ATEQ Hydra Silver Owner's manual

Hydra Silver
Four Channel Leak Testing System
Owner/Operator Manual
Reference: LHYS40101-R00

Front Inside Cover

Hydra Silver
Owner/Operator Manual
Foreword
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Copyright Information
The owner or authorized user of a valid copy of the product(s) supported by this Manual may
reproduce this publication only for the purpose of learning to use such product(s). No part of
this publication may be reproduced or transmitted for any other purpose, such as selling copies
of this publication or providing paid-for support services.
The information contained within this Manual is supplied purely for information purposes, and
can be changed at any time without need for prior consultation or warning. A complete
Document Revision History is provided at the end of this Manual (page 176).
© 2015 ATEQ Corp. All Rights Reserved.
Product Certification & Product Safety Requirements
Before installing this product, applying power to the product, or performing any type of service
upon the product that involves accessing internal components, you must first read all content
in Chapter 3 (Product Safety Requirements) beginning on page 23.
Failure to do so, may result in personal injury and/or product damage, and in most cases will
void any warranty associated with this product.
ATEQ Contact Information
USA, North America:
35980 Industrial Rd., Livonia, MI 48150
Phone:
Fax:
734-838-3100
734-838-0644
Sales (Email):
[email protected]om
Service (Ticket):
www.atequsa.com/tech-support/
Web Site:
Global Web Site:
www.atequsa.com
www.ateq.com
Business
Hours:
Monday
Tuesday
Wednesday
Thursday
Friday
(Eastern Standard Time)
8:00 AM - 5:00 PM
8:00 AM - 5:00 PM
8:00 AM - 5:00 PM
8:00 AM - 5:00 PM
8:00 AM - 5:00 PM

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Owner/Operator Manual
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WinAteq 300 Software Copyright Information
The WinAteq 300 software installed on the instrument(s) described in this Manual is the
exclusive property of ATEQ Corp., and may only be used in conjunction with the operation of
the instrument(s) described in this Manual.
However, the Owner of the instrument(s) and the authorized representatives of the Owner are
permitted to make a single safety back-up of the software as part of a safety backup of the
entire hard magnetic disk of the computer onboard the instrument(s) described in this Manual.
All other copies of the WinAteq 300 software installed on the instrument(s) described in this
Manual are prohibited, regardless of method.
Lending, loaning, reproduction, even partial, diffusion to a third party, as well as any and all
software modifications are not allowed without the expressed written consent of ATEQ Corp.
WinAteq 300 Software © 2015 ATEQ Corp. All Rights Reserved.

Hydra Silver
Owner/Operator Manual
Foreword
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PREFACE
Dear Customer,
You have just purchased an ATEQ instrument, and we thank you for the trust you have placed
in 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 maximize 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 familiarize yourself with the functions and capabilities of the instrument.
Our ATEQ Service Center can give you recommendations based upon your specific operations
requirements.
ATEQ Corp.

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Owner/Operator Manual
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Owner/Operator Manual
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Table of Contents
Chapter 1 INTRODUCTION ..........................................................................................13
1.1 Scope of this Manual....................................................................................13
1.2 Types of Alert Messages that may appear in this Manual.................................13
1.3 PRODUCT SUMMARY ...................................................................................14
1.4 Product Specifications & Identification Labeling..............................................16
1.5 Additional Product Labeling ..........................................................................16
1.6 Symbols used in this Manual.........................................................................17
Chapter 2 PRODUCT OVERVIEW ..................................................................................19
2.1 Hydra Silver Capabilities...............................................................................19
2.2 Hydra Silver Features...................................................................................19
2.3 Hydra Silver Leak Test Measurement Ranges .................................................19
2.4 Exterior Component Summary ......................................................................20
Chapter 3 PRODUCT SAFETY REQUIREMENTS .....................................23
3.1 Owner Responsibility....................................................................................23
3.2 ATEQ USA Safety Support ............................................................................23
3.3 Electrical Safety...........................................................................................24
3.4 Static Discharge and Electromagnetic Interference .........................................24
3.5 Testing Environment and Operational Safety..................................................25
3.6 Hydra Silver Clean/Dry Air Requirements .......................................................26
3.7 Required Competence..................................................................................26
Chapter 4 ONBOARD COMPUTER SYSTEM OVERVIEW ...................................................27
4.1 Onboard Computer with Touchscreen Monitor................................................27
4.2 Windows Operating System for Touchscreen Monitor Access ...........................28
4.3 Recommendations for using Windows on the Touchscreen..............................29
4.4 WinAteq 300 Software Overview and Major Screen Elements ..........................30
4.5 Major Function Sets available via the WinAteq 300 Software ...........................32
4.6 Optional External USB Devices for use with the Computer System ...................36

