HELISYSTEM

4.007.0.047
LEAK DETECTION SYSTEM

USER MANUAL

V.1.0

rev:

8.014.0.047

GALILEO TP
PROCESS EQUIPMENT
Via di Castelpulci, 17/M-17/H
50018 Scandicci - FI - ITALY

GALILEO TP
PROCESS EQUIPMENT

Mod. LDS:
S.N. 47105
Voltage:
Current:
Weight
Supply Pressure He:
Max Pressure N2:
Air Pressure:

CE
Date 20-11-2010
400 V 3 ph + n 50/60 Hz
63 A, 25 kW
4000 kg
4000 kPa
10000 kPa
600-800 kPa

Via di Castelpulci 17/M-17/H - 50018 Scandicci (FI) ITALY

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INDEX
SECTION 1

INTRODUCTION

SECTION 2

PLANT DESCRIPTIONS

SECTION 3

TEST CYCLE DESCRIPTIONS

SECTION 4

PLANT TECHNICAL SPECIFICATIONS

4.1
4.2
4.3
4.4

SECTION 5

ANALYSIS SPECIFICATIONS
AUTOMATIC CYCLE SPECIFICATIONS
STRUCTURAL PERFORMANCES
4.3.1 TEST CHAMBER
4.3.2 OPEN/CLOSE CHAMBER SYSTEM
GENERAL PERFORMANCES
MAINTENANCE AND INSTALLATION

5.1
5.2
5.3
5.4
5.5
5.6

STORING AND HANDLING

SPECIFICATIONS PLANTS TRANSPORT
INSTALLATION
INSTALLATION OF ELECTRICAL SUPPLY
CONNECTION DISCHARGE VACUUM PUMP
CONNECTION TECHNICAL GAS

SECTION 6

TECHNICAL FEATURES

SECTION 7

OPERATIVE INSTRUCTIONS
7.1
7.2
7.3
7.4
7.5

SECTION 8

STARTING OF THE PLANT

CYCLE SELECTION
CHANGE OF THRESHOLD VALUE AND INSTRUMENT
CALIBRATION
LUMINOUS COLUMNS
INSTRUCTIONS FOR AUTOMATIC START CYCLE
DESCRIPTIONS OF ELECTROMECHANICAL COMPONETS

8.1
8.2
8.3
SECTION 9

BEFORE SWITCH ON THE PLANT

PLANT PUSHBUTTON
CHAMBER TEST LIGHT PUSHBUTTON AND SIGNALS
USER INTERFACE DESCRIPTION

9.1
9.2
9.3
9.4

INTRODUCTION
MAIN MENU
AUTOMATIC CYCLE
MANUAL CYCLE
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9.5
9.6
9.7

PLANT CALIBRATION
PARAMETERS
ARCHIVES
9.7.1
MODELS
9.7.2
USERS
9.7.3
TEST FOR DATA
9.7.4
TEST FOR MODELS
9.7.5
ALL TESTS
9.7.6
SAVE TESTS

9.8
9.9
9.10

EXIT FROM THE PROGRAMM

CHANGE PASSWORD
SNIFFER CYCLE

SECTION 10

MAINTENANCE
10.1
10.2
10.3
10.4
10.5
10.6

DAILY
MONTHLY
EVERY SIX MONTH PERIOD
ANNUAL
EVERY 2.000-6.000-10.000 HOURS
EVERY 3 YEARS

SECTION 11

FAILURE ANALISYS

SECTION 12

ALARM ANALISYS

SECTION 13

SPARE PARTS

SECTION 14

LAY-OUT and DIAGRAM

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SECTION 1: INTRODUCTION
The plant Leak Detection System (named in the following pages LDS) allows to make Helium test
on a lot of components (radiators, valves ) with the goal to detect and measure their leaks.
The unit contains a mass spectrometer with Helium as tracer element in order to measure global
leak of the component. This one is located into a vacuum chamber, also called analysis chamber.
After, a vacuum is created into the chamber and the component is pressured with Helium. When the
vacuum into the chamber reach an adapt value the mass spectrometer is put in contact with the
analysis chamber in order to measure the output quantity of Helium from the detected component
and define the leakage value.
The test cycle is totally automatic and is controlled by a PLC. The user interface is managed by an
industrial PC by means of dedicated software totally projected and developed by GALILEO TP.
LDS can be used:
To detect the absence of occlusions in the component (if present the input and output
junctions).
To detect the mechanical resistance of the component.
To detect the presence of big leakage
To detect the presence of small leakage and to measure them.
One complete test cycle is composed of the follow phases:
Vacuum chamber
the chamber is brought by the atmospheric pressure thin to a value <= to 25mbar ABSs,
value parameter setting. Reached the value of vacuum the chamber will be put in
communication with the circuit of analysis.
It verifies occlusion
the component loaded into the chamber will be pressurized with air to low pressure for the
verification of possible occlusions, for this verification a simple sensor of pressure can be
used installed to the opposite extremity to the load or a more sophisticated sensor of flow
where can also be verified the exact course of the made a will piece
High Pressure Loading
The component is pressurized with nitrogen or dry air until a prefixed value (about 20-100
bar) in order to detect the absence of occlusions and the circuit resistance. The maximum
value of pressure that the user can introduce is 100 Bar. The high pressure loading is enabled
if the vacuum of the chamber has reached the set point parameter min vacuum chamber for
charging HP nitrogen. This parameter must be less than 5000 mPsi.
Pressure Drop Test:
The component is isolated on itself in order to detect if its drop pressure go down the fixed
value
Vacuum component:
finished the verification of fall of pressure the component is voided with the purpose not to
create possible mixtures air/helium or to alter the percentage of mixtures of helium used for
the pressurization for the helium test
Helium Pressure Loading:
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The component is pressurized with Helium until a pressure fixed from the user for the Leak
Detection phase.
Leakage Detection Test:
Measure of the Helium quantity which escape from the component and relative comparison
with the value defined as threshold reject.

Helium discharge:
finished the phase of "Leak Detection" the plant will unload the residual helium from the
component bringing the component to the atmospheric pressure. Where foreseen the
unloaded helium will be carried at the recovery
Chamber ventilation:
also reached the atmospheric pressure in the piece the chamber through a valve of
ventilation will be brought to the atmospheric pressure and subsequently open for the unload
some test a will component

The above reported description is relative to a standard test cycle.

