineering)Affordability (through integrated measurement engineering)Multiple devices but one software (IMC Devices, IMC COM)Multiple devices but one software (IMC Devices, IMC COM)High reliability through widespread installationHigh reliability through widespread installation



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 manufacturer’s 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 manufacturer’s 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


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 manufacturer’s specifications carried out successfully, the conformity declaration "Calibrated according to manufacturer’s specifications traceable to national standards". Any additional measurement points specially ordered by the customer must be calibrated subsequently.



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

Item Remarks

Designation Description

1 x x Goods Received intake, unpacking, recording, device intake printout

2 x x Administration Service standard records, oder clarification, record service order, check history, assign to P, order confirmation to customer

3 x x Function test (IN) determine SW, in case of repairs: replicate error (see 4)

4 x x Temperature calibration (IN) manually with ISO-thermal box, Type K thermocouple1 MP * 1 input range * 8 channels (room temperature)

5 x x Administration Service Reparatur (IN) verify faults, clarify

6 x x Calibration (IN) automated (no input needed), 840 MP

6.1 Noise test 1 (RMS) 1 MP * 13 input ranges * 8 channels = 104 MP

6.2 Noise test 2 (peak-peak) 1 MP * 13 input ranges * 8 channels = 104 measurement points

6.3 Voltage measurement 3 MP * 13 input ranges * 8 channels = 312 MP

6.4 PT100 measurement 11 MP * 8 channels = 88 MP

6.5 internal reference PT1000 4 MP

6.6 Bridge Sense 4 MP * 8 channels = 32 MP

6.7 Current measurement 4 MP * input ranges * 8 channels = 192 MP

6.8 Bridge Supply 4 MP

7 x Adjustment / calibration (OUT) automated (no input needed), 840 MP

7.1 Noise test 1 (RMS) 1 MP * 13 input ranges * 8 channels = 104 MP

7.2 Noise test 2 (peak-peak) 1 MP * 13 input ranges * 8 channels = 104 MP

7.3 Voltage measurement 3 MP * 13 input ranges * 8 channels = 312 MP

7.4 PT100 measurement 11 MP * 8 channels = 88 MP

7.5 internal reference PT1000 4 MP

7.6 Bridge Sense 4 MP * 8 channels = 32 MP

7.7 Current measurement 4 MP * input ranges * 8 channels = 192 MP

7.8 Bridge Supply 4 MP

8 x Check protocol, generate certificate electronically plausibility, check validity on server

9 x x Final inspection (OUT) manually upon instruction

9.1 Module measurement9.2 Test PT100 @ 50 °C Sensorflash

9.3 Robustness test 1 disconnect power supply 3 times, connect, test reproducibility of measurement

9.4 Sensor info Test9.5 Divider test

9.6 Robustness test 2 disconnect power supply 3 times, connect, test reproducibility of measurement

9.7 Sensor info Test9.8 Test shunt calibration

10 x Temperature calibration (OUT) manually with ISO-thermal box, Type K thermocouple1 MP * 1 input range * 8 channels (room temperature)

11 x x Document results, label module

File service documents, print certificate, inspection markrt on the module

12 x Print protocol and certificate per ISO17025 optional

13 x Recording of time and materials, file and edit device intake document

14 x x Complete service documents Inspect documents, file in inforunder Service, edit device intake document

15 x Extended protocol set Inspect plausibility, adaptation to customer wishes

16 x Shipping preparation / shipping Shipping documents, packaging, shipping

17 x Wrap-up Conclude procedures, statistics

18 x Data administration Statistics, reports, archiving

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Synopsis: Maintenance – Calibration – Inspection – Repair – System Revision


Cost of Ownership

Maintenance WorkMaintenance WorkDefinitionsDefinitions

1.) Calibration1.) Calibration: : 2.) Inspection2.) Inspection3.) Revision3.) Revision4.) Repair, Remodeling, Update4.) Repair, Remodeling, Update

To date:To date: IMC calibration = 1 + 2 +(sometimes) 3 IMC calibration = 1 + 2 +(sometimes) 3

Now:Now: SystemSystem--inspection or Revisioninspection or Revision

1 can be done by anybody, 1 can be done by anybody, 2 2 –– 4 only the manufacturer imc4 only the manufacturer imc


