HeMaTech 3925-0050 User manual

leak test flow test volume test test systems test machines
Leak Tester 3925 –0060
Operating Instructions
EN 3925-0060 V207-00 MANUAL R03.doc
Please read these instructions, before installing, starting up, storing or handling this device.

Any trademarks referred to in this manual are the
sole property of the corresponding owner.
HeMaTech Prüftechnik GmbH & Co. KG
Siemensstrasse 7
DE-71409 Schwaikheim
Phone [phone]
Fax [phone]
Internet http://www.hematech.de
© 2010 All rights reserved
Edition 07/2010
EN 3925-0050 V205-00 MANUAL R01.doc

Contents
Leak Tester 3925 –0060................................................... 1
Operating Instructions........................................................ 1
Introduction ...................................................................... 7
Concerning these operating instructions .................................................7
Intended use .......................................................................................8
Warranty.............................................................................................9
Structure of the manual ......................................................................10
Safety measures .............................................................. 12
Safety notes....................................................................................... 12
Symbols used .................................................................................... 14
Product description.......................................................... 15
The differential pressure method.......................................................... 15
Performance characteristics.................................................................18
Design and working principle ..............................................................19
Scope of delivery ...............................................................................20
View of device ...................................................................................21
Control elements ...............................................................................23
Installation and start-up ................................................... 25
Connecting peripheral equipment........................................................25
Switching the device ON and OFF....................................................... 28
Initializing....................................................................... 29
The display ..................................................................... 30
Working with the program ..................................................................31
Using the write protection switch..........................................................31
Command reference........................................................ 32
Program structure ..............................................................................32
Menu 1. AUTOMATIC........................................................................33
Sequencer ........................................................................................... 35
Automatic mode without leak simulation ................................................. 36
Menu 2. MANUAL .............................................................................37
1. Test ................................................................................................ 37
1.1 Determination of a reference record ................................................. 39
1.1 Sequencer ..................................................................................... 40
2. Pressurize (Flooding)......................................................................... 42
Menu 3. SETUP ................................................................................. 44
1. Set parameter (Test program)............................................................. 44
1.1 Printout PARAMETER....................................................................... 51
1.2 Copying an existing test program ..................................................... 53
2. Date & Time. ................................................................................... 54
3. Serial ports ...................................................................................... 55
3.1 Output format Profibus.................................................................... 62

3.2 Output format Profinet....................................................................67
4. Sequencer........................................................................................77
4.1 Printout SEQUENCER PARAMETER....................................................79
5. Adjusting the filling/testing pressure manually (option 0050-04).............81
6. Adjusting the vacuum manually (option 0050-01).................................83
Menu 4. DELETE ............................................................................... 84
Menu 5. PRINT MENU....................................................................... 85
1. View Program Status..........................................................................85
2. Data Collection ................................................................................86
2.1 Print Data Collection .......................................................................87
3. Operating data.................................................................................88
4. Counter...........................................................................................88
5. Backup ............................................................................................89
6. Error counter status ...........................................................................90
7. Record.............................................................................................91
8. Record Reverence .............................................................................93
Menu 6. SETTINGS ........................................................................... 95
1. Display ............................................................................................95
2. System parameters ............................................................................97
3. Pressure control ................................................................................99
4. System status ....................................................................................101
5. Options ...........................................................................................102
Testing and Setup.......................................................... 104
Testing the leak tester .......................................................................104
Setting up the device for specimen .....................................................106
Leak simulation (option) ....................................................................107
Maintenance................................................................. 108
Maintenance contract .......................................................................108
Maintenance plan ............................................................................108
Errors, Causes and Remedy ...............................................................109
Acknowledging error messages ..........................................................109
Trouble Shooting Chart.....................................................................110
Signal Exchange with Machine Control............................ 114
Automatic operation .........................................................................115
In semi-automatic operation ..............................................................118
Sample printouts ........................................................... 122
Protocol printout ..............................................................................122
Program parameters.........................................................................123
Result memory .................................................................................124
System parameters............................................................................125
Appendix...................................................................... 127
Plug assignment...............................................................................128
Pneumatic diagram (vacuum device) ..................................................128
Pneumatic diagram (overpressure device)............................................130
Technical Data.................................................................................130