Considering the plant function is also possible to make test with sniffer method .
The sniffer method consists to pressurize the component with Helium and to detect the leakage
using a sniffer connected to the mass spectrometer.
THE MANUFACTURER IS RAISED FROM RESPONSIBILITY IN CASE OF:
Improper using of the plant.
Defects of feeding electrical worker and gases of not consistent tests.
Modifications and/or participations do not authorize to you.
Missed observation of these instructions.
TEST COMPONENT WARNINGS CAUSED.
SIMBOLS, COMMANDOS and CONVENTIONS
This symbol identifies of the operations that, if not executed like prescribed,
can take damages to the system or the persons assigned to the execution of
the described operations.

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SECTION 2: PLANT DESCRIPTION

The plant is manufactured with a frame, closed into varnishing panels and on adapt support. The
completed system is mounted on adapt supports in order to guarantee stability to the plant structure.
Into the frame are positioned all the components necessary for the test.
The test chamber is vacuum tight container, completely made in stainless steel, with the function to
contain the components to test. The chamber is divided in two parts: the cover that is mobile and the
chamber that is fixed. On the cover there is the support where to put the components to test. The
cover is the part that, with its movement, open and closes the chamber and the seal between cover
and chamber is guarantee by an adapt seal. The component to test can be put inside the chamber or
extracted from the chamber only when the chamber is opened. Each chamber is connected to the
vacuum pumping group and to the Helium mass spectrometer with components (stainless steel
pipes, valves,) previously tested, that means that these components have a leak that does not
modify the result of the test on the component.
The cover is connected to the pneumatic couplers in order to accommodate the piece for the test.
For the interface human/machine (HMI) the system is guaranteed from a program developed by
GALILEO TP and a pc and a monitor touch screen where all the phases of trial and the necessary
functions to the formulation of the parameters will be visualized.

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SECTION 3: TEST CYCLE DESCRIPTION

The test cycle can be described in the following way:

COMPONENT POSITIONING: Manually the component to be tested a will is positioned

on the support in the chamber
HOOK UP TO THE COUPLERS: The user manually hook up the component to the
couplers system which is fixed on the test chamber
LOCKING CHAMBER: The test chamber is closed manually.
START OF CYCLE: The user push the start cycle button and the door is pneumatically
locked.
CHAMBER EVACUATION: the pressure into the closet test chamber goes down until a
fixed value (usually 1 mPsi or down).
CHARGE LOW PRESSURE AIR: this is the first test on the component, testing the
absence the occlusion and when request measure the capacity (optional)
PRESSURE DECAY TEST: the component pressure go up until a set value, normally
between from 100 to 1000 Psi, in order to check gross leak of the component with the
pressure decay test.
AIR CHARGE IS CLOSED: after reaching the set pressure the component is isolated on
itself.
STABILIZATION: time to wait in order to have stabilization into the component, before
verify gross leaks with the method of pressure drop.
PRESSURE DROP VERIFICATION: Verification that in the set time interval the
pressure decrease inside the component is lower than the set value.
AIR DISCHARGE: discharge of the gas used to pressure the component.
COMPONENT EVACUATION: evacuation of the component in order to avoid the
formation of air pocket.
TRANSFER VALVE IS OPEN: when the adapt vacuum value is reach into the chamber
and when are finished the under reported tests on the component, the system open the
transfer valve which connect the mass spectrometer with the test chamber.
BACKGROUND SIGNAL READING: reading and memorization of the background
Helium signal.
CHARGE OF HELIUM IN THE COMPONENT: the component is pressurized with
Helium or with a Helium/Nitrogen mixture until an established value.
HELIUM LEAK TEST: helium leak test of the component.
LEAK CALCULATION: starting from the leak measured by the Helium mass
spectrometer, the software calculates the real leak of the component. The leak depends from
parameters used during test, from calibration.
HELIUM DISCHARGE: discharge of Helium inside the component.
VENTIALTION CHAMBER: the pressure in the test chamber returns to atmospheric
value
CHAMBER OPEN: the test chamber is open in order to remove the tested component.
COMPONENT REMOVING: the user removes from the chamber the tested component.

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The software LDS (Leak Detection System), developed by GALILEO TP on the basis of own
experience in the field of automatic leak detection systems, is a system that allows the supervision
of test process. The needs expressed by customers to have an automatic and certifying system,
convinced the company to develop this software that is able:
To store each test on an MSAccess database file (.mdb).
To manage calibration of the system.
To create/modify models code of the components to test.
To run a statistical analysis for period, for model, for operator.
To control the test for different test mixtures.
To control manually each component of the system.
To simulate manually the automatic test through the activation of the single component.
To allow the connection of the system to existing LAN .
To allow the service with TELESERVICE
The software LDS is today the only instrument dedicated to the analysis and control of Leak
Detection, totally developed by the company that manufacturers the system. In this way each
modification, hardware and/or software, required by the customer is immediate.

Warning

In case of temporary power supply failure can be lost the machines parameters temporary stored in
the pc ram.
Warning

Its necessary to do pc shut-down before switch off the power supply of the machine.

Warning

The machine must be used only by one operator, otherwise the machine can not be safety.

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SECTION 4: PLANT TECHNICAL SPECIFICATIONS

4.1 ANALYSIS SPECIFICATIONS
Plant Sensibility:
Reject threshold:
Number of test chamber:
Number of component into the chamber:
Number of connection between component and test chamber:
Number of chamber on test:

1E-5 mbarl/s of He
fixed by user
2
1
2
1

4.2 AUTOMATIC CYCLE SPECIFICATION

Hook up to the whips:
Component insert close the chamber:
Cycle parameter identification:

Manual
Automatic
archives in model

Start of the cycle:

Maximum time for open/close chamber:
Test time:
High pressure value:
Pressure value for Helium leak test:
Concentration of Helium in the mixture
for leak Helium test:
Discharge max time:
Air return time into the chamber:

Manual
plan by the user
plan by the user
plan by the user, max 100 bar
plan by user, max 40 Bar
plan by user in the range from 5 to 100%
plan by user
plan by user

4.3 STRUCTURAL PERFORMANCES

4.3.1 TEST CHAMBER
Chamber Dimension

parallelepiped shape, useful dimension: W1000 x D1030

x H630 mm

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Used Material:

Stainless still AISI 304, with TIG soldering.

Each chamber is equipped with aluminium lid of an automatic close system with electric power .

4.3.2 OPEN/CLOSE CHAMBER SYSTEM

The plant is equipped with a manual open/close chamber system.
To start the test the operator must close the lid and, keeping a hand on the handle, wait for the beep
and then press the start button.
If the chamber is not ready to perform the test cycle the start button is not lit.
At the end of the cycle the machine does a double beep to inform the operator that it is possible to
open the door. On the screen of HMI is also given the information "Chamber opening".
The operator must open the door in a maximum time (default value 20 seconds) otherwise the
machine show the following message: chamber opening alarm.

