ATEQ G520 User manual

USER MANUAL
ATEQ G520
Version 1.03
(Photo non contractual)
Reference: UM-19700E-U

REVISIONS OF THE ATEQ G520 USER MANUAL
Edition/Revision Reference Date
week/year Chapters updated
First edition UM-19700A-U 28/2002 -
Second edition UM-19700B-U 04/2004 Evolution of the program from version
1.01 to 1.02 (temperature correction).
Third edition UM-19700C-U 06/2005
Replace LEAK TEST text by FLOW
TEST text on all displays, chapter 3. Add
test output on chapter 1.
Fourth edition UM-19700D-U 24/2005
Up dating the measurements
characteristics in the preamble. Program
evolution to the 1.03 version. Differential
sensor coefficient adjustable in the line
production. Functioning identical to the
1.02 version. Add cut and external dump
valves options in the chapter 5.
Fifth edition UM-19700E-U 05/2006 Up dating the measurements
characteristics in the preamble.

Recommendations for leak testing
instruments
0039/Ret-U
Precautions for the test environment
•Keep the test area as clean as possible.
Precautions for the operators
•ATEQ recommends that the operators using the instruments should have a
suitable qualification and training with respect to the work bench requirements.
General precautions
•Read the user manual before using the instrument,
•all electrical connections to the instrument must be equipped with a safety
system (fuse, circuit breaker…) appropriate to its needs and complying with the
standards,
•to avoid electromagnetic interference, the cable connections to the instrument
should be less than two meters in length,
•it is essential that the electrical main is earthed,
•disconnect the electrical connections to the equipment before maintenance,
•cut the air supply for any kinds of operation on the pneumatic assembly,
•do not open the instrument when it is powered up,
•avoid water spillage near of the instrument,
•ATEQ is at your disposal for any further information concerning the use of the
instrument under maximum safety conditions.
We would like to bring to your attention that ATEQ will not be held responsible
for any accident connected to the improper use of the instrument, to the work
bench or to the lack of compliance with safety rules.
ATEQ Company is free from any responsibility for any adjustment of its
instrument which would not have been done by its own technicians.

SAV-Ub/0243
ATEQ, THE ASSURANCE OF A COMPETENT AFTER SALES
SERVICE
THE ATEQ AFTER SALES SERVICE IS :
•a team of qualified technicians,
•a permanent telephone assistance,
•agencies close to you for faster reaction,
•a stock of spare parts available immediately,
•a car fleet for rapid intervention,
•a commitment to quality ...
THE OVERHAUL
ATEQ carries out the overhaul of your instruments at interesting prices.
The overhaul corresponds to the maintenance of the instrument (checking, cleaning, replacing of used
parts) as part of preventive maintenance.
Preventive maintenance is the best way to guarantee reliability and efficiency. It allows the
maintenance of a group of instruments in good operational order and prevent eventual break-downs.
MAINTENANCE KITS
The ATEQ After Sales Service proposes, two kits destined for the preventive maintenance of the
pneumatic circuits of instruments.
CALIBRATION
This may be carried out on site or in our offices.
ATEQ is attached to the COFRAC and delivers a certificate following a calibration.
TRAINING COURSES
In the framework of partnership with our customers, ATEQ offers two types of training in order to
optimise the usage and knowledge of our instruments. They are aimed at different levels of technician:
•method / control training,
•maintenance / upkeep training.
A TARGETED TECHNICAL DOCUMENTATION
A number of technical documents are at your disposal to allow you to intervene rapidly in the event
minor breakdowns:
•problem sheets describing and offering solutions to the main pneumatic and electronic
problems,
•several maintenance manuals.
A QUALITY GUARANTEE
The instruments are guaranteed for parts and labour in our offices:
•2 years for leak detection equipment,
•1 year for electrical tests to norms instruments,
•1 year for the accessories.
Our After Sales Service is capable of rapidly answering all your needs and queries.
ATEQ recommends
to made realise by its departments
a revision and a calibration of the instruments
every year

0508/PREFc-U
PREFACE
Dear Customer,
You have just purchased an ATEQ instrument, we thank you for the trust you have
placed on our brand. This instrument has been designed to ensure a long and
unparalleled life expectancy, and we are convinced that it will give you complete
satisfaction during many long years of operation.
In order to maximise the life expectancy and reliability of your ATEQ instrument, we
recommend that you install this instrument on a secured workbench and advise you to
consult this manual in order to familiarise yourself with the functions and capabilities of
the instrument.
Our ATEQ After Sales Service centre can give you recommendations based on your
specific operation requirements.
ATEQ