EC - Declaration of Conformity ......................................................... 133
Index.............................................................................................. 134
Contact address: ............................................................................. 138

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HeMaTech Prüftechnik
Introduction
In this chapter you will find some introductory remarks concerning the use of this test-
er, as well as explanations concerning the structure of these operating instructions and
the symbols and text markings used in this manual.
The installation instructions for the device address to persons (skilled electricians and
service engineers) who are entrusted with the installation and maintenance of the de-
vice. These persons must be fully familiar with and strictly follow all regulations con-
cerning electrical engineering.
The installations for operation of the completely installed device are intended for all
persons who will use and make adjustments to the device.
Concerning these operating instructions
The following pages will inform you about the proper use of the device in your produc-
tion or testing environment.
HeMaTech Prüftechnik attaches great importance to the safe, appropriate and eco-
nomical use of the device. However, this requires that you read these operating in-
structions thoroughly before you install and use the device. It contains important
information, which will help you to avoid dangers and enhance the reliability and ser-
vice life of the device. Always keep these operating instructions close at hand near the
device and read the chapter Safety measures for your own safety. Strictly follow all
notes, to keep yourself and other members of staff out of danger and to avoid material
damage.
If you have any questions concerning work with the device, for which you have not
found an answer in these operating instructions, please contact:
HeMaTech Prüftechnik GmbH & Co. KG
Siemensstraße 7
D-71409 Schwaikheim
Phone [phone]
Fax [phone]
www.hematech.de

Intended use Introduction
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Intended use
The leak tester 3925-0050 from HeMaTech Prüftechnik is solely intended for profes-
sional use in leak testing of work pieces by means of compressed air. Any use beyond
these limitations is considered unintended. The user solely bears any risks.
Installation and maintenance of the device must only be performed by skilled electrical
engineers.
Type plate
The type plate with model designation and serial number is located on the back of the
device.
You require this information when consulting our Customer Service Department.
Please record this information in the following table, so that it is at hand when needed:
Device type
Serial-Number:
Software-Version
Information about the software version can be found under 6. Settings / 2. System pa-
rameters
Ordering spare parts
Use only original spare parts from HeMaTech Prüftechnik. If you would like to order
accessories or spare parts, you not only need to specify device type and serial number,
but also article number and designation of the required components, which you can
take from the list of consumables and spare parts.
Article number:
Designation:
Reporting transport damage
If you discover any transport damage when unpacking the device, you should immedi-
ately contact the forwarding agent to report the loss or damage.
Please ask for a corresponding confirmation and return the package to us together
with this confirmation and the delivery note.
Preparing a return delivery
Pack the article with all accessories (see scope of delivery) in the original packing ma-
terial and return the goods to us, together with an exact fault description and the de-
livery note. Please frank the delivery.
HeMaTech Prüftechnik GmbH & Co. KG
Siemensstraße 7 D 71409 Schwaikheim
Phone: [phone]
Fax.: [phone]
www.hematech.de
Type: ________________________________
Serial-No.: ________________________________
Voltage: ________________________________ V

Introduction Warranty
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Warranty
The warranty conditions for devices from HeMaTech Prüftechnik GmbH & Co. KG can
be found in our terms and conditions of sales and delivery.
If no other agreement has been made, the warranty period for design, material and
manufacturing faults (except consumables), as well as for the omission of explicitly
guaranteed properties, is generally 1 year, starting from the date of delivery.
We reserve the right to decide whether we will rectify a fault, deliver replacement or
submit a credit note covering the value of the goods.
In case of unintended use and damage caused by falling, water, dirt or any other ex-
ternal effects, warranty claims will become null and void.
Any malfunctions and damages caused by the user, such as soiling, faulty connections
and mechanical damage are excluded from warranty.
We reserve the right to invoice the repair costs for parts which had been returned for
warranty repair, but for which no or only partial warranty could be claimed.
If not agreed upon differently beforehand, HeMaTech Prüftechnik will only bear the
shipment costs for outgoing deliveries of devices and parts which are covered under
warranty.
However, if the delivery arrived with costs for HeMaTech Prüftechnik, these costs will
be added to the repair costs.
Import and/or export duties as well as costs arising for third parties must be borne by
the customer.

