Varian HeliTest User manual

87-900-045-01 (D)
JULY 2003
INSTRUCTION MANUAL
MANUALE ISTRUZIONI
NOTICE DE MODE D’EMPLOI
BEDIENUNGSHANDBUCH
HeliTest
Model 969-3510
Model 969-3570
Model 969-3575
vacuum technologies

HeliTest

SAFETY SUMMARY ...........................................................................................................1
CHAPTER 1 - DESCRIPTION.............................................................................................2
1.1 GENERAL.......................................................................................................................................2
1.2 HELITEST DESCRIPTION .............................................................................................................3
1.2.1 Theory of operation ..............................................................................................................3
1.2.2 Basic unit..............................................................................................................................4
1.2.3 Battery unit ...........................................................................................................................6
1.2.4 Ac/Dc converter - battery charger ........................................................................................7
1.2.5 Car battery cable..................................................................................................................7
1.2.6 Extension probe stick...........................................................................................................8
1.2.7 Long probe ...........................................................................................................................8
1.2.8 Probe pin heads set .............................................................................................................9
1.3 HELITEST MODULE SPECIFICATIONS .....................................................................................10
1.4 BATTERY UNIT SPECIFICATIONS.............................................................................................10
CHAPTER 2 - INSTALLATION .........................................................................................11
2.1 GENERAL.....................................................................................................................................11
2.2 SET UP FOR HELITEST TOGETHER WITH BATTERY UNIT ...................................................11
2.3 KNAPSACK ..................................................................................................................................12
2.4 SET UP FOR HELITEST WITH BATTERY CHARGER ...............................................................12
2.5 EXTRACTING THE PROBE FROM ITS HOUSING.....................................................................13
2.6 SET-UP WITH EXTENSION PROBE...........................................................................................13
2.7 SET UP WITH ACCESSORIES (LONG PROBE AND PROBE PIN HEADS) .............................14
CHAPTER 3 - OPERATING INSTRUCTIONS ..................................................................15
3.1 GENERAL.....................................................................................................................................15
3.2 HELITEST START UP..................................................................................................................16
3.2.1 Self test ..............................................................................................................................16
3.3 OPERATIVE MODE......................................................................................................................18
3.3.1 PROBE operation...............................................................................................................19
3.3.2 LIGHT operation.................................................................................................................19
3.3.3 AUDIO operation................................................................................................................19
3.3.4 Sensitivity changes ............................................................................................................19
3.3.5 ZERO operation .................................................................................................................19
3.3.6 SET POINT mode ..............................................................................................................20
3.3.7 CLEANUP operation ..........................................................................................................20
3.3.8 Battery check .....................................................................................................................21

3.4 OPERATION WITH AC/DC CONVERTER ..................................................................................21
3.5 SHUT-DOWN................................................................................................................................21
CHAPTER 4 - MAINTENANCE & SPARE PARTS...........................................................22
4.1 GENERAL.....................................................................................................................................22
4.2 CALIBRATION (CAL) ...................................................................................................................22
4.3 PROBE FILTER CLEANING ........................................................................................................23
4.4 EXTENSION PROBE FILTER CLEANING ..................................................................................23
4.5 SELF TEST MESSAGES .............................................................................................................24
4.6 BATTERY RECHARGE................................................................................................................25
4.7 HELITEST SPARES AND ACCESSORIES .................................................................................25
NORME DI SICUREZZA ...................................................................................................26
CAPITOLO 1 - DESCRIZIONE..........................................................................................27
1.1 INFORMAZIONI GENERALI ........................................................................................................27
1.2 DESCRIZIONE DELL'HELITEST .................................................................................................28
1.2.1 Principio di funzionamento.................................................................................................28
1.2.2 Unità base ..........................................................................................................................29
1.2.3 Batteria ...............................................................................................................................31
1.2.4 Alimentatore - carica batteria .............................................................................................32
1.2.5 Cavo per l'alimentazione tramite presa accendisigari di autoveicoli..................................32
1.2.6 Braccio telescopico ............................................................................................................33
1.2.7 Sonda con tubazione lunga ...............................................................................................33
1.2.8 Set di ugelli per sonda........................................................................................................34
1.3 CARATTERISTICHE TECNICHE DEL MODULO BASE HELITEST...........................................35
1.4 CARATTERISTICHE TECNICHE DELLA BATTERIA..................................................................35
CAPITOLO 2 - INSTALLAZIONE .....................................................................................36
2.1 DESCRIZIONE GENERALE.........................................................................................................36
2.2 MONTAGGIO DELL'HELITEST CON LA BATTERIA ..................................................................36
2.3 ZAINETTO ....................................................................................................................................37
2.4 UTILIZZO DELL'HELITEST CON L'ALIMENTATORE .................................................................37
2.5 ESTRAZIONE DELLA SONDA DAL SUO ALLOGGIAMENTO ...................................................38
2.6 INSTALLAZIONE DEL BRACCIO TELESCOPICO......................................................................38
2.7 INSTALLAZIONE DEGLI ACCESSORI (SONDA CON TUBAZIONE LUNGA E UGELLI)..........39