4.3 GENERAL PERFORMANCE

Total power absorbed
Service pneumatic pressure
Electrical power:

25 KW
6-8 BAR
400 V, 50/60 Hz, 3 Phase + Neutral pole +
Ground

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SECTION 5: MAINTENANCE AND INSTALLATION

5.1 STORING AND HANDLING
There are no problems if the system doesnt work for few days: in this case it is recommended to
carry out only operations indicated in the table daily maintenance.
In case the system is unused for a period longer than 30 days it is necessary:
To verify the status of the area where the system is placed.
To close chamber.
To avoid to store the system in high humidity areas.
To keep ambient temperature between 5C and 40C.
After long period of un-use of the system it is also necessary to run a general verification of all the
components of the system. Above all, it is recommendable a careful cleaning of all vacuum parts
and connections (piping, o-rings )

WARNING : During handling dont slope the plants with angle of

inclination upper than 10 regarding the vertical. For advanced slopes
the system must be slinging.

5.2 SPECIFICATIONS PLANTS TRANSPORT

Before transport the system, pumping groups are separated from rack.
The entire system comes transported separating it in the following groups of which comes
indicates weights to you (in Kg), the dimensions (in mm) and volumes totals (in m3):

TOTAL WEIGHT:
PUMP GROUP DIMENSION:
PUMP GROUP WEIGHT:
CHAMBER AND STRUCTURE
DIMENSION
CHAMBER AND STRUCTURE
WEIGHT
MAIN STRUCTURE DIMENSION

4000Kg
1300 (W) x 1500 (D) x 2000 (H)
mm
910Kg
3500 (W) x 1000 (D) x 2000 (H)
mm
1475Kg
3350(W) x 1800 (D) x 2460 (H)
mm
1500 Kg
26 m3

MAIN STRUCTURE WEIGHT

TOTAL VOLUM:
REMARK:
For installation and positioning of the components we recommend using skilled workers or
GALILEO TPs workers .
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5.3 INSTALLATION
Only workers of the company that has manufactured the system can complete the installation of the
system. So the following instruction do not authorize the customer to carry out the installation by
himself.
1. Put the rack in the selected place.
2. Verify the alignment of the supports and that the system is stable.
3. Position pumping groups in the right place.
4. Verify oil level of all rotary vane pumps.
5. Make electrical and vacuum connections.
6. Verify electrical connections.
7. Connect compressed air for pneumatic components, with a pressure between 5 and 7 Bar.
8. Connect Nitrogen and Helium.
9. Connect the system to power supply.
10. Connect the system to the recovery machine (optional).

WARNING:

It is necessary to verify the perfect electrical compatibility between the power supply and the
system.

5.4 INSTALLATION OF ELECTRICAL SUPPLY

Before give voltage to the plant be sure that no user is near the plant or in area (like pump area,
compressor area, and area between the chambers) which could be dangerous after the switch on.
Before give voltage to the plant is better to open the electric switch-board and check the follow:
That the 3 phases R, S, T and neutral N are well connected to the junction box before the
switch wording QS1;
That the ground is well connected to the yellow/green terminal or equipotential
bar,
positioned near to the general line terminals;
Verify that the external rotary movement is collimated with the internal rotary movement;
Verify that the general interrupter bringing in position ON the door is jammed from the
manoeuvre.

ATTENTION: the electric line of service , illumination, ventilation and

service socket is connected awry of the general switch. In these instruments
the electric tension will also be had to switch off plant.

The signal of main power present will be given by a signaller flashing place inside the electric
cabinet.

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Now it is possible to switch on the plant bringing the main switch from the position 0 (OFF)
to the position 1 (ON).
Just operated the main switch it will have to ignite the white spy of line it posts on the door of
the electric cabinet (HL1), now the plant is electrically fed. If it didn't ignite this spy to verify
that the light bulb has not burnt, that the tension arrives to the terminals of the light bulb, that
the connections of the main line entry have correctly been effected.
The main switch will immediately give tension to:
PLC;
personal computer;
mass spectrometer and your pump;
REMARKS:
The group of pumping has his electric cabinet, to verify that the main switch is in position 1
(ON) and that also the relative switch of dissection of the motors of the pumps are in
position 1 (ON).
Only the first starting is recommended to hold the switch of dissection of the pumps in
position 0 (OFF), since necessary to verify the exact sense of rotation of the motors.
To verify the sense of rotation to bring the switch of the pump to verify in position 1 (ON)
and to check that the sense of rotation corresponds to the arrow pointed out on the carter of
the motor.
We suggest us you to perform the verification in the following sequence:
1. mechanicals pump of chamber vacuum.
2. roots pump of chamber vacuum.
3. mechanicals pump component vacuum.
4. mechanicals pump of mass spectrometer.
5. other pumps or motor installed on the plant.
We suggest you to verify the exact sense of rotation of the roots pump operating at least a
mechanical pump in unloaded to it with the purpose not to create over pressure to the collector of
unloading.
Besides we suggest you if there were problems with the rotation of the pump of analysis to switch
off the controls of the spectrometer and turbo pump , otherwise they will turn on him same without
having the unload necessary and therefore to damage him.

ATTENTION: the verification of the sense of rotation of the pumps must

have effected from skilled workers every time disconnect any pump for
maintenance or repair or disconnect the principal electric line. In contrary
case he will risk the break-up of the pump.

5.4 CONNECTION DISCHARGE VACUUM PUMP

At the end of the helium test the pump carries out a brief evacuation of the residual helium
atmosphere inside the circuit. As a consequence, not to pollute the work environment, it is necessary
to convey the discharge to an area very far away from the work environment. The exits of the
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discharge vacuum pump are on the roof of the machine. We suggest to use an aspiration system to
help the discharging of the pumps.

5.5 PNEUMATIC AND FLUID CONNECTIONS

The machine has four income lines of gas supply:
nitrogen low pressure (max 40 Bar): this line must have a pressure regulator installed before
the machine. This pressure regulator must be set in function of the different model tested on
the machine.
nitrogen high pressure (max 100 Bar): this line must have a pressure regulator installed
before the machine. This pressure regulator must be set in function of the different model
tested on the machine.
helium high pressure (max 40 Bar): the pressure of this line must be regulated by means the
regulator of the recovery system.
air for pneumatic supply (6-8 Bar): the air must be drier (minimum dew point about 5-6C).

WARNING:

WARNING:

WARNING:

It is necessary to verify the maximum pressure of the incomes lines. This value must be higher of
the maximum pressure of the machine. This line must be protected with safety valves.

The system has four safety valves regulated to 130 Bar to protect from overpressure the flexible
hoses of the chamber and the manifold of pneumatic box.