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Chapter 5 PRODUCT TECHNICAL DESCRIPTION............................................................37
5.1 Leak Test Channel Communications & Control Modes .....................................37
5.2 Leak Test Channel Components ....................................................................38
5.3 Pressure Measurement Methods supported by the Hydra Silver .......................40
5.4 Direct Pressure Decay Measurement Method..................................................40
5.5 Indirect Pressure Decay Measurement Method ...............................................40
5.6 Leak Test Cycle Stages for Direct Pressure Decay Measurement ......................41
Chapter 6 INSTALLATION PROCEDURES.......................................................................43
6.1 Hydra Silver Basic Environmental & Operational Requirements ........................43
6.2 Hydra Silver Test Area Requirements ............................................................43
6.3 Hydra Silver Clean/Dry Air Requirements .......................................................44
6.4 Hydra Silver Basic Installation and Initial Startup............................................46
6.5 Connecting a Clean/Dry “Test Air” Supply to the Hydra Silver ..........................50
Chapter 7 INSTRUMENT STARTUP / OPERATIONS / SHUT-OFF ......................................53
7.1 Key Operational Basics about the Hydra Silver Instrument ..............................53
7.2 Instrument Power Up and Computer System Startup ......................................54
7.3 What to Do when the Computer will NOT Power Up .......................................57
7.4 How to Regulate Test Air Pressure ................................................................58
7.5 How to Quickly Set a Specific Test Air Pressure ..............................................59
7.6 Leak “Test Cycle” Stages..............................................................................62
7.7 Leak “Test Cycle” Status Indicators on Front Panels........................................64
7.8 How to Run and Monitor a “Test Cycle” .........................................................65
7.9 Instrument Shut Down and Complete Power Off ............................................70
Chapter 8 TEST CHANNEL SETUP / TEST PART CONNECTION ........................................75
8.1 Summary of this Task ..................................................................................75
8.2 Prerequisite Tasks .......................................................................................75
8.3 Configure ONE Leak Test PROGRAM for the Leak Test Channel. ......................76
8.4 Connect a “Test Part” to the Leak Test Channel .............................................78
8.5 Configure & Test additional Parameter Programs for this Channel....................80
8.6 Saving the Results of your Leak Channel Tests...............................................82
8.7 Saving your Program-Channel Assignments and Configurations .......................83

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8.8 [OPTIONAL] Connect a Device to the Channel’s 16-Pin I/O Port .....................84
8.9 [OPTIONAL] Connect a Device to the Channel’s RS-232 Port ..........................86
8.10 [OPTIONAL] Re-Test Channel after External Device Installs............................88
Chapter 9 LEAK TEST CHANNEL CALIBRATION .............................................................91
9.1 Calibrated Leak Tools...................................................................................91
9.2 Calibrated Leak Pressure/Leak Rate Specifications..........................................92
9.3 Establishing a “Baseline” between Pressure Drop and Flow Rate......................93
9.4 Running Tests on a Leak Test Channel using a Calibrated Leak .......................94
Chapter 10 WINATEQ 300 S/W “PARAMETERS” FUNCTION SET .......................................97
10.1 Access to this Function Set ...........................................................................97
10.2 “Parameters” Function Set and User Interface................................................98
10.3 Leak Test Program PARAMETERS Defined [Basic Settings] ........................100
10.4 ADVANCED Program PARAMETERS Defined .................................................103
10.5 Creating a completely New Parameters Program ..........................................106
10.6 Using an existing Parameters Program to create a New Program ...................108
10.7 How to Edit Leak Test Program Parameter Values ........................................112
10.8 Running a Test Cycle per the Configured Parameters Program ......................115
10.9 Additional Functions available via the “Parameters” Toolbar ..........................116
Chapter 11 WINATEQ 300 S/W “CYCLE” FUNCTION SET................................................117
11.1 Access to this Function Set .........................................................................117
11.2 “Cycle” Function Set and User Interface ......................................................118
11.3 Test Result Status Lights below each Test Cycle Data Panel ..........................120
11.4 “Cycle” Screen Display Types......................................................................121
11.5 Test Cycle “Front Panel”.............................................................................122
11.6 Test Cycle Controls from the “Cycle” Function Screen ...................................123
Chapter 12 WINATEQ 300 S/W “RESULTS” FUNCTION SET............................................125
12.1 Access to this Function Set .........................................................................125
12.2 “Results” Function Set and User Interface....................................................126
12.3 Test Cycle “Front Panel”.............................................................................128
12.4 Test Cycle Controls from the “Results” Function Screen ................................129