Table of contents
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TABLE OF CONTENTS
Preamble DEFINITION AND PRINCIPLES OF THE G520
1. DEFINITION .........................................................................................................................................5
2. CHARACTERISTICS MEASUREMENT..............................................................................................6
2.1. Flow measurement.......................................................................................................................6
2.2. Pressure measurement................................................................................................................6
2.3. Mechanical pressure regulation ...................................................................................................6
3. OPERATIONAL CHARACTERISTICS................................................................................................7
4. PRESENTATION OF THE SYMBOLS ................................................................................................8
Chapter 1 INSTALLATION OF THE INSTRUMENT
1. APPEARANCE OF THE ATEQ G520 ...............................................................................................11
1.1. Layout of connectors on the G520 rear panel............................................................................12
1.2. Connector details .......................................................................................................................12
1.2.1. Electrical connectors ...................................................................................................................... 12
1.2.2. Pneumatic connectors .................................................................................................................... 17
1.2.3. Pneumatic test output ..................................................................................................................... 17
Chapter 2 USER INTERFACES
1. ATEQ G520 FRONT PANEL APPEARANCE...................................................................................19
2. APPEARANCE OF THE KEYBOARD ..............................................................................................20
2.1. Navigation keys..........................................................................................................................20
2.2. Cycle keys ..................................................................................................................................20
3. LOCKABLE SWITCH ........................................................................................................................21
4. INFRA-RED INTERFACE ..................................................................................................................21
5. 4 LINE LCD DISPLAY .......................................................................................................................21
6. FUNCTIONS OF THE INDICATOR LIGHTS.....................................................................................22
Chapter 3 INSTALLATION AND SETTINGS
1. POWERING UP THE ATEQ G520 ....................................................................................................23
2. CREATION OF A TEST PROGRAM.................................................................................................23
2.1. Choice of the program number ..................................................................................................24
2.2. Test type selection .....................................................................................................................24
2.2.1. Flow test ......................................................................................................................................... 24
2.2.2. Operator mode test......................................................................................................................... 24
2.3. Parameter settings .....................................................................................................................25
2.3.1. Coupling time.................................................................................................................................. 26
2.3.2. Fill time ........................................................................................................................................... 26
2.3.3. Stabilization time ............................................................................................................................ 27
2.3.4. Test time......................................................................................................................................... 27
2.3.5. Pressure units................................................................................................................................. 27
2.3.6. Set pressure ................................................................................................................................... 28
2.3.7. Maximum fill.................................................................................................................................... 28
2.3.8. Minimum fill..................................................................................................................................... 28
2.3.9. Test pressure adjustment ............................................................................................................... 28
2.3.10. Reject unit..................................................................................................................................... 28
2.3.11. Volume ......................................................................................................................................... 29
2.3.12. Test reject..................................................................................................................................... 29
2.3.13. Functions ...................................................................................................................................... 29
3. DUPLICATION OF A TEST PROGRAM ...........................................................................................30
4. DELETING A PROGRAM OR A PROGRAM NAME ........................................................................31
5. CHOICE OF THE PROGRAM TO BE RUN ......................................................................................32
6. STARTING A MEASUREMENT CYCLE...........................................................................................32
7. STOPPING A CYCLE ........................................................................................................................32

