Pfeiffer Vacuum MiniTest 300 User manual

IG 0300 BEN_E (1605)
Operating Instructions
MiniTest 300
EN
Translation of the original operating instructions

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Product identification
The information on the rating plate is required for communication with Pfeiffer
Vacuum.
Validity
This document is valid for products with the article number
You can find the article number on the rating plate.
This document is based on the MiniTest firmware version 1.2 and higher. To use all
functions, a remote control RC500 with firmware version 1.1 or higher is needed.
In case the unit does not function as described, check whether your unit is
equipped with this version.
We reserve the right to make technical changes without prior notice.
The figures are not to scale.
Product characteristic
This product has been tested in accordance with the requirements set forth in
guideline CAN/CSA-C22.2 No. 61010-1-12, second edition including revision 1,
or a later version of the same standard applicable to the same level of rules of
procedure for testing.
For more information on additional certifications, refer to the test seal (if appli-
cable) or log on to:
www.tuvdotcom.com
Certificate number: 72132770
Abb. 1 Rating plate
MiniTest 300 PT L03 000

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Content
1 Operating instructions 6
1.1 Description of the target group 6
1.2 Other applicable documents 6
1.3 Presentation of information 6
1.3.1 Warnings 6
1.3.2 Information, instructions and notes 7
2 Safety 8
2.1 Intended use 8
2.2 Restrictions of use 8
2.3 Dangers 9
2.3.1 Danger due to electric voltage 9
2.3.2 Danger due to permanent magnets 9
2.3.3 Danger due to radio interference 10
2.3.4 Danger of material damage to unit 10
2.3.5 Dangers due to handling of the battery 11
2.4 Operator requirements 11
2.5 User requirements 11
3 Transport, storage, unpacking 12
3.1 Transport 12
3.2 Storage 12
3.3 Unpacking 12
4 Description 13
4.1 Scope of delivery 13
4.2 Design of the unit 13
4.2.1 Display and operation 14
4.2.2 Connecting flange 14
4.2.3 Connection of optional vacuum pump 15
4.2.4 Electrical connections 16
4.3 Components and accessories 17
4.3.1 Power supply pack for the MiniTest 300 17
4.3.2 Mains adapter/charger for the wireless remote control
RC 500 WL 18
4.3.3 Sinter filter for vacuum connection 18
4.3.4 Calibrated test leak (pin leak) 19
4.3.5 Coupling for a hose to the vacuum pump 19
4.4 Function 20
4.5 Remote control 22
4.5.1 Paging function 23

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4.5.2 User interface 24
5 Technical data 30
5.1 Mechanical data 30
5.2 Ambient conditions 32
5.3 Electrical data 32
5.4 Physical data 32
6 Installation 34
6.1 Preparation 34
6.2 Connecting the vacuum system 35
6.3 Connecting the controller 36
6.3.1 Wireless remote control 36
6.3.2 Wired remote control 37
6.4 Installing accessories 37
6.4.1 Connecting the test leak 37
6.5 Connecting the electrical power supply 38
6.6 Connecting external pressure gauges 38
7 Operation 40
7.1 Switching on the unit 40
7.1.1 Wireless remote control RC 500 WL 40
7.1.2 Wired remote control RC 500 40
7.1.3 Startup of the unit 41
7.2 Navigation in the menu 42
7.3 Basic functions 45
7.3.1 Use key with basic functions 45
7.4 Settings 45
7.4.1 Setup 45
7.4.2 Calibration 48
7.4.3 Purge 49
7.4.4 Trigger 49
7.4.5 Audio 49
7.4.6 Recorder 50
7.4.7 Radio 51
7.5 Access ctrl 51
7.6 View 52
7.6.1 Lower display limit for leakage rate 52
7.6.2 P Adjustment 52
7.7 Information 53
7.8 Cal 53
7.9 Measurement variants 54
7.9.1 Measurement and search mode 54
7.9.2 Preparing calibration 56

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7.9.3 Calibrating the unit 56
7.10 Measuring 57
7.10.1 Preparing the measurement 57
7.10.2 Scale display area 57
7.10.3 Use helium underground 58
7.10.4 Leak test 58
7.10.5 Recording measured data 59
7.10.6 Evaluation of measured signals 59
7.10.7 Contamination 60
7.11 Switching Off 60
7.12 Disconnecting the unit 60
8 Malfunctions 61
8.1 Warning and malfunction messages 61
9 Maintenance and service 63
10 Taking out of service 65
10.1 Return 65
10.2 Disposal 65
11 Appendix 66
11.1 CE Declaration of Conformity 66
11.2 Ordering Information 67
11.3 Conversion tables 67
11.4 Index 68