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12.5 Saving the Results of your Leak Channel Tests.............................................130
12.6 Automatic Backup Options..........................................................................131
Chapter 13 WINATEQ 300 S/W “GRAPHS” FUNCTION SET.............................................133
13.1 Access to this Function Set .........................................................................133
13.2 “Graphs” Function Set and User Interface....................................................134
13.3 Additional Functions available via the “Graphs” Function Set .........................136
Chapter 14 WINATEQ 300 S/W “STATISTICS” FUNCTION SET .......................................139
14.1 Access to this Function Set .........................................................................139
14.2 “Statistics” Function Set and User Interface .................................................140
14.3 “Statistics” Function TABS ..........................................................................142
Chapter 15 WINATEQ 300 “STORAGE” FUNCTION SET..................................................143
15.1 Access to this Function Set .........................................................................143
15.2 “Storage” Function Set and User Interface ...................................................144
Chapter 16 WINATEQ 300 S/W “GENERAL” FUNCTION SET ...........................................145
16.1 Access to this Function Set .........................................................................145
16.2 “General” Function Set and User Interface ...................................................146
16.3 Displaying one Leak Test Channel “Device”..................................................147
16.4 Renaming one Leak Test Channel “Device” ..................................................148
Chapter 17 SPECIAL CYCLES (“PARAMETERS” FUNCTION SET) ......................................151
17.1 Access “SPECIAL CYCLES” & Prepare for Special Cycle Functions ...................151
17.2 SPECIAL CYCLES MENU..............................................................................152
17.3 SPECIAL CYCLES FUNCTIONS.....................................................................153
Chapter 18 ACCESSORIES ...........................................................................................155
18.1 Calibrated Leak Kit.....................................................................................155
18.2 Air Filtration Kit .........................................................................................156
Appendix A GLOSSARIES .............................................................................................157
Glossary of Acronyms: ..........................................................................................157
Glossary of Terms: ...............................................................................................157

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Appendix B Pressure Measurement Unit Conversion .......................................................159
Appendix C Circuit Diagram Symbols (Pneumatic and Electrical)......................................161
Appendix D Leak Test Module 16-Pin I/O Port Specifications...........................................165
Appendix E Leak Test Module RS-232 Port Specifications ...............................................169
Appendix F DIAGNOSTICS & TROUBLESHOOTING.........................................................171
1. Diagnostic Indicators on the WinAteq 300 “Cycle” Screen..............................171
2. Troubleshooting Error Messages .................................................................172
3. Long-Term Operational Troubleshooting and Maintenance ............................174
Document Revision History ..............................................................................................176

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Hydra Silver
Owner/Operator Manual
INTRODUCTION
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Chapter 1 INTRODUCTION
This chapter introduces the Hydra Silver and provides an orientation for this Manual.
1.1 Scope of this Manual
This Manual provides the information and procedures necessary to install, configure,
operate, and monitor the ATEQ Hydra Silver.
ATEQ recommends that all engineers, technicians, leak testers, and technical managers
read this manual and understand its content before accessing this equipment.
1.2 Types of Alert Messages that may appear in this Manual
Indicates a potentially hazardous situation which, if not avoided, will result in death or
serious injury. This signal word shall be limited to the most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury and/or equipment damage or generally unsafe practices.
Indicates an important notice to the reader, that does not necessarily involve the
possibility of personal injury or equipment damage.
Indicates a useful method or information that may be of interest to the reader.
All warnings, cautions, notices, and instructions presented in this Manual should be read
and followed by all personnel who will install, configure, operate, and/or maintain this
equipment.
Failure to follow all such warnings, cautions, notices, and instructions may result in
damage to the equipment and/or personal injury, and may also nullify any warranties
provided by the manufacturer.

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1.3 PRODUCT SUMMARY
The ATEQ Hydra Silver is a fully integrated air-to-air leak detection instrument that
enables simultaneous or sequential pressure decay leak testing on four completely
independent channels.
Each of the four independent test channel “modules” has its own leak test transducer,
less than 1.5 cc of internal volume, and includes a port on the front of the case for
connection to the external part which is being leak tested, plus a 16-pin Input/Output
(I/O) port and an RS-232 port. A variety of front test port fittings are also available.
The Hydra Silver allows you to remove one or more test channel modules for service or
calibration, and still be able to conduct leak testing with the remaining channels.
An onboard computer with a color touchscreen monitor enables you to configure the
Hydra instrument, set up multiple sets of leak testing parameters, then control and
monitor all leak testing scenarios. Test results can be stored upon multiple media.
Figure 1–1: ATEQ Hydra Silver 4 Channel Leak Testing System

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The “plug and play” interface on the Hydra Silver, supported by ATEQ’s WinAteq 300
software and touchscreen, makes this fully integrated system very easy to use.
The on-screen displays offered by the Hydra Silver (some of which are shown below), in
conjunction with the 4 input-output channels and dual rear USB ports, result in:
a simple process for Production and Test Engineers to install and configure the unit;
an intuitive and efficient test setup, plus useful screen displays of leak test results;
multiple options for exporting all test results, so that Quality Control Engineers are
able to obtain leak test data in a timely manner and in whatever format needed; and
the ability to build, facilitate, and support thorough and efficient training in the
Hydra Silver, even when targeted for those new to leak testing.
Figure 1–2: Sample WinAteq 300 Displays on the Hydra Silver Touchscreen

