The 3rd generation water jacket testing systems

The new 3rd generation water jacket testing systems sign out through extremely quick and highly accurate measurement result, as well as many further optimizations. This is amongst other things achieved using highly modern PLC-Components. Depending on the version and features, the test process is carried semi-automatically or fully automatically.

Global data of the 3rd generation water jacket testing systems

  • Test basin sizes according to customer wishes 2, 6, 6.8 und 9 litre bottles
  • Test duration of two 6.8 litre cylinders in under 4 minutes
  • Cylinder specific changeable and thermodynamic isolated basins for the minimization of temperature affects, which will affect the measurement results
  • According to the configuration of the test basins it is possible to test two composite cylinders of the same or different size at the same time
  • Modular built (technical unit and test unit), gradually expandable by two basins if necessary
  • determination of the volumetric extension in ml respectively tenth ml
  • Test pressure up to 450 bar (600 bar optional)
  • Modules executed in stainless steel/alloy/polyamide
  • Measurement data recording and machine control by PLC
  • Controlled via Windows© Touch Panel Industrial PC
  • Optional voice guidance for the test process and results
  • Software side visualisation of the test process
  • Multilingualism “German“ “English“ and “Polish“ further languages possible by agreement
  • Local database for the management of gas cylinders (customer specifications possible)
  • Possible connection to a central gas cylinder database (optional)
  • Cylinder labelling and input via barcode label and barcode scanner (optional)
  • Customizable selective test/result report (selection by customer, day, etc.)
  • Remote maintenance possibility for the systems via RJ45
  • Mechanical & software-based security features
  • Connect a calibrateable scale to determine the weight of the cylinders
  • Extensible and customizable hardware & software
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Processvisualisation of the Waterjacket3.0 with factory data capture

  • Visualisation of the current pressure
  • Course of the pressure covering the whole testprocess
  • All Bottledata at a glance
  • Showing all machinestates (Airpressure, Pressure on pneumatic hoses, Bottlepositions etc.)
  • All facory Data of each and every Test is saved and can be viewed at any given time
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WaterJacket 3.0 Basic Version

[Partially automated]

The Basic3.0 variant offers quick and efficient handling of the testprocedure, while maintaining high meas-urement quality and speed. After inputting the bottle data on the industrial PC, the composite cylinders which were previously filled with water and provided with a test adapter are inserted directly into the test tanks. Locking grooves inside the test adapter make it easier to insert and adjust / lock / secure the cylinders during the test process.

After initiating the test process on the PC, the basins get levelled and zeroed. The system builds up the operating pressure and determines the expansion of the cylinders. Thereafter the procedure is repeated with the test pressure instead. After completing these steps, the pressure has to be released and the percentual lasting expansion related to the expansion under test pressure is determined. The whole Process runs automated, only the release of the pressure has to be done by hand.

The test results and the expansion values are automatically saved to a database. The test report can be saved on a network storage or handed over to a printer.

Further characteristic of the basic version:

  • Control by mobile device e.g. tablet pc is possible (optional)
  • System can also be used with an existing pressure generator
  • Soft start of the high-pressure pump during pressure build-up to increase the lifetime
  • Possible additional parameterization of boundary conditions (temperature influences/footprint)
    •
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    WaterJacket 3.0 Basic Demo Video

    [Partially automated] Video is outdated and will be updated soon. Test Procedure (except Release of Pressure) is now fully automated on the Basic Version

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    WaterJacket 3.0 Professional Version

    [Fully automated]

    The professional3.0 variant is the first water jacket test system working fully automated.

    After entering the cylinder data, mounting the already water filled basins and connecting all test pipes, the whole test process will be done fully automated.