CAPITOLO 3 - ISTRUZIONI OPERATIVE ........................................................................40
3.1 DESCRIZIONE GENERALE.........................................................................................................40
3.2 ACCENSIONE DELL'HELITEST ..................................................................................................41
3.2.1 Autodiagnosi ......................................................................................................................41
3.3 FUNZIONAMENTO.......................................................................................................................43
3.3.1 Funzione PROBE (sonda)..................................................................................................44
3.3.2 Funzione LIGHT (illuminazione display) ............................................................................44
3.3.3 Funzione AUDIO (segnale acustico)..................................................................................44
3.3.4 Funzione SENS (cambio di sensibilità)..............................................................................44
3.3.5 Funzione ZERO .................................................................................................................44
3.3.6 Funzione MODE (misurazione/set point) ...........................................................................45
3.3.7 Funzione CLEANUP ..........................................................................................................45
3.3.8 Controllo della batteria .......................................................................................................46
3.4 FUNZIONAMENTO CON L'ALIMENTATORE.............................................................................46
3.5 SPEGNIMENTO DELL'HELITEST ...............................................................................................46
CAPITOLO 4 - MANUTENZIONE E PARTI DI RICAMBIO...............................................47
4.1 INFORMAZIONI GENERALI ........................................................................................................47
4.2 CALIBRAZIONE (CAL) .................................................................................................................47
4.3 PULIZIA DEL FILTRO DELLA SONDA ........................................................................................48
4.4 PULIZIA DEL FILTRO DEL BRACCIO TELESCOPICO .............................................................48
4.5 MESSAGGI DI AUTODIAGNOSI .................................................................................................49
4.6 RICARICA DELLA BATTERIA......................................................................................................50
4.7 RICAMBI ED ACCESSORI DELL'HELITEST...............................................................................50
INFORMATIONS SÉCURITÉS..........................................................................................51
CHAPITRE 1 - DESCRIPTION..........................................................................................52
1.1 GÉNÉRALITÉS..............................................................................................................................52
1.2 DESCRIPTION DE L'HELITEST ..................................................................................................53
1.2.1 Théorie de fonctionnement .................................................................................................53
1.2.2 Unitè de base .....................................................................................................................54
1.2.3 Batterie ...............................................................................................................................56
1.2.4 Convertisseur/Chargeur de batterie Ac/Dc ........................................................................57
1.2.5 Câble allume-cigare ...........................................................................................................57
1.2.6 Canne télescopique d'extension de sonde ........................................................................58
1.2.7 Extension de sonde............................................................................................................58
1.2.8 Kit d'embouts de sonde......................................................................................................59
1.3 SPÉCIFICATIONS TECHNIQUES DU HELITEST.......................................................................60
1.4 SPÉCIFICATIONS TECHNIQUES DU MODULE BATTERIE......................................................60