The exhaust of nitrogen can be dangerous due to high pressure of the system: we suggest to pipe on
the roof of the plant the exhaust end protect or install a silent filter on the exits exhaust.

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SECTION 6 : TECHNICAL FEATURES

Connection to the tested unit:
N. income lines gas
pressure:
Types of usable gases:

in

Pressure max income lines 1

Max error pressare measure:
Attack N2 LP line income:
Attack N2 HP line income:
Attack He HP line income:
Attack air 6 bar line income:
Exhaust vacuum pump :
Exhaust N2 or dehumidified
air:
Exhaust He :
Vacuum Pump :
Weight:
Work temperature :
Temperature Storing :
Supply voltage :
Power absorption :
Noise Level : Leq (A)
Protection Class :

2 fixturing for chamber with manual couplers or

attacks personalize to you.
4
Not inflammable, inert gas or mixtures not explosive
as He, N2, air. The gases must moreover be not
condensing to the pressures and temperatures of use.
5000 KPa
2,5% FS in the interval of temperature of job
Connection 1/4" G female
Connection 1/4" G female
Connection 1/4" G female
Connection 1/4" G female
In atmosphere(eventually directing)
Connection 1/2" G female
Connection 1/2" G female
1000 m3/h
4000 Kg
+5 + 45 C without condensation
-5 + 45 C
230 / 400 V 50/60 Hz 3 ph + neutral pole
25 KW
< 80 dB (A)
Electrical Part and vacuum pump engine IP54
Mechanical Part IP20

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SECTION 7: OPERATIVE INSTRUCTIONS

7.1 STARTING OF THE PLANTS
Main power is connected to main switch with door lock placed in the right side of the system, on
the door of electric cabinet.
In order to switch on the plant its enough to turn the principal switch from position 0 to position
1. After this phase will switch on:
LINE indicating light
If the LINE indicating light doesnt switch on please check:
Light status.
Electrical connections.
Fuse (FU1-FU2)
On touch screen pushing the button SWITCH ON PUMPS, pumping groups will turn on. For a
proper use of vacuum pumps it is necessary to wait at least 10 minutes after turning on before using
the pumps, in this time the pump reaches optimal conditions of work.
After this start up time also the mass spectrometer is ready, so the system is now ready o work.
After turning on the system the PLC controls and eventually signals any anomaly in the system.
Each alarm is identified during this phase, because the switch on of the red light and the relative
wording on the PC monitor. In order to us the plant it is necessary to remove the alarm cause and
push the RESET button.

REMARK:
In any case, before start to use the plant it is better to wait 3-5 minutes, at least, in order to
permit to the mass spectrometer to reach the optimal working conditions. This time gap is
also necessary to reach the high vacuum into the spectrometer for very low background
signal. Also during the heating phase the PLC check and, eventually, indicate the presence
of alarms and/or absence of auxiliary use (compressed air, nitrogen).

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Figure 7.2:

screen relative to plant ready to work (main menu)

7.2 CYCLE SELECTION

When the system is ready, the operator has to choose the type of cycle that he is going to run. The
plant can work:
Automatic cycle
Manual functions
Calibration
The choice of these cycles can be selected pressing the button function on the touch-screen.
In particular:

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Figure 7.2.1 manual cycle PC screen

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Figure 7.2.2 automatic cycle PC screen

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Figure 7.2.3 calibration cycle PC screen

7.3 CHANGE OF THRESHOLD VALUE AND INSTRUMENT

CALIBRATIONS
If it is necessary to modify the threshold value of the instruments or calibration it, we suggest
consulting to the specific manual of the single instruments which are added to this one.
In case of lack of relative manual, we suggest you to contact GALILEO TP service.
For calibration pressure transducer and Pirani or other measurement mounted on plant push the
Instrument Calibration on main screen (fig. 7.2) and following will be opened shielded
(fig 7.3.1).

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Figure 7.3.1 Instrument calibration PC screen

In this page is possible change the instrument range and scale.

7.4 LUMINOUS COLUMNS

The signal lights of the brightness column positioned under the plant identify the status of the plant
with the follow conventions:
SIGNAL
SIREN
GREEN LIGHT

STATUS
It switches on to indicate an alarm
situation.
It switches on to indicate that the plant is
ready for automatic cycles as soon are
verified all the safety condition and pre-

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RED LIGHT
BLU LIGHT
WHITE LIGHT

warning.
It switches on to indicate an alarm of the
plant or plant not ready to work
It switches on to indicate that the plant is
working in manual condition.
It switches on to indicate that the plant is
making an automatic cycle.

7.5 INSTRUCTIONS FOR AUTOMATIC START CYCLE

Select the automatic cycle modality. Select the model corresponding to the component to test. Put
the component in the test chamber. When the components are connect at the fixture be careful that
they dont obstruct the closure of the chamber. Push the START CYCLE button. In case of
manual movement of the chamber, close manually the cover.Wait the end of the cycle. During the
cycle sequence of messages described in the following table will appear one.
MESSAGGE
LP NITROGEN CHARGE
HP NITROGEN CHARGE
PRESSURE STABILIZATION
PRESSURE DECAY READING
NITROGEN DISCHARGE

COMPONENT EVACUATION

CHAMBER EVACUATION
BACKGROUND READING

LP HELIUM CHARGE/ HP HELIUM

CHARGE

LEAK RATE READING

END OF TEST

CYCLE PHASE
In the component is introduced nitrogen for
removing possible pieces of workmanship
It comes loaded nitrogen to high pressure
in the component.
Phase of stabilization of the pressure into
the component.
Measurement of the fall of pressure in the
component.
Drainage of residual pressure from the
component
Phase of evacuation in the component
before loading helium to the aim to
guarantee air absence in order not to create
mixtures
Phase of evacuation in the chamber until
the set up value of vacuum
Reading and memorization of the value of
background of the spectrometer
Phase of loaded helium in the component
for successive phase with search of the
leak. It is possible to charge at a low
pressure value and then at high pressure
value.
Reading and calculation of the real leak
through the spectrometer
Finished phase search of the leak, will
come marked if the piece is in specification
or is discarded

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HELIUM DISCHARGE
CHAMBER VENTILATION
CHAMBER OPENING
END OF CYCLE

Drainage of residual helium pressure from

the piece
Phase of I re-enter air in the chamber for
the successive opening
After the time of ventilation the system
begins the phase of opening of the room for
the discharge component
The system has finished all is made of test
and the component can be unloaded

