ATEQ Hydra Owner's manual

Hydra
Four Channel Leak Testing System
Owner/Operator Manual
Reference: LHYD40101-R00

Front Inside Cover

Hydra
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 238).
© 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 should read all content in
Chapter 3 (Product Safety Requirements) beginning on page 25.
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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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.

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Owner/Operator Manual
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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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Table of Contents
Chapter 1 INTRODUCTION ..........................................................................................15
1.1 Scope of this Manual....................................................................................15
1.2 Types of Alert Messages that may appear in this Manual.................................15
1.3 PRODUCT SUMMARY ...................................................................................16
1.4 Product Specifications & Identification Labeling..............................................18
1.5 Additional Product Labeling ..........................................................................18
1.6 Symbols used in this Manual.........................................................................19
Chapter 2 PRODUCT OVERVIEW ..................................................................................21
2.1 Hydra Capabilities........................................................................................21
2.2 Hydra Features............................................................................................21
2.3 Hydra Leak Test Measurement Ranges ..........................................................21
2.4 Exterior Component Summary ......................................................................22
Chapter 3 PRODUCT SAFETY REQUIREMENTS .....................................25
3.1 Owner Responsibility....................................................................................25
3.2 ATEQ USA Safety Support ............................................................................25
3.3 Electrical Safety...........................................................................................26
3.4 Static Discharge and Electromagnetic Interference .........................................26
3.5 Testing Environment and Operational Safety..................................................27
3.6 Hydra Clean/Dry Air Requirements ................................................................28
3.7 Required Competence..................................................................................28
Chapter 4 ONBOARD COMPUTER SYSTEM OVERVIEW ...................................................29
4.1 Onboard Computer with Touchscreen Monitor................................................29
4.2 Windows Operating System for Touchscreen Monitor Access...........................30
4.3 Recommendations for using Windows on the Touchscreen..............................31
4.4 WinAteq 300 Software Overview and Major Screen Elements ..........................32
4.5 Major Screens available via the WinAteq 300 Software....................................34
Parameters Screen: .....................................................................................34
Cycle Screen: ..............................................................................................35

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Results Screen: ...........................................................................................35
Graphs Screen:............................................................................................36
Statistics Screen:.........................................................................................36
Storage Screen:...........................................................................................37
General Screen:...........................................................................................37
Journal Screen: with WinAteq 300 Version 1.35.................................38
4.6 Optional External USB Devices for use with the Computer System ...................39
4.7 WinAteq 300 Software “Options” Menu..........................................................40
Options Menu Access:..................................................................................40
A. Options: “Styles” Menu:.........................................................................41
B. Options: “Settings” Dialog Box: ..............................................................43
C. Options: “Admin” Dialog Box:.................................................................53
4.8 WinAteq 300 Software “Help” Menu ..............................................................54
Chapter 5 PRODUCT TECHNICAL DESCRIPTION............................................................55
5.1 Leak Test Channel Communications & Control Modes .....................................55
5.2 Leak Test Channel Components ....................................................................56
5.3 Pressure Measurement Methods supported by the Hydra ................................58
5.4 Direct Pressure Decay Measurement Method..................................................58
5.5 Indirect Pressure Decay Measurement Method ...............................................58
5.6 Leak Test Cycle Stages for Direct Pressure Decay Measurement ......................59
Chapter 6 INSTALLATION PROCEDURES.......................................................................61
6.1 Hydra Basic Environmental & Operational Requirements .................................61
6.2 Hydra Test Area Requirements .....................................................................61
6.3 Hydra Clean/Dry Air Requirements ................................................................62
6.4 Hydra Basic Installation and Initial Startup.....................................................64
6.5 Connecting a Clean/Dry “Test Air” Supply to the Hydra ...................................68
Chapter 7 INSTRUMENT STARTUP / OPERATIONS / SHUT-OFF ......................................71
7.1 Key Operational Basics about the Hydra Instrument .......................................71
7.2 Instrument Power Up and Computer System Startup ......................................72
7.3 Test Air Pressure Limits................................................................................75
7.4 How to Regulate Test Air Pressure ................................................................76