CHAPITRE 2 - INSTALLATION ........................................................................................61
2.1 GÉNÉRALITÉS.............................................................................................................................61
2.2 INSTALLATION DE L'HELITEST ET DE LA BATTERIE .............................................................61
2.3 SAC A DOS ..................................................................................................................................62
2.4 UTILISATION DE L'HELITEST AVEC LE CHARGEUR DE BATTERIES ..................................62
2.5 EXTRACTION DE LA SONDE DE SON RÉCEPTACLE ............................................................63
2.6 UTILISATION DE LA CANNE D'EXTENSION ............................................................................63
2.7 INSTALLATIONS DES ACCESSOIRES (EXTENSION DE SONDE
ET EMBOUTS DE SONDE) .........................................................................................................64
CHAPITRE 3 - UTILISATION............................................................................................65
3.1 GÉNÉRALITÉS.............................................................................................................................65
3.2 MISE EN MARCHE DE L'HELITEST ...........................................................................................66
3.2.1 Auto-contrôle......................................................................................................................66
3.3 UTILISATION................................................................................................................................68
3.3.1 Utilisation de la touche "PROBE”.......................................................................................69
3.3.2 Utilisation de la touche "LIGHT".........................................................................................69
3.3.3 Utilisation de la touche "AUDIO"........................................................................................69
3.3.4 Changement de sensibilité.................................................................................................69
3.3.5 Utilisation de la touche "ZERO" .........................................................................................69
3.3.6 Mode point de consigne .....................................................................................................70
3.3.7 Nettoyage rapide................................................................................................................70
3.3.8 Vérification de la charge de la batterie...............................................................................71
3.4 FONCTIONNEMENT AVEC L’ALIMENTATEUR ........................................................................71
3.5 ARRÊT..........................................................................................................................................71
CHAPITRE 4 - ENTRETIEN & PIECES DÉTACHÉES .....................................................72
4.1 GÉNÉRALITÉS.............................................................................................................................72
4.2 ETALONNAGE .............................................................................................................................72
4.3 NETTOYAGE DU FILTRE DE LA SONDE...................................................................................73
4.4 NETTOYAGE DU FILTRE DE LA CANNE D'EXTENSION........................................................73
4.5 AUTODIAGNOSTIC......................................................................................................................74
4.6 RECHARGE DE LA BATTERIE ...................................................................................................75
4.7 PIÈCES DE RECHANGES ET ACCESSOIRES .........................................................................75

SICHERHEITSHINWEIS ...................................................................................................76
KAPITEL 1 - BESCHREIBUNG ........................................................................................77
1.1 ALLGEMEINES.............................................................................................................................77
1.2 HELITEST BESCHREIBUNG.......................................................................................................78
1.2.1 Arbeitsprinzip .....................................................................................................................78
1.2.2 Grundgerät .........................................................................................................................79
1.2.3 Batterie ...............................................................................................................................81
1.2.4 Lade-und Netzgerät ...........................................................................................................82
1.2.5 Verlängerungskabel für Autobatterie .................................................................................82
1.2.6 Teleskopschnüffelsonde ....................................................................................................83
1.2.7 Verlängerung der Handsonde............................................................................................83
1.2.8 Satz von Wechselköpfen....................................................................................................84
1.3 HELITEST SPEZIFIKATIONEN....................................................................................................85
1.4 BATTERIE SPEZIFIKATIONEN ...................................................................................................85
KAPITEL 2 - INSTALLATION ...........................................................................................86
2.1 ALLGEMEINES.............................................................................................................................86
2.2 INBETRIEBNAHME DES HELITESTS MIT EINER BATTERIE..................................................86
2.3 RUCKSACK ...................................................................................................................................87
2.4 HELITEST ANSCHLUSS ANS NETZ ÜBER DAS LADEGERÄT ...............................................87
2.5 SCHNÜFFLER DEM GEHÄUSEENTNEHMEN ..........................................................................88
2.6 ANSCHLUß DES TELESKOP- SCHNÜFFLERS ........................................................................88
2.7 INBETRIEBNAHME MIT ZUBEHÖR (VERLÄNGERUNG DER MEßSONDE
UND ERSATZPROBENKÖPFE) ..................................................................................................89
KAPITEL 3 - BETRIEBANWEISUNG ...............................................................................90
3.1 ALLGEMEINES.............................................................................................................................90
3.2 HELITEST START........................................................................................................................91
3.2.1 Eigentest ............................................................................................................................91
3.3 MEßBETRIEB ...............................................................................................................................93
3.3.1 Handhabung der Schnüffelsonde ......................................................................................94
3.3.2 Beleuchtung der Anzeige ...................................................................................................94
3.3.3 Akustische Leckanzeige.....................................................................................................94
3.3.4 Änderung der Empfindlichkeit ............................................................................................94
3.3.5 Nullabgleich........................................................................................................................94
3.3.6 Schwellwert-Modus ............................................................................................................95
3.3.7 Funktion "CLEANUP".........................................................................................................95
3.3.8 Batterie prüfen....................................................................................................................96
3.4 BETRIEB MIT DEM NETZGERÄT ...............................................................................................96
3.5 ABSCHALTEN ..............................................................................................................................96