.and some information

INFORMATION
PRESS ACK BUTTON

SPECTROMETER CALIBRATION

WAITING FOR SPECTROMETER

CALIBRATION
CHAMBER CALIBRATION OR
SENSITIVITY REQUIRED
CHECK MAINTENANCE VACUUM
VALVE
CHECK MAINTENANCE PRESSURE
VALVE

COMMENT
After a test with piece to discard it comes
demanded the confirmation through blue
push-button ACK
As set up in the relative parameter
periodically it comes demanded the
calibration of the spectrometer. This
operation blocks the system and obligates
to carry out the calibration
Attended for the phase of calibration of the
spectrometer. the system will remain
blocked until a positive outcome
Demand for calibration or sensibility. the
system will remain blocked until a positive
outcome.
Demand for maintenance to the vacuum
valves. to supply to the maintenance and to
annul the counter
Demand for maintenance to the pressure
valves. to supply to the maintenance and to
annul the counter

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SECTION 8: DESCRIPTIONS OF ELECTROMECHANICAL

COMPONENTS
8.1 BEFORE SWITCH ON THE PLANT
Before give voltage to the plant be sure that no user is near the plant or in area (like pump area,
compressor area, area between the chambers,) which could be dangerous after the switch on.
Before give voltage to the plant is better to open the electric switch-board and check the follow:
That the 3 phases R, S, T and neutral N are well connected to the junction box before the
switch wording GS1;
That the ground is well connected to the yellow/green terminal or equipotential bar,
positioned near to the general line terminals;
With a test, measure the coming voltage of 400V between the phase R and S, 400 V between
R and T, 400 V between S and T, 220 V between the R or S or T phases and the neutral N;
Verify that the external rotary movement is collimated with the internal rotary movement;
After these check is possible close the door of the electric switch board with the apposite lock.
Now is possible to give voltage to the electrical switch-board using the suitable handle, changing
from position 0 to position 1.
As soon as the switch is hook up, it switches on the white light signal with wording LINE to
indicate that there is power to the electrical switch-board. If this light signal doesnt work, please
check if it is burn or if the voltage to the plant is coming well.

8.2 PLANT PUSH BUTTON

On the front panel of operator console there are the follow push buttons:
PUSH BUTTON
EMERGENCY RESET

EMERGENCY

ACTION
Red Light signal button with N.O. contact.
This button permits the reset of an
emergency after the elimination of the
emergency cause.
Red head button with N.C. contact. This
button permit the uncouple of the general
switch removing voltage to the movement
components and stopping the pumping
group (where it is foreseen, it discharge
also the high pressure). In order to remove
the emergency it is necessary to eliminate
the cause and push the red light button
REMOVE EMERGENCY. Moreover it is
necessary to go in the manual modality and
check the configuration of the machine. We

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8.3 CHAMBER TEST LIGHT PUSHBUTTON AND SIGNALS

The operator console or remote control (option) are equipped of the follow buttons:
PUSH BUTTON AND LIGHT
START CYCLE

STOP CYCLE

ACK
ACKNOWLEDGE
(operator consol)
ACK
ACKNOWLEDGE
(remote control)

RESET ALLARM

ACTION
White light button with N.O. contact
scheme codified. Pushing this button it
starts the automatic cycle into the chamber.
The white light confirm the cycle is
running.
Black button with N.C. contact. It permits
to stop the test cycle in the chamber.
Blue light button with N.O. contact. After a
negative test it is necessary to push this
button in order to open the chamber. When
the test is negative the blue light is on
Blue button with N.O. contact. After a
negative test it is necessary to push this
button in order to open the chamber.
Red light head button with N.O. contact.
This button permits the reset of any alarm
after the elimination of the alarm cause.
When there are the alarms the red light is
on.

When install the remote control there are two spy lamps on it:
RED SPY LAMP: this lamp lighting when the component is not in specification.
GREEN SPY LAMP: this lamp lighting when the component is in specification.

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SECTION 9:

USER INTERFACE DESCRIPTION

REMARKS:
The software Leak Detection System (wording LDS) described in the follow pages is
developed considering the request of the final user and can be different respect to what is
above reported considering the modifications and/or upgrade established with the customer,
after give this manual.

9.1 INTRODUCTION
The LDS software realized from GALIELO TP basing on its experience in the leak detection field is
a supervision system of the test process. The necessity of the final customer to have an automatic
system and, in particular, to certify the made tests, have suggested to our company to develop this
packet which is able to:

Instantaneous show the status of the plant and its components.

Stock the results of each test in stock files, mdb type.
Manage the test calibration system.
Manage the parameters of the test cycle through the model code of the component to test.
Make production statistic analysis:
o For date
o For model
Show all the effectuated tests
Print a certificate of the effectuated tests
Manage the indication/signal of maintenance request
Manage test condition also with tracer gas mixture.
Express the final leakage with the unit of measure requested from customer.
Manually manage each component of the plant.
Offer the possibility of connection to local network

The LDS software is today the only instrument dedicated to the management of leakage plants
developed directly from the plant manufacturer. This permit to offer immediately assistance for
hardware and software.

9.2 START MAIN MENU

When the plant is switch on the computer directly charge the operative system and the software for
the check of the plant.
When the screen of the computer shows the figure 7.2, the plant is ready to be used. At this time the
user must chose the operation method of the plant with the selector as first (located on the system)
and then with the corresponding function button.
An alarm appears, eventually, in the lower side of the screen.
After switch on the plant is necessary to wait at least 5 minutes before start to use the plant in order
to permit to all the components to reach the excellent work conditions (in reality, this phase can be
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longer, specially after a long stop period of the plant). In any case it is possible to use the plant
when the software main screen appear like in figure 7.2
All the software functions, except the input automatic cycle screen and the switch off of the PC, are
protected with a password. All the passwords are imposed in our factory at 1234 but they can be
changed from the user.
The software is sensible to capital and small letters. It means that it is necessary to introduce a
password or a code exactly as defined the first time otherwise it doesnt consider valid the
introduced data.
EXAMPLE: if the introduced password is TeSt it must be introduced always as under reported in
order to be recognized from the system. Otherwise, introducing for example TEST or test or Test
the message Not exactly password will appear on the screen.
The main menu of the LDS software is divided in the follow parts, each one dedicated to different
plant functionality:
Cycle selection for the chose of the plant modality use (automatic, manual or calibration).
Functions for the definition of the chambers parameters, instrument calibration, switch
on/off pumps, spectrometer calibration, open/close chambers and encoder zeroing.
File for show the archives and statistic. Show the virtual key on the screen
Exit to log out from the LDS software and prepare the computer to the switch off or to
accede to the Windows Desktop.