Structure of the manual Introduction
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Structure of the manual
This manual contains the description, installation and operation of the device. It con-
sists of the following chapters:
Safety measures
Read and follow these safety notes, because they serve the safety of persons and
ensure the reliability and operational safety of the device.
Product description
Here you will become familiar with the device and its modules, functions and control
elements.
Installation and start-up
You must prepare the place of use for the device and provide the necessary supply
connections.
Operation
Once all preparations have been made switch on the device, set the test parameters
and start the test device.
Command reference
Here you find a complete description of the control software with all possible settings.
Maintenance
Apart from the list of maintenance intervals, this chapter also contains the trouble
shooting chart with information on faults, causes and possible remedy.
Signal exchange
This section shows which signals are used in operation with a machine control.
Sample printouts
In this section you find some examples for printouts of measurements, parameters, etc.
Appendix
This chapter contains wiring diagrams and technical data for the device.
The index
The index helps you to find required text passages quickly.

Introduction Structure of the manual
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Representation
Bold type
Designations of control keys are printed bold.
Italic type
Cross-references to other chapters or text passages are printed italic .
Operating steps
Operating steps are marked as follows:
Turn key switch clockwise.
Write protection is disabled, entries can be made.
Make all following entries and confirm these individually by pressing the ENTER-
key. The insertion point jumps to the next field.
Lists
Lists are marked as follows:
−Variant A
−Variant B
−Variant C
−…

Safety notes Safety measures
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Safety measures
Safety notes
Thoroughly read and strictly follow these safety notes. They serve your own safety, the
safety of other members of staff and help to avoid damage to the device and accesso-
ry parts.
Danger caused by electric current
Make sure that no fluid can enter into control cabinet, control panel or other parts of
the housing. If this should happen, immediately disconnect the device from the electric
power supply, secure the corresponding socket against reconnection and inform ap-
propriately trained expert personnel or the customer service department of
HeMaTech.
Make sure that the electrical connecting leads are free of damage and well protected
against buckling or squashing. If you detect any damage, immediately disconnect the
device from the electric power supply, secure the corresponding socket against recon-
nection and inform appropriately trained expert personnel or the customer service de-
partment of HeMaTech.
Work in the electrical system –e.g. changing fuses –must only be performed by
trained expert staff. Further maintenance and repair work must only be performed by
the customer service of HeMaTech Prüftechnik or by persons who have been author-
ized by HeMaTech Prüftechnik.
Use this device and any connected devices only on a dedicated electric voltage.
Strictly follow all warnings and instructions given on the device.
If smoke or pungent smells causes suspicion of a defect, you should disconnect the
device from the mains supply and from any other equipment.
Take care that no other objects find their way into the inside of the device. These may
come into contact with live parts or cause a short-circuit, which in turn could cause a
fire or electric shock
Before starting cleaning work disconnect the device from the mains supply and from
all other devices. Use only a slightly damp cloth to clean the device, do not use fluids
and sprays!
Disconnect the device from the mains supply if it is not to be used for a longer period
of time. Store the device only in dry and weather protected rooms.
If safe operation of the device can no longer be assured, you must disconnect the device
from the mains supply and secure it against being switched on again unintentionally.
Risk-free operation is, for example, no longer possible,
−if device or supply lead are visibly damaged,
−if the device does not work properly,
−if the devices was exposed to moisture or rain,
−if condensation water has accumulated,
−if objects have found their way into the device,
−if the device does not work properly, despite orderly performed operating
steps,