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Chapter 4 FUNCTIONS OF THE INSTRUMENT
1. MENU STRUCTURE..........................................................................................................................33
1.1. Main menu..................................................................................................................................33
1.2. "FUNCTIONS" menu when activated.........................................................................................37
2. CONFIGURATION MENU .................................................................................................................39
2.1. Extended menus ........................................................................................................................39
2.1.1. Activation of the additional functions .............................................................................................. 39
2.1.2. Setting the additional functions....................................................................................................... 40
2.1.3. List of additional functions .............................................................................................................. 40
2.2. Automatic save...........................................................................................................................52
2.3. Piezo auto zero ..........................................................................................................................52
2.4. Bar Graph...................................................................................................................................53
2.5. Hour............................................................................................................................................53
2.6. RS232 ........................................................................................................................................53
2.6.1. C540/580 ........................................................................................................................................ 53
2.6.2. Printer ............................................................................................................................................. 53
2.6.3. Modbus........................................................................................................................................... 57
2.7. RS485 ........................................................................................................................................58
2.7.1. C540/580 ........................................................................................................................................ 58
2.7.2. Modbus........................................................................................................................................... 58
2.8. Security ......................................................................................................................................58
2.9. Lighting the screen.....................................................................................................................58
2.10. External dump option ...............................................................................................................59
2.11. Shut off (option)........................................................................................................................60
2.12. Negative flow alarm..................................................................................................................61
2.13. I/O configuration.......................................................................................................................61
3. SPECIAL CYCLES MENU.................................................................................................................62
3.1. Special cycles available .............................................................................................................62
3.2. Volume calculation .....................................................................................................................63
3.3. Infinite fill ....................................................................................................................................64
3.4. Piezo auto zero ..........................................................................................................................65
3.5. Print ............................................................................................................................................66
3.6. Atmospherics conditions ............................................................................................................66
4. SERVICE MENU ................................................................................................................................67
4.1. Parameters service ....................................................................................................................67
4.2. Servicing of the sensors.............................................................................................................68
5. RESULTS MENU ...............................................................................................................................69
6. LANGUAGE MENU ...........................................................................................................................69
7. STAND BY MENU .............................................................................................................................69
7.1. Standby using the menu ............................................................................................................70
Chapter 5 ACCESSORIES
1. ACCESSORIES SUPPLIED WITH THE INSTRUMENT...................................................................71
1.1. Power supply..............................................................................................................................71
2. OPTIONAL ACCESSORIES..............................................................................................................72
2.1. Calibrated leak ...........................................................................................................................72
2.2. Needle valve and Leak/Flow Calibrator (CDF) ..........................................................................73
2.2.1. Needle valve................................................................................................................................... 73
2.2.2. CDF (Leak/flow Calibrator) ............................................................................................................. 73
2.3. Automatic connectors with expandable joints ............................................................................74
2.3.1. Operation........................................................................................................................................ 74
2.3.2. Standard dimensions ...................................................................................................................... 74
2.4. Filtration kit .................................................................................................................................74
2.5. Simple remote control ................................................................................................................75
2.5.1. Casing reset/start ........................................................................................................................... 75
2.5.2. S5 four-function remote control ...................................................................................................... 75
2.6. External shut off valve option .....................................................................................................76
2.7. External dump valve and shut off function .................................................................................76

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Chapter 6 ERROR MESSAGES
ERROR MESSAGES ....................................................................................................77
Chapter 7 OPERATIONAL PROBLEMS
1. PHENOMENON NOTED....................................................................................................................79
1.1. Condition of the machine's seals ...............................................................................................79
1.2. Damaged instrument seals ........................................................................................................79
1.3. Bumper pad................................................................................................................................79
1.4. Pneumatic air supply too low .....................................................................................................79
1.5. Pneumatic Link...........................................................................................................................79
1.6. Environment ...............................................................................................................................80
1.7. Calibration ..................................................................................................................................80
1.8. Concerns about reliability of the instrument’s circuits................................................................80
Appendices ATEQ G520
1. TECHNICAL CHARACTERISTICS OF THE G520...........................................................................81
2. MECHANICAL DEFINITION DRAWINGS OF G520.........................................................................82
3. CONVERSION TABLE ......................................................................................................................83
4. PARAMETERS STORED ..................................................................................................................84
5. VALVES CODES USED IN YOUR APPLICATION ..........................................................................85
6. USER NOTES ....................................................................................................................................86
Index 87