9.3 AUTOMATIC CYCLE

Pushing the Automatic button from the screen of it is possible to enter in the screen of automatic
test cycle manage. (Fig 9.1)
Before proceed it is necessary to insert the user code and push OK (ENTER) to confirm. If the
introduced code doesnt exist in the stock or if the user push OK without introduce a code .The
software will lock and will wait a valid code.
If the introduced code is valid, the software show the manage screen of the automatic cycle.
After the introduction of a valid user code the software show the screen for automatic test cycle
management.
The screen is vertically divided in two sub-screens, one for each camera.
Each sub-screen is horizontally divided in two parts: the higher side contain the cycle parameters
while the lower side contain the test results, the signal of eventually alarm and the phase of the
cycle in work.

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FIG 9.1 automatic cycle screen

Here follow is described the automatic test cycle screen. Each sub-screen contains, in the high side,
the indication of the reference chamber number.
Are further visible the follow indications and buttons:
LABEL
MEANING
MODEL
Alphanumeric code which identify the
model of the component to test. The
software identifies the test parameter from
this input (model code).
NITROGEN PRESSURE
Nitrogen pressure to reach in the
component for the pressurization test in
nitrogen or dry air.
MAXIMUM PRESSURE DROP
Maximum pressure drop in the stabilization
phase.
TEST PRESSURE
Helium pressure to reach in the component
for the leakage test with mass spectrometer.
REJECT LIMIT
Reject threshold of the selected model
means the maximum leakage value to
consider in specification with the
component imposed value.
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HELIUM CONCENTRATION
TEST RESULT

LEAK VALUE
NITROGEN PRESSURE

Value of helium concentration mixture for

the test
In this window is indicated the result of the
test. It could be in specification or not
considering the leakage value measured
during the test.
Real leak value measured during the test.
Real value of nitrogen or dry air pressure
reached into the component.

PRESSURE DROP
TEST PRESSURE

Real value of the Decay Pressure

Real value of helium pressure reached into
the component.
REAL TIME COMPONENT PRESSURE
Real value of pressure in the component
during all the cycle
REAL TIME CHAMBER EVACUATION Real value of pressure in the chamber
duriring all the cycle
REAL
TIME
SPECTROMETER Real value of vacuum in the spectrometer
VACUUM
ALARMS
Window for the indication of eventually
alarm which could be identify during the
automatic cycle.
CYCLE PHASE
Window for the instantaneous indication of
the plant cycle phase.
INFORMATION
Window for the indication of additional
information of cycle and alarm.
TOTAL

PARTIAL

REAL TIME SPECTROMEETR VALUE

RESET BUTTON
EXIT BUTTON

MODEL BUTTON

Indication of the number of cycle with

positive or negative result from the start of
the plant.
Indication of the number of cycle with
positive or negative result from the last
reset.
This counter can be reset pushing the
button Reset.
The progress bar show the real time value
of the spectrometer
Button to reset the counter partial
Button to exit from the automatic cycle
screen and turn back to the main screen
plant management.
Button to change the model code of the
component to test. After push button on the

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OPERATOR BUTTON

SENSITIVITY BUTTON

TYPE TEST BUTTON

ORDER BUTTON

monitor will appear the list of the existing

models(fig. 5.8)
The user, with the cursor rises run the list
and pushing the Enter button confirm the
selected model. The software charge and
automatically show the test parameter
relative to the selected model.
Button to change the user code.
Before proceed it is necessary to insert the
user code and push OK (enter button) to
confirm. If the insert code doesnt exist in
the stock or if the user push OK without
introduce a code the software will lock and
will wait a valid code If the introduced
code is valid, the software turn back to the
automatic cycle manage screen.
With this button pressed, the cycle that start
is a normal one but instead charging helium
will be opened the calibrated leak. The
software controls that the leak value read
by the spectrometer is like the calibrated
leaks one and that is inside the tolerance of
the calibrated leak.
With this button can view the window
where it is possible to select different type
of test (sniffer)
With this button can be insert the order
reference in the report of the test

9.4 MANUAL CYCLE

Pushing the manual cycle button from the screen of figure 7.2 it is possible to enter in the screen for
the manual check of the plant.
As already described, in order to enter to this function it is necessary to introduce a password. The
software indicates if this password is not correct (and automatically turns back to the previous
screen.
The manual check of the plant can be useful in case of assistance or put in line the plant.
After the introduction of the correct password on the PC monitor will appear the screen which
checks the manual function of the plant (fig9.4.1).
To work on the different components of the plant its enough to push the correspondent function
button indicated on the video.

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FIG 9.4.1 manual cycle screen

All the software realized from GALILEO has the follow convention:
Red colour means switch off component.
So, if a valve is red it means that it is close; a red contact means that the correspondent signal
is not verify.
Green colour means switch on component.
So, if a valve is green it means that it is open; a green contact means that the correspondent
signal is verify.
Also during the manual function the system continue to work in safety condition for the user and for
the plant. That means, for example, that it will not possible to open the transfer valve if the chamber
isnt in vacuum condition.
To exit from the manual screen and turn back to the software main screen, push the EXIT button .

9.5 PLANT CALIBRATION

Using the calibration button from main men (fig. 7.2) it is possible to enter in the plant calibration
screen. It is possible the calibration of the chamber one each time (fig 9.5.1).
As already described, to enter to this function it is necessary to introduce a password.
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The software show if the enter password is not correct and automatically turn back to the previous
screen.
The calibration is necessary to calculate the K coefficient of each chamber and to check the correct
working of the plant. For this reason the plant is equipped of a certificated calibrated leak

Figure 9.5.1 plant calibration screen

In the upper side of screen (fig. 9.5.1) are indicated the data of the calibrated leak introduced in the
plant. These data are directly draw out from the calibration certificate which is equipped with the
leak, from the supplier.
In particular are visible:
LABEL
TYPE OF LEAK

SERIAL NUMBER

MEANING
Reference to type code or model of the
calibrated leak .
Serial number or building number of the
calibrated leak
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VALUE

Leak value as reported in the calibration

certificate

DATA

Certificate data

ANNUAL DECREMENT

Annual decrement coefficient as reported

in the calibration certificate

ACTUAL TEMPERATURE

Actual temperature check with probe

installed on the plant
Real leakage value considering the actual
temperature and the time spent from the
certificate data.
Coefficient of the leak value variation with
the temperature

REAL LEAKAGE VALUE

THERMAL COEFFICIENT

The real value is obtained from as follow reported:

Real leak

= Leak (20C) +
+ Leak (20C) (T-20)
Leak (20C) DifData

Where:
Real leak:
Leak (20C):
:
DifData:
calibration test.
:

Leak value at the temperature T

Leak value at 20 C
Temperature coefficient
Difference between the certificate data of the leak and the data of the
Leak value annual reduction coefficient.