Safety measures Safety notes
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−if the permissible storage or operating temperature is exceeded or fallen short
of.
Installation
The installation measures described in this manual must only be carried out by trained
specialists. The applicable regulations for electrical engineering must in any case be
observed and complied with.
The device must stand in a firm position, protected against vibration.
Avoid locations near heating or air conditioning systems.
Only install the device inside a control cabinet, if adequate ventilation is assured.
Operation
Ensure unrestricted circulation of air around the device. In case of insufficient
ventilation the device will overheat. This may result in severe damage to the
device and further material damage.
Maintenance
The maintenance work described in this manual must only be carried out by trained
specialists. The applicable regulations for electrical engineering must in any case be
observed and complied with.
Only perform the maintenance work described in this instruction manual. Any work
beyond these limitations can cause damage to persons, material or device.
Repair
Do not carry out any repair work that is not explicitly permitted in these operating in-
structions. Consult the customer service department of
HeMaTech Prüftechnik GmbH & Co. KG.
Unprofessionally performed work can cause damage to persons, material or device.

Symbols used Safety measures
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Symbols used
Thoroughly read and strictly follow these safety notes. They serve your own safety and
will help you to avoid damage to the device.
The following symbols are used in this instruction manual:
DANGER!
This safety note points to dangers, which could cause fatal injuries or
severe damage to persons.
ATTENTION!
This safety note draws the attention to dangers, which could cause
material damage or incorrect tests.
NOTE!
This symbol highlights hints and special features, which will ease the
operation of the leak tester.

Product description The differential pressure method
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Product description
The Leak Tester 3925 - 0050 is a device for pneumatic and thus non-corrosive leak
testing of series production parts, such as fittings, pump housings, cylinder blocks,
vacuum controls, batteries and many more. Its function is based on the differential
pressure method.
The differential pressure method
This method is particularly suitable for use in series production, because it can be easi-
ly automated with sufficient accuracy.
The test medium is low cost compressed air. Due to its low viscosity it can pass
through existing porosities and other leak points with sufficient speed. The test does
not generate any dirt. Cleaning and drying as well as corrosion protection measures
are not required. Maintenance of the measuring system is unproblematic. Prerequisite
for this method is the leak tightness of measuring system and testing device.
As already indicated by the name differential pressure method, the pressure difference
in the measuring branch caused by a leak in the specimen is compared with the pres-
sure in the blocked off reference branch.
Function schematic of differential pressure test

The differential pressure method Product description
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The testing process consists of three phases:
1. Filling
With the filling and isolating valve open, the testing pressure set on the pressure regu-
lator is applied to reference volume, measuring transducer and specimen The filling
time is determined by the performance of the pressure regulator, the total volume of
the facility including testing and reference volume, the piping resistance and the cross-
section of the valves.
2. Stabilizing
This is the phase of pressure and temperature stabilization in the entire system. The
reference volume shown in the illustration –one normally uses a pressure tight original
work piece –serves the purpose of creating the highest possible symmetry level be-
tween testing and reference circuits. This enables a reduction of stabilization time, be-
cause possibly existing interfering influences affect both circuits of the system and thus
reduce the effect on the measuring result. Empirical values reveal that with volumes
< 5000 ccm a reference volume is normally not needed.
3. Measuring
The actual measuring phase starts after the stabilization time has expired. By closing
the filling and isolation valves the measuring and references branches are separated
from each other. If the specimen has a leak, the pressure in the measuring branch will
drop in comparison to the reference branch. The measuring transducer shows the re-
sulting pressure difference in the measuring value display. If the pressure difference ex-
ceeds the preset limit value during the measuring phase, a signal Reject will be
submitted and the test stopped.
Pressure course in the test system during the test process
Pressure
Leak
work piece
Filling
Stabilizing
Venting
Measuring
Test time
leak tight
work piece
Time