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1 Operating instructions
1.1 Description of the target group
This operating manual is intended for the user of the MiniTest 300 and for
technically qualified specialists who are trained in the operation of the MiniTest
300 and have gained experience in vacuum technology, leak detection and leak
testing.
1.2 Other applicable documents
• Operating instructions for remote control RC 500 / RC 500 WL, IG 0140 BDE.
1.3 Presentation of information
1.3.1 Warnings
DANGER
Imminent threat of danger resulting in death or severe injuries.
WARNING
Dangerous situation potentially resulting in death or severe injuries.
CAUTION
Dangerous situation resulting in minor injuries.
NOTICE
Dangerous situation resulting in damage to property or the environment.

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1.3.2 Information, instructions and notes
Check a precaution.
►An action to be taken
1Execute actions in the specified sequence.
2…
3…
Shows the result of an action.
•List
•...
•...
Tip: Tips and useful information
“Settings”:
Terms in quotation marks appear on the display as text or as a button.

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2Safety
2.1 Intended use
The MiniTest 300 is a helium leak detector and is used for localizing and
measuring the smallest leaks.
It is intended for use in vacuum leak detection. The specimen must be
evacuated and its outside sprayed with helium.
Tip: In order to have a comparison for the behavior of the MiniTest 300, use a
reference pressure for the first measurement and observe the behavior of the
MiniTest 300.
The unit is designed for mobile, industrial applications; however, it can also be
installed as a stationary unit:
• for manufacturers and users of vacuum systems,
• to test for leaks in apparatuses, plants and pipe systems,
• to test for leaks in assemblies and components.
►Install, operate and service the unit only in compliance with this operating
manual.
►Comply with the limits of application.
Unauthorized use
►Do not use the unit to vacuum off liquids. Never hold the inlet port in or near
fluids; it must be connected to a vacuum system.
►Never expose the unit to overpressure. Pressure of more than 1100 hPa can
damage the unit.
2.2 Restrictions of use
WARNING
Explosion hazard!
If the unit is operated in explosive areas, explosive mixtures could be ignited.
Temperatures of up to 400 °C can occur in the unit’s vacuum system.
►The unit may be used only outside of explosive areas.
►Do not allow the vacuum system to come into contact with explosive
gases.

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Supposed risk
If safe operation is no longer possible, take the unit out of service and secure it
against accidentally being switched on.
This can be the case, if:
• the unit shows signs of damage (outside or inside),
• a fluid has penetrated the unit,
• the unit is no longer operable,
• after extended storage under unfavorable conditions,
2.3 Dangers
Improper use of the unit can endanger the user or third parties and can damage
the unit and other property items.
2.3.1 Danger due to electric voltage
2.3.2 Danger due to permanent magnets
WARNING
Possible danger due to electric voltage!
If a supply voltage of 24 V DC is applied, higher voltage is generated in the
unit, which can be dangerous if the unit is opened in this state.
►Never open the unit when it is connected to the supply voltage.
WARNING
Possible danger due to electric voltage!
Opening a power supply pack can result in electric shock or injuries.
►Never open external power supply packs.
WARNING
Strong magnetic fields can disturb or impair the function of electronic
instruments, such as pacemakers.
►Maintain a safety clearance of 10 cm between pacemaker and magnet or
prevent the influence of magnetic fields with appropriate shields.

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2.3.3 Danger due to radio interference
(1) The RC 500 WL complies with Part 15 of the FCC regulations.
FCC: Federal Communications Commission,
approval authority for communication devices (USA)
2.3.4 Danger of material damage to unit
CAUTION
Possible danger due to radio interference!
During operation of the wireless RC 500 WL, a minimum distance of 7 cm
must be maintained between the remote control and personnel, with the
exception of hands and wrists(1).
►Operation at a shorter distance is not allowed.
NOTICE
Possible material damage due to helium.
Even when the unit is switched off, the sensor is affected by nearby helium.
Contact with increased concentrations of helium has a negative effect on the
minimum detection limit and can cause damage.
►Always keep the connecting flange of the unit closed with a blank flange.
Remove the blank flange only when installing the device on a system.
►Do not store the unit together with helium-filled gas cylinders (such as test
leaks) in a transport case, container, housing or cabinet.
►Do not spray the unit directly with helium.
NOTICE
Material damage due to overpressure.
Absolute pressure of more than 1100 hPa in the unit’s vacuum system can
destroy the sensor.
►The absolute pressure must remain below 1100 hPa at all times.
NOTICE
Possible material damage due to chemical solutions.
Alkalis, acids or solvents can damage the unit.
►Keep the unit away from alkalis, acids and solvents; in particular, avoid
penetration of these media into the connection flange.