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Owner/Operator Manual
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1.4 Product Specifications & Identification Labeling
On the rear of the Hydra Silver case, there are labels identifying the specific unit and
providing a summary of its specifications. Below is an example of this type of labeling.
Figure 1–3: Product Specifications & ID Labels on the Hydra Silver
1.5 Additional Product Labeling
Electrical Supply is ON (Energized)
This symbol on the machine indicates a component or a position of a
component (e.g. a switch) that powers “ON” (energizes) an electrical
supply to the machine or to a component.
Electrical Supply is OFF (De-Energized)
This symbol on the machine indicates a component or a position of a
component (e.g. a switch) that powers “OFF” (de-energizes) an
electrical supply to the machine or to a component.

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1.6 Symbols used in this Manual
General Purpose Symbols:
Caution, Risk of Electric Shock
This symbol indicates content in this manual regarding hazardous
voltages present when the machine is energized.
Protective Conductor Terminal
This symbol indicates content in this manual regarding a terminal
which is bonded to conductive parts of the machine for safety
purposes and is connected to the external protective earthing or
grounding.
Anti-Static
This symbol indicates content in this manual regarding anti-static
electricity precautions that should be used to prevent damage
from occurring to components on the machine.
Compressed Air
This symbol indicates content in this manual regarding
precautions that must be taken when handling a compressed air
source or compressed air delivery device.
Pressurized Device
This symbol indicates content in this manual regarding
precautions that must be taken handling the pressurized devices
within the instrument.
Slippery Spillage
This symbol indicates content in this manual regarding a potential
fall hazard when slippery liquids are spilled around the machine.
Book Symbol
This symbol indicates a reference in this Manual to document(s)
that should be read, which may include manuals from OEMs. This
symbol is also used to highlight definitions inserted into the text.

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Owner/Operator Manual
PRODUCT OVERVIEW
& USER INTERFACE
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Chapter 2 PRODUCT OVERVIEW
This chapter provides an external overview of the Hydra Silver instrument, including a
summary description of each major external component.
2.1 Hydra Silver Capabilities
The ATEQ Hydra Silver is a fully integrated air-to-air leak detection instrument that
enables simultaneous or sequential pressure decay leak testing on four completely
independent channels.
With an onboard computer and color touchscreen monitor driven by the WinAteq 300
software, combined with dual USB ports, plus leak test channel-specific I/O ports
enabling communication with PLCs and other external control and data storage devices,
the Hydra Silver is equally suitable for fully automated, semi-automated, and manual
leak testing environments.
2.2 Hydra Silver Features
Leak Testing by Pressure Decay (up to 10 bar)
Measurement Ranges: (AP) P.E.: 500 Pa to 50 kPa
Integrated Fill and Dump Valves
Flexible Communication Formats:
RS232
USB (for printer, keyboard, flash drive, and External Windows PC)
2.3 Hydra Silver Leak Test Measurement Ranges
PRESSURE
Max Resolution
AP Measurement
Max Resolution
Vacuum
500 Pa -1000 Pa -2000 Pa- 5 kPa
1 Pa - 10 Pa
-500/+500 mbar
1 mbar
500 Pa -1000 Pa - 2000 Pa -5 kPa
1 Pa -10 Pa
0- 500 mbar
500 Pa -1000 Pa -2000 Pa
1 Pa
0 - 2 bar
1000 Pa - 2000 Pa- 5 kPa- 10 kPa
1 Pa - 10 Pa
0 - 5 bar
10 mbar
2000 Pa - 5 kPa - 10 kPa - 20 kPa
1 Pa - 10 Pa
0-10 bar
5 kPa - 10 kPa - 20 kPa - 50 kPa
10 Pa
Note: 1 Pascal (Pa) = 0.000145 psi. See Appendix B for additional unit conversions.

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2.4 Exterior Component Summary
The Hydra Silver has 4 separate Leak Test Modules built-in to the instrument casing,
which provide leak testers with 4 independent Leak Test “Channels”that can be
employed to conduct separate concurrent testing or multi-channel sequential testing.
As illustrated in Figure 2–1 below, the front of the Hydra Silver casing provides a set of
4 ports for direct hookup to external “test parts”.
As illustrated in Figure 2–1 on the next page, the rear of the Hydra Silver casing are 4
corresponding sets of:
RS-232 ports for connecting a memory device to each Leak Test Module, and
16-pin Input/Output (I/O) ports for connecting a PLC or other automated
control or feedback device to each Leak Test Module.
Figure 2–1: Front Exterior Components