Cost of Ownership

System CalibrationSystem CalibrationComparison with a reference having the same unitsComparison with a reference having the same unitsCalibration means certificate of Calibration means certificate of traceability traceability Only valid at the time performedOnly valid at the time performedReRe--calibration appointment the user’s responsibilitycalibration appointment the user’s responsibilityUser must monitor interval between calibrationsUser must monitor interval between calibrations

We recommend:We recommend:Calibration interval of 1Calibration interval of 1--2 years2 years

Who can perform calibration?Who can perform calibration?Any calibration laboratoryAny calibration laboratory

Usually in accordance with DIN EN ISO/IEC 17025Usually in accordance with DIN EN ISO/IEC 17025


Cost of Ownership

System InspectionSystem InspectionCalibration of inputsCalibration of inputsMaintenance (repair if appropriate)Maintenance (repair if appropriate)AdjustmentAdjustmentFunction testFunction testFinal inspection incl. Calibration of outputsFinal inspection incl. Calibration of outputsShipping with manufacturer’s calibration certificate and serviceShipping with manufacturer’s calibration certificate and service

reportreportProtocol of data for each channel and input range offered for exProtocol of data for each channel and input range offered for extra chargetra charge

Inspection only performed by imcInspection only performed by imcRecommended at 12 Recommended at 12 -- 24 month intervals24 month intervals


Cost of Ownership System RevisionSystem RevisionInspection plus System UpdateInspection plus System Update

Bringing systems up to dateBringing systems up to date

Benefits of further developmentsBenefits of further developments

Extends system life spanExtends system life span

Revision only performed by imcRevision only performed by imcRecommended at 12 Recommended at 12 -- 36 month intervals36 month intervals


Cost of Ownership

RepairsRepairsRepair (basic) Repair (basic) (not recommended)(not recommended)Test for reproducibility of error message and repairFunction test of overall system (incomplete)Calibration history is lost

Repair incl. System InspectionRepair incl. System Inspection (recommended)(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 rangesOverall system inspection Maintenance work (if appropriate)Function test of overall system Final inspection and calibration protocol compositionShipping with manufacturer’s calibration certificate and service report


Cost of Ownership

Why perform a system inspection Why perform a system inspection (former calibration)(former calibration)with every repair orderwith every repair order

The device returns to the user in reliable working conditionThe device returns to the user in reliable working condition

Calibration history not lostCalibration history not lost

Best, most reliable 100% function test (even finds hidden errorsBest, most reliable 100% function test (even finds hidden errors))Fault remedy/ component replacement often necessitates readjustmFault remedy/ component replacement often necessitates readjustment, anywayent, anyway

Example: an adapter defect is reported. Example: an adapter defect is reported. Error profile: defective input channels strain the adapter. Error profile: defective input channels strain the adapter.

Also: DAC (analog outputs) Channel 2 defective.Also: DAC (analog outputs) Channel 2 defective.



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.



Contacts You’re welcome @ http://www.imc-berlin.de/en

imc Meßsysteme GmbH integrated measurement & control Quality Assurance Voltastraße 5 D-13355 Berlin

hotline Tel.: +49-(0)30-467090-26 Fax: +49-(0)30-467090-22 email: [email protected] Internet: http://www.imc-berlin.de

Additive GmbH Tel.: +49 (0) 641 5905-0 email: [email protected] 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 you’re 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 Qualitätsmanagementsystem

VDA Band 6 Teil 1 (Verein der Deutschen Automobilindustrie e. V.) • DIN 55350-11 (1987): Begriffe der Qualitätssicherung und Statistik;

Grundbegriffe der Qualitätssicherung • DIN: Internationales Wörterbuch der Metrologie (1994) • DIN 1319-1:1995: Grundlagen der Meßtechnik - 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 für elektrische Größen

(describes calibration procedures generally) Blatt 3: Kalibrierrichtlinien für Digitalmultimeter Blatt 4: Kalibrierrichtlinien für Oszilloskope Blatt 5: Funktionsgeneratoren Blatt 11: Kalibrierrichtlinien für Spektrumanalysatoren Blatt 20: Kalibrierung von Gleichspannungsmessverstärkern

• 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)


Service and Calibration of Imc Devices 2006

Documents

grundlagen

sample inspection

test equipment

term test

dkd calibration

additional

manufacturers

imc manufacturers