The software makes automatically the calculation under reported and show the real value of the
leak.
When there are the necessary condition to start the calibration cycle, the button START CYCLE
flash. Now, pushing the START CYCLE button, the calibration cycle will start.
It can be described as follow:

Close test chamber

Evacuation of the test chamber until ad adapt vacuum value for the transfer
Transfer
Measure of the background in the test chamber.
Aperture of calibrated leak valve
Read of the leak calibration

The K coefficient of the plant is given from the ratio between the real leak value (calculated with
the under reported law) and the leak net value (the difference between the signal helium value after
the open of the calibration valve and the background correspondent). So:
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Manual 8.014.0.047

Real leak / (Read leak Background)

Where:
Real leak:
Read leak:
Background:

Leak value at the actual temperature T calculated with the under

reported law.
Helium signal value read from the mass spectrometer after the open of
the calibration valve.
Helium signal value corresponding to the background

The K value calculated is memorized until the next calibration and it is used to correct the read
during the automatic cycle. It means that the real leak value will be the product between the read
from the mass spectrometer and the K coefficient now calculated.
The software further shows real time eventual alarms and the phase of the cycle. Are also indicated:
1.
2.
3.
4.

The background value

The mass spectrometer read correspondent to the calibrated leak
The net leak value, difference between point 2 and point 1.
The calculated K coefficient

The software offers the possibility to memorize the data of more calibrated leak. In order to do it is
enough to push the EDIT button. After the introduction of the protection password there is the
access to the list of the memorized calibrated leak.
To modify the data of the already memorized calibrated leak or to introduce a new one it is enough
to push the EDIT button and appear the calibrated leak screen (fig. 9.5.2). To save the
modifications push the SAVE button .

Here follow is showed the parameters and screen that appear pushing EDIT Button:

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Fig. 9.5.2 calibrated leak screen

LABEL

MEANING

CALIBRATED LEAK TYPE

Alphanumeric code which identify the leak

type.

SERIAL NUMBER

Serial number of the calibrated leak

NOMINAL VALUE

Nominal value of the calibrated leak

NOMINAL TEMPARATURE

Nominal temperature reported on the leak

calibration certificate.

CERTIFICATION DATE

certification date of the calibrated leak

TEMPERATURE COEFFICIENT

Variation coefficient of the leak value with

the temperature.

ANNUAL REDUCTION

Reduction coefficient of the leak value with

the data.

TOLERANCE

Tolerance on the leak value.

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The data to introduce are included in the calibration certificate which is supplied with the same
calibrated leak.
REMARKS:
To cancel the data relative to a calibrated leak, push the CANCEL button
To select a calibrated leak which is different from the proposed ones in the calibration
software screen ,un the list with the cursor indicators to find the selected leak and push the
SAVE and EXIT buttons.
Instead, to exit without change the calibrated leak proposed by the software in the
calibration screen, push the EXIT button.
To exit from the calibration screen and turn back to the main screen of the software push
EXIT .

9.6 PARAMETERS
Pushing the PARAMETERS chamber 1 or chamber 2 button from the main men (fig. 7.2) is
possible to enter in the screen for the introduction of the chamber parameters. (fig. 9.6.1)
As already described, to enter to this function it is necessary a password .The software show if the
introduced password is not correct and automatically turn back to the previous screen.

Figure 9.6.1: parameters screen

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Here follow is described the meaning of the plant parameters.

LABEL
MEANING
CHAMBER VACUUM RATE FOR Imposed chamber vacuum value to start leak detection.
TEST BEGINNING (mPsi)
CHAMBER
MAXIMUM TIME

EVACUATION Is the maximum time to reach the adapt vacuum for

the transfer (indicated in the set point number 2 of the
vacuum gauge) into the chamber. If the vacuum
doesnt reach the imposed value into the time here
indicated, an alarm signal will appear.
NITROGEN DISCHARGE
Is the maximum time within the component must turn
MAXIMUM TIME
back to atmospheric pressure discharging nitrogen. If
the return to atmospheric temperature doesnt reach in
the here imposed time an alarm signal will appear.
CHAMBER VACUUM VALVE
Delay in the closure of the vacuum chamber valve
CLOSING DELAY
after reach the adapt vacuum value for the transfer.
VACUUM PUMP DISENGAGEMENT Delay in the user time of the vacuum pump: waiting
DELAY
time between the end of the use of the first chamber
evacuation pumping group and the successive start of
the use of the second chamber evacuation pumping
group.
SPECTROMETER ZEROING DELAY Delay of the mass spectrometer reset before charge
helium and start with the leakage test.
BACKGROUND NOISE READING Delay in the read of the background noise when the
DELAY
adapt conditions are reached.
SPECTROMETER
DISENGAGEMENT DELAY

Delay in the user time of the mass spectrometer:

waiting time between the end of the use for the
analysis of the first chamber and the next start of the
use for the analysis of the second chamber.

CHAMBER VANTILATION DELAY

MAXIMUM
PRESSURE
HELIUM DISCHARGE END

Delay before open the ventilation chamber, at the end

of the test. This parameter is introduced to permit the
closure of the mass spectrometer transfer valve
FOR Pressure value to consider finished the helium
discharge of the component.

MAXIMUM
PRESSURE
FOR Pressure value to consider finished the nitrogen
NITROGEN DISCHARGE END
discharge of the component.
CHAMBER VENTILATION TIME

Aperture time of the chamber ventilation valve to

return the chamber at the atmospheric pressure.
HELIUM DISCHARGE MAXIMUM It is the maximum time within the component must
TIME
turn back to atmospheric pressure, discharging helium.
If this turn back doesnt reach in the time here
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indicated, an alarm signal will appear.

CHAMBER OPENING MAXIMUM
TIME

Is the maximum time for the chamber aperture at the

end of the cycle. If the chamber isnt open within the
here indicated value, an alarm signal will appear

HELIUM PRESSURE FOR SNIFFER Helium pressure when is used the sniffer per leak
TEST
measurements.
MIN CHAMBER VACUUM FOR Vacuum value of the chamber for beginning the HP
CHARGING HP NITROGEN
nitrogen charge.
K COEFFICIENT

K coefficient calculated during the calibration.

MIN K COEFFICIENT

Minimum value that the K coefficient can reach. If

value calculated during the calibration is lower to the
here indicated value, an alarm signal will appear.