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7.5 How to Quickly Set a Specific Test Air Pressure ..............................................77
7.6 Leak “Test Cycle” Status Indicator Lights .......................................................80
7.7 Leak “Test Cycle” Status Indicators on Front Panels........................................81
7.8 Leak “Test Cycle” Stages..............................................................................82
7.9 How to Run and Monitor a “Test Cycle” .........................................................84
A. Which Screens to use for Running and Monitoring Test Cycles ...................84
B. How to Run and Monitor Leak Test Cycles using ONE Leak Test Channel ....85
C. Running Single Leak Test Channel Tests from the “Cycle” Screen ..............87
D. Running Simultaneous Test Cycles on MULTIPLE Leak Test Channels ........88
7.10 Saving the Results of your Leak Channel Tests...............................................89
7.11 Instrument Shut Down and Complete Power Off ............................................90
Chapter 8 TEST CHANNEL SETUP / TEST PART CONNECTION ........................................97
8.1 Summary of this Task ..................................................................................97
8.2 Prerequisite Tasks .......................................................................................97
8.3 Configure ONE Leak Test PROGRAM for the Leak Test Channel. ......................98
8.4 Connect a “Test Part” to the Leak Test Channel ...........................................100
8.5 Configure & Test additional Parameter Programs for this Channel..................102
8.6 [OPTIONAL] Connect a Device to the Channel’s I/O Relay Connector ............104
8.7 [OPTIONAL] Connect a Device to the Channel’s RS-232 Connector ...............106
8.8 [OPTIONAL] Re-Test the Channel after External Device Installs....................108
A. Re-Testing Procedure ...........................................................................108
B. Saving your Leak Channel Setup Re-Tests and External Device Installs .....108
8.9 Saving your Program-Channel Assignments and Configurations .....................110
Chapter 9 LEAK TEST CHANNEL CALIBRATION ...........................................................111
9.1 Calibrated Leak Tools.................................................................................111
9.2 Calibrated Leak Pressure/Leak Rate Specifications........................................112
9.3 Establishing a “Baseline” between Pressure Drop and Flow Rate....................113
9.4 Running Tests on a Leak Test Channel using a Calibrated Leak .....................114
Chapter 10 WINATEQ 300 SOFTWARE “PARAMETERS” SCREEN .....................................117
10.1 Access to this Screen .................................................................................117
10.2 “Parameters” Screen and User Interface......................................................118

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10.3 Purpose of the Parameters Screen Data Fields .............................................120
10.4 Program Parameters Sections and corresponding “Data Tabs”.......................120
10.5 Test-Program-Specific versus “GLOBAL” Data Fields .............121
10.6 How to Edit Leak Test Program Parameter Values ........................................122
A. Numerical Fields:..................................................................................122
B. Choice Fields: ......................................................................................123
C. Checkbox Fields: ..................................................................................123
D. Expanding/Contracting Fields containing Sub-Fields: ...............................123
10.7 Creating a completely New Parameters Program ..........................................124
10.8 Copying an “Existing” Parameters Program to create a New Program.............126
A. “Methods” available to “Copy” and “Paste” Parameter Data......................126
B. Selecting an existing Parameters Program from which to COPY Data ........127
C-1. Transfering Program Data using In-Line Program Menus......................128
C-2. Transfering Program Data using the “Clipboard” Toolset......................130
D. Editing a Test Program’s Parameters Data after being Transferred ...........132
10.9 PARAMETERS Tab Data Fields Defined [Basic Settings].............................134
10.10 PARAMETERS Tab Data Field: TYPE TEST....................................................135
LEAK TEST (LEAK).....................................................................................136
DESENSITIZED MODE TEST (MODE D)........................................................137
BLOCKAGE MODE TEST (MODE P) ..............................................................137
10.11 PARAMETERS Tab Data Field: WAIT A.........................................................137
10.12 PARAMETERS Tab Data Field: FILL TIME .....................................................138
10.13 PARAMETERS Tab Data Field: STAB ............................................................139
10.14 PARAMETERS Tab Data Field: TEST ............................................................140
OPTION: Setting the Test Time to “Infinite” -- NO Test Time Limit .............141
NOTE about Running Test Cycles with “Infinite” Test Time............................142
10.15 PARAMETERS Tab Data Field: DUMP ...........................................................143
10.16 PARAMETERS Tab Data Field: PRESSURE UNIT............................................143
10.17 PARAMETERS Tab Data Field: MAX FILL ......................................................144
10.18 PARAMETERS Tab Data Field: MIN FILL.......................................................144
10.19 PARAMETERS Tab Data Field: REJECT UNIT ................................................145
Type of Leakage Rate Unit determines “Operation Mode”: ............................146