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2.3.5 Dangers due to handling of the battery
Battery of the wireless remote control RC 500 WL
When handling the battery of the wireless RC 500 WL, comply with the
information in the operating manual for the remote control. (Document
number IG0140BDE).
2.4 Operator requirements
Safety conscious operation
►Operate the unit only if it is in perfect working order and as intended, in a
safety-conscious manner and fully aware of dangers, in compliance with this
operating manual.
►Observe and ensure compliance with the following regulations:
• Intended use,
• Statutory or other safety and accident prevention regulations,
• International, national and local standards and guidelines.
►Use only original spare parts or spare parts approved by the manufacturer.
►Keep this operating manual available at the operating site, also for later use.
Personnel qualifications
►All work must be performed only by technical specialists who have been
trained on the unit.
►Make sure that the authorized personnel have read and understood this manual
and all other applicable documents, especially the information on safety and
operation of the unit, before starting work.
►Define responsibilities, authorizations and supervision of personnel.
►Allow personnel in training to work on the unit only under the supervision of
technical specialists.
►Observe additional provisions and regulations that are specific to the unit.
2.5 User requirements
►Read, observe and follow the information in this operating manual and the
working instructions created by the owner, especially the safety instructions
and warnings.
►Perform all work based on the complete operating manual.

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3 Transport, storage, unpacking
3.1 Transport
►Transport the unit only in the original packaging.
3.2 Storage
Tip: To prolong the life of the sensor and to shorten the run-up time, we
recommend evacuating the unit or storing it in a helium-free gas (e.g. N2).
3.3 Unpacking
►Check shipment to make sure it is complete (see Chapter 4.1).
NOTICE
Possible material damage due to helium.
Even when the unit is switched off, the sensor is affected by nearby helium.
Contact with increased concentrations of helium has a negative effect on the
minimum detection limit and can cause damage.
►Always keep the connecting flange of the unit closed with a blank flange.
Remove the blank flange only when installing the device on a system.
►Do not store the unit together with helium-filled gas cylinders (such as test
leaks) in a transport case, container, housing or cabinet.

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4Description
4.1 Scope of delivery
• MiniTest 300
• Power supply unit
• Power cable
• Product documentation
• Coupling for an external vacuum pump
Note: The remote control required for operation of the unit is not included in the
scope of delivery (for ordering information, see Chapter 11.2)
4.2 Design of the unit
The unit features a compact housing for mobile use.
On the rear side there is a DN KF 25 connection flange (see Fig. 3).
It is used to connect the unit to the system to be tested for leaks.
The MiniTest 300 has no wear parts and is therefore maintenance-free.
Fig. 1 MiniTest 300

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4.2.1 Display and operation
On the front side there is an operating mode display, which can light up in
different colors:
All other operating and display elements are located on the remote control.
4.2.2 Connecting flange
The connection flange on the rear side of the unit must be closed with a blank
flange when the unit is not in operation.
During installation on a system, a sealing ring with a sinter filter must be
inserted at the connection flange (see Chapter 4.3.3).
Color Meaning
Green Ready for operation or in operation
Yellow No connection to the remote control RC 500/RC 500 WL and
no continuous connection to the computer.
Red Malfunction
Fig. 2 The display element lights up in three different colors

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4.2.3 Connection of optional vacuum pump
Fig. 3 Vacuum connection flange of the unit
Fig. 4 Connection of vacuum pump

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The connection for the optional vacuum pump has a shut-off valve. The valve
allows passage when the coupling of the connecting hose is attached.
If the valve is actuated otherwise, this can result in venting of vacuum system
and the connected system.
All vacuum pumps that generate a final pressure that is lower than the pressure
in the system can be connected. See also Chapter 4.3.5.
4.2.4 Electrical connections
* This connection is not yet enabled.
Fig. 5 Electrical connections on the MiniTest 300
No. Description of connection
1 Radio transmitter:
Radio transmitter for wireless remote control D-SUB (DE9)
2 Input / Output:
Inputs and outputs for D-SUB (DB25)
3 RS-485:
Host RS-485 (serial port)
4 * Extension:
Extension set
5 RC (Remote control):
Wired remote control (RJ-25)
6 Gauge:
External pressure sensor
7 24 V DC:
Supply voltage to the unit (24 V DC power supply pack)
1
2
3
4
6
7
5