Product description The differential pressure method
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The isolating valve shown in the illustration is an isolating valve which has been spe-
cially developed for leak testers from HeMaTech Prüftechnik. The special requirements
for leak testing were already accounted for in the development of the valve.
Due to the symmetric design, both measuring branches are simultaneously isolated
from each other when closing the valve. Volume and pressure differences therefore act
uniformly on both measuring branches, whereby measuring faults are ruled out. By
distinct separation of both measuring circuits, measuring errors caused by leaks in up-
stream filling valves are reliably prevented. The isolating valve is pneumatically con-
trolled and heating, caused by e.g. the coil of a solenoid valve, is thus avoided.
Leak testing equipment using the differential pressure method is well established in se-
ries production. A vast variety of work pieces and assemblies, ranging from ball-point
cartridges to vehicle engine blocks, are reliably tested for leaks.

Performance characteristics Product description
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Performance characteristics
The test device offers the user a number of functions and possibilities to set parameters
for measurements, as well as for the output and distribution of these measuring results:
Function monitoring
The device takes over the monitoring of parts and function sequence. The user re-
ceives error messages through the plain text display and floating contact.
99 Test programs
There is a possibility to create up to 99 different programs and to select these either
via the control panel, or by means of external signals (BCD, 8 bit) in automatic opera-
tion.
Data exchange
All test parameters and measuring results can be entered and output, printed or pro-
cessed further by PC through the serial interface.
Result signals
The device delivers several result signals:
−I.O. (Accept)
−Rework
−Reject and gross leak (gross leak message only through V24 interface)
−Envelope curve,
Filling fault. (optional)
−Fault
The result signals can vary depending on device variant or have different designations.
Fill pressure, underfill pressure, underfill time and test pressure,
are separately set/disabled via keypad for each test program.
Times for fill, stabilization, pause, tare, measure and vent,
are separately adjustable via keypad from 0.1 …999.9 seconds for each test pro-
gram.
Measuring range
∆ p 0 … 3000 Pa.
Resolution 1 Pa; limit contact setting up to max. 2000 Pa
(100 Pa = 1 mbar = 10 mmWC).
Measuring value display
You can switch over to:
PASCAL, mbar, psi, mmWC, mmHg, ml/min

Product description Design and working principle
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Design and working principle
The test device is microprocessor controlled, of modular design and, due to its division
into pneumatic and electronic sections, can be adapted to the most different require-
ments of customers. The design as a 19 inch plug-in unit (3HE) enables problem free
integration into control cabinets. The device dimensions W × H × D are:
−for standard housing 590 × 165 × 456 mm (3 HE without front door)
−for optional version 590 × 300 × 456 mm (6 HE without front door)
Devices with lockable front door have a depth (D) of 496 mm.
Pneumatics
The pneumatic section of the tester consists of the following main components:
−the pressure control for filling and testing pressure via electronic pressure set-
ting (set up specification by computer) with pressure monitoring by means of
an adjustable tolerance window
−a pneumatically controlled isolating valve, which rules out heating of the valve
−a temperature compensating differential pressure measuring transducer for
testing test volumes up to 5000 ml without reference volume
−a high single-side overload protection (max. 150 bar/g) of the differential
pressure measuring transducer
−an optional leakage simulation with precision needle valve
(flow meter to be connected externally)
−pressure sensors for function monitoring of the pneumatic circuit
See also Pneumatic Diagram in the appendix
Electronics
The electronics section of the tester consists of
−microprocessor system,
−battery buffered RAM memory,
−alpha-numerical membrane keyboard for all input functions,
−On/Off switch integrated in the membrane keyboard,
−key switch to protect against unauthorized changing of test parameters and
−graphics display for device menus and up to 2 serial interfaces

Scope of delivery Product description
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Scope of delivery
1 Leak Tester 3925 - 0050
1 Power cable
1 Counter plug to machine control
2 Key for write protection switch
1 Operating instructions
2 Caps
(for specimen connection and reference volume connection)
Should one of these items be missing or damaged, you should immediately consult
your supplier.
Accessories