KAPITEL 4 - WARTUNG UND ERSATZTEILE ................................................................97
4.1 ALLGEMEINES.............................................................................................................................97
4.2 EICHUNG (CAL) ...........................................................................................................................97
4.3 FILTER AN DER SCHNÜFFELSONDE REINIGEN....................................................................98
4.4 REINIGEN DES GESINTERTEN BRONZEFILTERS AN DER
TELESKOPSCHNÜFFELSONDE ................................................................................................98
4.5 EIGENTEST ANZEIGEN ..............................................................................................................99
4.6 BATTERIE AUFLADEN ..............................................................................................................100
4.7 HELITEST ERSATZTEILE UND ZUBEHÖR.............................................................................100

1 87-900-045-01 (D)
SAFETY SUMMARY
Operators and service personnel must be aware of all
hazards associated with this equipment. They must
know how to recognize hazardous and potentially
hazardous conditions, and know how to avoid them.
The consequences of unskilled, improper, or careless
operation of the equipment can be serious. This
product must only be operated and maintained by
trained personnel. Every operator or service person
must read and thoroughly understand
operation/maintenance manuals and any additional
information provided by Varian. All warnings and
cautions should be read carefully and strictly observed.
Address any safety, operation, and/or maintenance
questions to your nearest Varian office.
The following format is used in this manual to call
attention to hazards:
!
Warnings are used when failure to observe instructions
or precautions could result in injury or death.
CAUTION
Cautions are used when failure to observe instructions
could result in damage to equipment, whether Varian-
supplied or other associated equipment.
NOTE
Information to aid the operator in obtaining the best
performance from the equipment.
WARNING!

CHAPTER 1 - DESCRIPTION
2 87-900-045-01 (D)
1.1 GENERAL
The HeliTest is a self contained, ready to use portable
leak detector able to detect, in fully automatic,
autoranging mode, a helium concentration as small as
2 parts per million (ppm).
The leak value is displayed on an LCD alphanumeric
display, and an audio signal proportional to Helium
concentration is provided.
It incorporates all facilities required for self-diagnostic
and protection features, and all controls are on the front
panel.
The operator can hang the entire unit over the shoulder
and will search for leaks using the extension probe.
Fig. 1-1 is a picture of the HeliTest with battery.
Figure 1-1 - Helitest with battery