    After initiating the test process on the PC, the cylinders will be lowered by pneumatic cylinders down into the basins. As soon as the pneumatic cylinders reach their end position, the basins get levelled and zeroed. The system builds up the operating pressure and determines the expansion of the cylinders. Thereafter the proce-dure is repeated with the test pressure instead. After completing these steps, the pressure is released and the percentual lasting expansion related to the expan-sion under test pressure is determined. Finally, the test process end by returning the cylinders back to their start position

    During the whole test, the process is visualized on the PC screen. Additional, audio feedback for e.g., safety instructions, process results, or other relevant infor-mation are also possible.

    Test data and results are automatically saved to a data-base. Test reports can be saved on a network storage handed over to a printer.

    Further characteristic of the professional version:

    • Control by mobile device e.g. tablet pc is possible (optional)
    • Characteristic controlled pressurizing for a standard-compliant pressure increase and an increase in the pump lifespan
    • Water-tank to decouple high-pressure pump from water network
    • Possible additional parameterization of boundary conditions (temperature influences/footprint)
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    WaterJacket 3.0 Professional Demo Video

    [Fully automated]

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    WATER JACKET3.0 PROFESSIONAL VERSION

    The water jacket testing systems are used for the extended hydrotesting. The compressed gas cylinders are not only subjected to operating- and testpressure (pressure test), but it also expands the compressed gas cylinders at operating pressure, test pressure and the percentage expansion after relief determined. The extent is determined via the displacement in a water jacket.

    The limit values are based on the test standards:

    Area Norm
    Germany DIN EN ISO 11623:2018-01
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    Technical specifications:

    WJ Basic 3.0 WJ Professional 3.0
    Operating Voltage 230V AC 230V AC
    Air Pressure max. 10 bar max. 10 bar
    Water Pressure max. 2 bar max. 2 bar
    Humidity 40% - 60% 40% - 60%
    Ambient Temperature 21-23°C (69,8-73,4°F) 21-23°C (69,8-73,4°F)
    Max. Test Pressure 450 bar (600 bar opt.) 450 bar (600 bar opt.)
    Softstart High Pressure Pump Mechanically Characteristic Controlled
    Dimension (Technology Module) BxTxH: 0,4m x 0,6m x 1,9m BxTxH: 0,6m x 0,6m x 1,85m
    Dimensions (Pool Module) BxTxH: 1,2m x 0,6m x 1,21m BxTxH: 1,2m x 0,6m x 1,85m
    Overall Dimensions BxTxH: 1,8m x 0,6m x 1,0m BxTxH: 1,8m x 0,6m x 1,85m
    Exchangeable Test Basins ✔ ✔
    External pressure generator can be used ✔ ✘
    Modularly expandable (2 pools each) ✔ ✔
    Water-Tank ✘ ✔
    Water-Filter ✔ ✔
    Cylinders entering the test basin Manually Automatically
    Pressurizing of operating and test pressure Manually Automatically
    Pressure-depleting of test pressure Manually Automatically
    Control PC Industrial PC (Win10) Industrial PC (Win10)
    Remote Control Tablet/Pad (Optional) Tablet/Pad (Optional)
    Multilingual software ✔ ✔
    Voice Guidance Optional ✔
    Data recording of the extension SQL-Database (internal/external) SQL-Database (internal/external)
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    Services and Machines for your Breathing Air Workshop

    Our goal is to bring all the necessary equipment for a breathing air workshop up to the latest modern standards. This means automation, measurement accuracy, minimization of human errors as well as easy handling and work simplification.

    Our current Machines ans Services

    • Upgrades of existing waterjackets (automation of the test process, documentation of the test)
    • Upgrades of analog Hydrotest to automated
    • A Valve Screwing Machine
    • Weight Control System (as standalone or also as integration into the Waterjacket
    • Individual PLC & machine solutions
    • Extensions and adaptations to our existing systems according to your wishes. Would you like to have 4 basins in the Waterjacket instead of 2? Do you want to test larger bottles than 9 liters? Would you like to test larger bottles than 9 liters? We are there for you.

    Our current Project: A Waterjack3.0 / Hydrotest standard combination system.

    For more information you can contact us at any time.