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INPUT / OUTPUT
Input and output signals, 25-pin, D-sub socket
* The functions of the digital inputs Pin 6, 8 and 9 are triggered by a positive
flank (+18 … +30 V; ca. 1.2 mA) and are at the same level as the control unit.
4.3 Components and accessories
4.3.1 Power supply pack for the MiniTest 300
The power supply pack for the MiniTest 300 provides the supply voltage for
operating the unit.
On the input side the power supply pack is connected to the mains voltage by
means of a mains cable. The mains cable plugs into the power supply pack.
On the output side the cable is permanently connected to the power supply
pack.
The cable has a coaxial power connector with a lock nut.
(For technical data, see Chapter 5.3.)
WARNING
Possible danger due to electric voltage
If voltages >60V (DC) or 24V (AC) are connected to the socket, this can destroy
the unit or cause danger to life and limb.
►Never connect a higher voltage than >60V (DC) or 24V (AC).
Fig. 6
Pin Assignment Explanation
1 Channel 1 Analog output 0 … 10 V
2 Channel 2 Analog output 0 ... 10 V
3 AGND Reference potential of the analog outputs
6 PLC_In_1 Clear: Resets warnings and errors *
8 PLC_In_2 Zero: Same function as ZERO key *
9 PLC_In_3 currently not used
14 DGND Reference potential of the digital inputs
16 PLC_OUT_1 Set at factory: Ready; see Chapter 7.4.1.6.
17 PLC_OUT_2 Set at factory: Trigger; see Chapter 7.4.1.6.
18 PLC_OUT_3 Set at factory: WrnErr; see Chapter 7.4.1.6.
23 DGND Reference potential of the digital outputs
25 +24 V +24 V e.g. for actuating the digital inputs; max 100 mA
1
14
13
25

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4.3.2 Mains adapter/charger for the wireless remote
control RC 500 WL
The mains adapter/charger is used to charge the battery of the wireless remote
control RC 500 WL.
The coaxial power connector on the cable of the power supply pack must be
connected to the remote control for charging.
During charging the remote control is always switched on and the LED
“CHARGING” lights up.
The LED switches off as soon as the battery has fully charged.
The battery can be charged during operation.
The power supply pack can be used anywhere in the world. The mains plug can
be exchanged for adaptation to the national design.
(For technical data, see Chapter 5.3.)
4.3.3 Sinter filter for vacuum connection
The sinter filter protects the unit’s vacuum system from contamination.
It is inserted at the vacuum connection flange of the unit (see Fig. 10, no. 1).
Fig. 7 Sinter filter for vacuum connection

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4.3.4 Calibrated test leak (pin leak)
An optional calibrated test leak is installed on the system to be tested by means
of a KF16 flange.
It provides defined leakage.
It is used to calibrate the MiniTest 300 on the system.
(See also Chapter 4.4.)
4.3.5 Coupling for a hose to the vacuum pump
Fig. 8 Calibrated test leak with connection flange
Internal diameter of the hose: 4mm
External diameter of the hose: 6mm
Fig. 9 Coupling

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4.4 Function
Functioning principle of the unit and of leak detection
Connect the unit to the system to be checked (6) via the vacuum connection
flange (1).
The system (6) must be evacuated (P < 20 hPa) to test for leaks or find leaks.
The connection (3) can optionally be connected to an additional vacuum pump.
To prepare for the leak test, this pump can evacuate the unit’s vacuum system
while the shut-off valve (9) is still closed.
For the test, the shut-off valve (9) has to be opened. The optional pump can
generate a gas flow, which reduces the response time of the sensor at higher
system pressures.
The sensor (2) measures the partial pressure of helium in the vacuum.
The displayed leakage rate is calculated based on this pressure and the
throughput of the installed pump (10).
Fig. 10 For example: Vacuum diagram of the MiniTest 300 on a system
No. Description
1 Vacuum connection flange DN KF 25
2Sensor
3 Connection of optional vacuum pump
4 Valve
5 Inlet with throttle valve for purging the sensor with air
6 System being tested under vacuum
7 Calibrated test leak (pin leak)
8 Shut-off valve for test leak
9 Shut-off valve to MiniTest 300
10 Vacuum pump of system being checked
2
1
6
9
10
8
7
4
3
5
MiniTest 300