CHAPTER 1 - DESCRIPTION
3 87-900-045-01 (D)
1.2 HELITEST DESCRIPTION
The HeliTest set is available in five configurations.
Model 969-3510, consisting of:
• 1 HeliTest basic unit;
• 1 Battery;
• 2 Straps;
• 2 Spare main fuses 1.6 A.
Model 969-3570, consisting of:
• 1 HeliTest basic unit;
• 2 Batteries;
• 2 Straps;
• 1 Ac/Dc converter-battery charger, 100-240 Vac
input (50/60 Hz);
• 1 Power cable (battery to HeliTest);
• 1 Car battery cable;
• 1 Extension probe stick;
• 2 Spare main fuse 1.6 A;
• 1 Travelling case.
Model 969-3575, consisting of:
• 1 HeliTest basic unit;
• 1 Ac/Dc converter battery charger, 100-240 Vac
input (50/60 Hz);
• 2 Spare main fuse 1.6 A.
1.2.1 Theory of operation
The piece to be tested is filled with a helium/air mixture.
The probe is passed over the suspected area, and a
gas sample is continuously sucked through the flexible
extension by the sampling line.
The pump blows the gas sample over a special heated
silica capillary which stops atmospheric gases but
allows Helium to pass through due to its small
molecule. The atmospheric gas is exhausted at the top
of the sensor, while Helium molecules reach the
pressure detector. The electric signal related to Helium
pressure is processed by a dedicated software and
hardware combination allowing a direct read-out of
Helium concentration on the display (refer to fig. 1-2).
Figure 1-2 - Operating principle

CHAPTER 1 - DESCRIPTION
4 87-900-045-01 (D)
1.2.2 Basic unit
HeliTest is driven by a single chip microcomputer and
consists of:
• front panel display and keyboard;
• microprocessor PCB, where sensor temperature
controller and pressure detector circuitries are
located;
• high voltage PCB, which contains the high voltage
power supply for pressure detector;
• Helium sensor (based on a silica capillary), with
pressure detector;
• sampling line, where a membrane pump conveys
the sampling gas into the detector;
• sniffing probe, connected to the module by a
standard 1.5 meter long flexible extention.
A dedicated non-volatile RAM is used to store the
operating parameters and information if power failure
occurs for a period of 10 years accumulated off time.
Figure 1-3 - Basic unit

CHAPTER 1 - DESCRIPTION
5 87-900-045-01 (D)
The HeliTest front panel controls are shown in fig. 1-4.
Figure 1-4 - HeliTest from panel
1. ON - key board pushbutton to switch on the unit.
2. OFF - key board pushbutton to switch off the unit.
3. LCD back lighted alphanumeric display, dot matrix, 2
lines, 16 characters.
4. MODE - Key board pushbutton used to select operation
with adjustable set point.
5. SENS - key board pushbutton used to switch the
sensitivity from high to low, and vice versa.
6. AUDIO - key board pushbutton used to switch on and off
the buzzer.
7. PROBE - key board pushbutton used to switch on and
off the sampling line when the probe is out of its housing.
8. ZERO - key board pushbutton used to switch from
automatic zero to fixed zero.
9. CLEANUP - this function, activated by simultaneously
pressing the ZERO and the PROBE pushbuttons for at
least 2 seconds, is used for a fast zero recovery after an
Helium saturation condition.
10. BATTERY - this function, activated by simultaneously
pressing the PROBE and the AUDIO pushbuttons for at
least 2 seconds, is used to check the battery voltage.
11. LIGHT - this function, activated by simultaneously
pressing the AUDIO and the SENS pushbuttons for at
least 2 seconds, is used to switch on and off the back
light of the display.
12. CAL - this function, activated by simultaneously pressing
the SENS and the MODE pushbuttons for at least 2
seconds, is used to initiate the calibration routine.
13. Jack for remote earphone.

CHAPTER 1 - DESCRIPTION
6 87-900-045-01 (D)
The HeliTest side and rear panel controls are shown in fig. 1-5.
Figure 1-5 - HeliTest side and rear panel
1. Mains power cable connector
2. Mains quick spring connection
3. Mains fuse
4-5. Labels
6. Belt attachment point
7. Gas outlet (not to be covered)
8. Pushbutton (for battery release)
1.2.3 Battery unit
The battery unit (see fig. 1-6) consists of "maintenance free" sealed rechargeable batteries, with gelled electrolyte.
Figure 1-6 - Battery unit side and front panel
1. Belt attachment point
2. Label
3. Mains quick connection
4. Mains power cable connector
When the battery is fully charged, it allows 4 operating
hours for HeliTest, with the display back light on, and 5
operating hours with the display back light off, prior to
being discharged.