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How Operation Mode affects Testing and Required Parameters: ....................146
10.20 PARAMETERS Tab Data Field: REJECT MAX .................................................147
10.21 PARAMETERS Tab Data Field: REJECT MIN [OPTIONAL]............................147
10.22 PARAMETERS Tab Data Fields Defined [Advanced Settings] ......................148
10.23 PARAMETERS Tab Data Field: THRESHOLD RECUP.......................................149
10.24 PARAMETERS Tab Data Field: END OF CYCLE ..............................................151
10.25 Data Fields related to Attenuated Transient Reduction (ATR).........................153
10.26 PARAMETERS Tab Data Field: ATR0 ...........................................................155
10.27 PARAMETERS Tab Data Field: CYCLING......................................................157
10.28 PARAMETERS Tab Data Field: EXTERNAL DUMP..........................................159
10.29 PARAMETERS Tab Data Field: VALVE CODE ................................................160
10.30 PARAMETERS Tab Data Field: CONTINUOUS DUMP.....................................161
10.31 SYSTEMS SETTINGS Tab Data Fields Defined...............................................162
10.32 SYSTEMS SETTINGS Tab Data Field: Dump Thres. ......................................163
10.33 SYSTEMS SETTINGS Tab Data Fields: Input 5 and Input 6............................164
10.34 SYSTEMS SETTINGS Tab Data Field: Handshake .........................................165
10.35 Test Program Data Management via the Parameters Screen’s Toolbar............166
Parameters Screen “Actions” Toolset:..........................................................167
Parameters Screen “Backup” Toolset: .........................................168
Chapter 11 SPECIAL CYCLES (“PARAMETERS” SCREEN).................................................177
11.1 Access “SPECIAL CYCLES” & Prepare for Special Cycle Functions ...................177
11.2 SPECIAL CYCLES MENU..............................................................................178
11.3 SPECIAL CYCLES FUNCTIONS.....................................................................179
Chapter 12 WINATEQ 300 SOFTWARE “CYCLE” SCREEN................................................181
12.1 Access to this Screen .................................................................................181
12.2 “Cycle” Screen and User Interface...............................................................182
12.3 Test Result Status Lights below each Test Cycle Data Panel ..........................184
12.4 “Cycle” Screen Display Types......................................................................185
12.5 Test Cycle “Front Panel”.............................................................................186
12.6 Test Cycle Controls from the “Cycle” Screen.................................................187

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Chapter 13 WINATEQ 300 SOFTWARE “RESULTS” SCREEN............................................189
13.1 Access to this Screen .................................................................................189
13.2 “Results” Screen and User Interface............................................................190
13.3 Test Cycle “Front Panel”.............................................................................192
13.4 Test Cycle Controls from the “Results” Screen..............................................193
13.5 Saving the Results of your Leak Channel Tests.............................................194
13.6 Automatic Backup Options..........................................................................195
Chapter 14 WINATEQ 300 SOFTWARE “GRAPHS” SCREEN .............................................197
14.1 Access to this Screen .................................................................................197
14.2 “Graphs” Screen and User Interface ............................................................198
14.3 Additional Functions available via the “Graphs” Screen..................................200
Chapter 15 WINATEQ 300 SOFTWARE “STATISTICS” SCREEN .......................................203
15.1 Access to this Screen .................................................................................203
15.2 “Statistics” Screen and User Interface .........................................................204
15.3 “Statistics” Function TABS ..........................................................................206
Chapter 16 WINATEQ 300 “STORAGE” SCREEN ............................................................207
16.1 Access to this Screen .................................................................................207
16.2 “Storage” Screen and User Interface ...........................................................208
Chapter 17 WINATEQ 300 “JOURNAL” SCREEN.............................................................209
17.1 Access to this Screen .................................................................................209
17.2 “Journal” Screen and User Interface............................................................210
Chapter 18 WINATEQ 300 SOFTWARE “GENERAL” SCREEN ...........................................211
18.1 Access to this Screen .................................................................................211
18.2 “General” Screen and User Interface ...........................................................212
18.3 Displaying one Leak Test Channel “Device”..................................................213
18.4 Renaming one Leak Test Channel “Device” ..................................................214
Chapter 19 ACCESSORIES ...........................................................................................217
19.1 Calibrated Leak Kit.....................................................................................217
19.2 Air Filtration Module...................................................................................218

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Appendix A GLOSSARIES .............................................................................................219
Glossary of Acronyms: ..........................................................................................219
Glossary of Terms: ...............................................................................................219
Appendix B Pressure Measurement Unit Conversion.......................................................221
Appendix C Circuit Diagram Symbols (Pneumatic and Electrical)......................................223
Appendix D Leak Test Module 16-Pin I/O Relay Connector Specs ....................................227
Appendix E Leak Test Module RS-232 Connector Specifications.......................................231
Appendix F DIAGNOSTICS & TROUBLESHOOTING.........................................................233
1. Diagnostic Indicators on the Winateq 300 “Cycle” Screen..............................233
2. Troubleshooting Error Messages .................................................................234
3. Long-Term Operational Troubleshooting and Maintenance ............................235
3.1 Fixture Seals Damaged .........................................................................235
3.2 Pneumatic Air Supply Too Low ..............................................................235
3.3 Environment ........................................................................................235
3.4 Calibration ...........................................................................................235
3.5 Reliability of a Hydra’s Circuits...............................................................236
Document Revision History ..............................................................................................238

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Chapter 1 INTRODUCTION
This chapter introduces the Hydra 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.
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 is an 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) relay connector and an RS-232 connector. A variety of front test port fittings are
also available.
The Hydra 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.
The Hydra’s cabinet exterior includes an Ethernet port and two USB ports (front/rear).
Figure 1–1: ATEQ Hydra 4 Channel Leak Testing System

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The “plug and play” interface on the Hydra, 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 (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, even when targeted for those new to leak testing.
Figure 1–2: Sample WinAteq 300 Displays on the Hydra Touchscreen

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1.4 Product Specifications & Identification Labeling
On the rear of the Hydra 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
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 should 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 should 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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