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Preamble – Definition and principles of the ATEQ G520
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Preamble
DEFINITION AND PRINCIPLES OF THE G520
1. DEFINITION
The ATEQ G520 is the latest air/air leak detector operating on a continuous basis
(automatic test start).
The instrument has been designed to test low pressure components and assemblies
(less than 500 mbar) and more particularly gas applications in compliance with
European standards, but it can also work with high pressure.
The use of continuous testing may allow the localisation and repair of leaks.
The instrument may also operate in "controlled" mode, a mode which is advantageous
for certain applications, with pre-fill or rapid fill or on automatic workbenches.
Compressed
air supply
Absolute pressure
sensor
Calibrated flow tube
Regulator
Internal
reserve
Differential
transducer
Flow
∆P
Temperature
sensor
Test
part
Test volume
lower than four
times the
volume of the
internal reserve
The ATEQ G520 includes:
a pneumatic assembly allowing:
•the pressurisation of the test part and the reserve through the use of a
regulator,
•the measurement of the leak flow image with a differential transducer
placed on the end of a calibrated flow tube,
•the monitoring of the test pressure with a piezo sensor acting as a
pressure controller,
•the temperature measurement of the calibrated flow tube to correct the
measured flow,
a programmable electronic board allowing:
•the saving of all the cycle adjustments,
•the calculation, display and transmission of the test results.

Preamble – Definition and principles of the ATEQ G520
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2. CHARACTERISTICS MEASUREMENT
2.1. FLOW MEASUREMENT
RANGE ACCURACY Maximum
RESOLUTION
100 cm3.atm/h +/- (3,5% of the flow + 0,5 ml/h) 0,1 cm3.atm/h
1000 cm3.atm/h +/- (3,5% of the flow + 5 ml/h) 1 cm3.atm/h
2.2. PRESSURE MEASUREMENT
The characteristics are common for all the 5th series instruments.
RANGE ACCURACY Maximum
RESOLUTION
F. S. = 7,5 kPa*
(F. S. = 75 mbar*) +/- (1,5% of the pressure + 0,2 hPa) 0,1 % F. S.
F. S. < 30 kPa
(F. S. < 0,3 bar) +/- (1,5% of the pressure + 1 hPa) 0,1 % F. S.
30 ≤F. S. ≤100 kPa
(0,3 ≤F. S. ≤1 bar) +/- (1,5% of the pressure + 3 hPa) 0,1 % F. S.
100 ≤F. S. ≤1000 kPa
(1 < F. S. ≤10 bar) +/- (1,5% of the pressure + 7.5 hPa) 0,1 % F. S.
* Specific (relative)
G 5th series pressure range
5 – 50 kPa 50 – 400 kPa
2.3. MECHANICAL PRESSURE REGULATION
5 kPa to 50 kPa / 50 kPa to 400 kPa

Preamble – Definition and principles of the ATEQ G520
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3. OPERATIONAL CHARACTERISTICS
The ATEQ G520 carries out a pressure measurement on the ends of calibrated flow
tubes connecting the test part and the internal instrument reference part (reserve) which
have been previously equalised at the same pressure.
The measurement is displayed in ml/minute or in ml/hour returned to atmospheric
pressure.
The flow measurement is dependant on a certain number of parameters: test pressure,
the volume of the part to be tested, the volume of the reference. Additionally, it is
necessary to optimise a number of adjustments (timings). We have strived towards the
production of a user friendly instrument, that is why a few adjustments are not
accessible to the operator. These are set in the factory depending on a customers’
required specifications.
It's also possible to work in standard conditions mode.

Preamble – Definition and principles of the ATEQ G520
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4. PRESENTATION OF THE SYMBOLS
Symbol Name Function
Adjust leak
connector
Pneumatic connector for the plugging of a calibrated leak
(ruby kind) or an adjustable leak.
Pressure
connector
Pneumatic connector for the plugging of a manometer for an
external checking of the pressure.
Pressure
supply of the air supply from the 6 bar network.
Test circuit
supply
Pneumatic connector (according to option) for the plugging
of a supplementary pneumatic supply, used in case of test
pressure greater than 8 bar.
Ground
connector Connector for the electric plugging to the ground.
Automatic
connector
Pneumatic connector for the driving of an external logic or
pneumatic components (pneumatic sealing connector).
Connector Connector for pneumatic output.
Connector Connector for pneumatic input.
!
Warning! Read and respect the instructions of the user manual,
before plugging and using the instrument.
Remote
control Connector for a remote control.
Printer Connector for printer plugging.

Preamble – Definition and principles of the ATEQ G520
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Symbol Name Function
Bar code
reader Connector for bar code reader plugging.
Output Dry contact output.
Input Dry contact input.
Infrared link Infrared link, at this place there's the receiver and
transmitter of the infrared link.
Analogue
output Analogue output.
Analogue
input Analogue input for the temperature sensor.

Preamble – Definition and principles of the ATEQ G520
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