CHAPTER 1 - DESCRIPTION
7 87-900-045-01 (D)
1.2.4 Ac/Dc converter - battery charger
The Ac/Dc converter (see fig. 1-7) consists of a power
supply 100/240 Vac, 50/60 Hz input.
The output can be:
• 13.8 Vdc with no load
• 12.5 Vdc with a 1.8 A absorption.
It may be used instead of the battery unit and to
recharge the battery.
Figure 1-7 - Battery charger
1. Battery charger cable (12 Vdc output)
2. Green/red LED
3. Mains cable
1.2.5 Car battery cable
The car battery cable (see fig. 1-8) consists of a 10
meters long cable, with cigarette lighter plug and
HeliTest mains connector.
Figure 1-8 - Cigarette lighter cable
1. HeliTest
2. Car cigarette lighter plug

CHAPTER 1 - DESCRIPTION
8 87-900-045-01 (D)
1.2.6 Extension probe stick
The extension probe stick (see fig. 1-9), consists of 4
telescoping sectors, with a funnel shaped guard.
Figure 1-9 - Extension probe stick
1. Guard
2. Telescoping sectors
1.2.7 Long probe
The long probe (see fig. 1-10) is available as an option.
It consists of a standard hand held probe with 10 m
long tubulation, coiled on 8 cm diameter.
Figure 1-10 - HeliTest long probe

CHAPTER 1 - DESCRIPTION
9 87-900-045-01 (D)
1.2.8 Probe pin heads set
The probe pin heads set, available as option, includes
(see fig. 1-11):
• Metal flexible tubulation (semi-rigid), total length
184mm
• Rilsan tubulation, total length 175 mm
• Stainless steel straight tubulation, total length
133 mm
• 2 sintered bronze filters
• 2 O-rings for probe seal.
Figure 1-11 - HeliTest probe pin head set

CHAPTER 1 - DESCRIPTION
10 87-900-045-01 (D)
1.3 HELITEST MODULE SPECIFICATIONS
Detectable concentration 2 to 9x105ppm (parts
per million)
Response time 2 seconds for Helium, in
accordance with AVS
standard 2.1.
Reading drift maximum 10 ppm every
10 minutes
Leak indicator
A
lphanumeric display, 2
lines, 16 characters
Audio alarm Variable frequency
Clean-up time 30 seconds typical,
5 minutes maximum
after helium saturation
Self test and Warm-up
time
3 minutes minimum
Turn-off time Immediate
Operating conditions
- temperature
- humidity
+5 °C to +40 °C
90% maximum relative
humidity
(without condensation)
Jack for earphone 3.5 mm diameter
earphone mono or
stereo 32 ohm
Power requirement 12 Vdc, 1.4 A
Portability Belt
Weight 2 kg - 4.4 lbs
Dimensions
(inches)
(mm)
Width 7.9
Height 3.5
Depth 6.7
Width 200
Height 90
Depth 170
1.4 BATTERY UNIT SPECIFICATIONS
Nominal voltage 12 Vdc
Nominal capacity 7.2 Ah (rated capacity at
20 hours discharge)
Self discharge 0.1% max. of the rated
capacity per day at +20
°C of ambient
temperature
Life 4-5 years (end of life
being defined as when
60% of the rate capacity
is reached, as per DIN
43534)
Operating
- temperature
- position
-20 °C to +40 °C
any
Storage
- temperature
- position
- recharge
-20 °C to +40 °C
any
at least every 6 months
Weight 2.7 Kg - 6 lbs
Dimensions
(inches)
(mm)
Width 7.9
Height 3.5
Depth 6.7
Width 200
Height 90
Depth 170