MAX K COEFFICIENT

Maximum value that the K coefficient can reach. If

value calculated during the calibration is higher to the
here indicated value, an alarm signal will appear.
DELAY IN THE BACKGROUND Delay in the background noise read when adapt
NOISE READ
conditions are reached. This parameter is referred to
the calibration cycle and not to the automatic cycle like
the precedent point
CALIBRATED LEAK READING Delay in the calibrated leak read when adapt
DELAY
conditions are reached during the calibration.
MINIMUM SIGNAL NOISE RATIO

MIN. BACKGROUND NOISE

Minimum value of the signal/noise ratio. If the real

value of this ratio is lower to the here reported value,
an alarm signal will appear
Its the minimum value allowed of background noise

ENABLE HELIUM RECOVERY

If select the system dont read the value of helium

concentration and use the value of helium set in the
parameter.

HELIUM CONCENTRATION

Helium concentration in nitrogen-helium mixture

PUMPS ENABLE

If select it enable the pump

ENABLE SENSITIVITY CHECKING

It is possible to enable sensitivity check

SENSITIVITY CHECK INTERVAL

It is possible to set the cycles number after that the

machine stop the automatic cycle and it is necessary to
check the sensitivity of the plant.

LANGUAGE SELECTION

It is possible to set the language of software

ENABLE CHAMBER

It is possible to enable the chamber

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MINIMUM SIGNAL/RATIO NOISE

Set point for the alarm

SPECTROMETER
INTERVAL

CALIBRATION It is possible to set automatic calibration of the

spectrometer

CHAMBER
INTERVAL

CALIBRATION It is the interval between the calibration cycle. If there

is the flag after the interval value the machine stop and
wait for the cycle calibration.

Push the SAVE button to save the effectuated modifications and turn back to the main manage
software screen of the plant.
Push the CANCEL OR EXIT button to not save the effectuated modifications and turn back to
the main manage software screen of the plant.
REMARK:
It is further possible change the language of the software.

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9.7 Archives
Pushing the ARCHIVES MANAGEMENT button from the main menu (fig7.2) is possible to
enter in manage stock screen of the plant check software. (fig. 9.7.1)
As already described, to enter into this function it is necessary to introduce a password. The
software show if the introduced password is not correct and automatically turn back to the previous
screen.
From the stock manage screen it is possible:
To show/change the models and the test parameters of the components
To show/change the user code
To show the data relative to the effectuated test.

Figure 9.7.1: Manage stock screen

BUTTON
MODELS
OPERATOR
DATE
ALL
SAVE

ACTION
To Enter in the model stock.
To Enter in the user stock.
To look the effectuated test in a selected
time interval.
to look all the effectuated value
To save in the database the tes.
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ORDER
ORDER LIST
EXIT

Order
Order List
turn back to the main screen
To look the effectuated test with a selected
model.

MODEL

9.7.1 MODELS ARCHIVE

Pushing the Models button from the screen of fig. 9.7.1 it is possible to enter in the screen for the
models manage of the components to test (fig. 9.7.2). In other word to look/modify the test
parameters associated to each model code.

Figure 9.7.2 models archives screen.

BUTTON
EDIT

ACTION
To change the existent data and/or

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DELETE
EXIT

introduce new ones.

To cancel the selected model.
Turn back to the stock manage main screen
(fig. 9.7.1).

Here follow is described the meaning of the parameters corresponding to each model:
LABEL
MODEL

MEANING
Alphanumeric code of the model of the
component to test. It is possible to
introduce all the characters normally
accepted from Windows.

DESCRIPTION

Model description

CUSTOMER CODE
LP NITROGEN PRESSURE (PSI)

CUSTOMER CODE
Pressure value at which it check the correct
connection of the component and the
clogged of the circuit of the unit.
Maximum time to reach the imposed
nitrogen pressure.

LP NITROGEN LOADING MAX TIME

(SEC)
HP NITROGEN PRESSURE (PSI)

Pressure set point for high pressure

nitrogen charging. At this value the
machine automatically closes the valves of
nitrogen charge.

HP NITROGEN LOADING MAX TIME

(SEC)
PRESSURE STABILIZATION TIME
(SEC)

Maximum time to reach the imposed

nitrogen pressure.
Stabilization pressure time after reach the
imposed pressure value.

MINIMUM PRESSURE AFTER THE

STABILIZATION (BAR)

Minimum pressure into the component

after the stabilization.

MAX PRESSURE AFTER

STABILIZATION (BAR)

Maximum pressure into the component

after the stabilization.

PRESSURE FALL CHECKING TIME

(SEC)
MAXIMUM PRESSURE DROP (PSI)

Time for check/duration of decay pressure.

COMPONENTS VACUUM TIME (SEC)

Time for component vacuum.

MINIMUM COMPONENT VACUUM

RATE (PSI)
HELIUM PRESSURE FOR HIGH
PRESSURE TEST (PSI)

Minimum vacuum pressure value into the

component.
Pressure set point for high pressure helium
charging. At this value the machine

Maximum decay pressure.

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HELIUM CHARGE MAXIMUM

TIME(SEC)
HIGH PRESSURE TEST DURATION
TIME (SEC)

automatically closes the valves of helium

charge.
Maximum Time loading Helium
Time test for high pressure helium leak
detection

REJECTION THRESOLD (Mbar*l/s)

Maximum leakage value acceptable

FINAL VACUUM PERIOD (SEC)

Evacuation duration phase of the

component, at the end of the test.
Duration of the phase of the final pressure
check into the component.

FINAL PRESSURE CHECKING

PERIOD(SEC)
MAX FINAL PRESSURE (< 10 PSI)

Maximum pressure acceptable into the

component after the final discharge. If the
real pressure is high then this value, the
software turn back to the final vacuum
phase

9.7.2 USER
Pushing the Operator button from the screen of fig. 9.7.1 it is possible to enter in the user code
manage screen (fig. 9.7.3).In this page is possible show or modify the user code and insert a new
one.

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Figure 9.7.3: user code manage screen

BUTTON
EDIT
DELETE
EXIT

ACTION
to change the existent data and/or introduce
new ones.
to cancel the selected user code.
turn back to the stock manage main screen
(fig. 9.7.1)

9.7.3 TEST FOR DATA

Pushing the Data button from the screen of fig. 9.7.1 on the screen will appear a request to
introduce the dates corresponding to the period at which should be showed the test. (fig.9.7.4).

Figure 9.7.4: date introduction of the date for the test research
BUTTON
OK
CANCEL

ACTION
to look the effectuated test in the defined
period.
turn back to the screen of fig. 9.7.1.

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REMARK:
During the introduction of the date must be followed the same points:
The date introduced in the window to the date must be successive to the date introduced in
the window from the date.
The introduced date must be a valid date.
If the introduced dates are valid, pushing the button OK the software will show the entire
effectuated test between that periods. For the description of the test see the section 9.7.5(test)

9.7.4 TEST FOR MODEL

Pushing the Model button from the screen of figure 9.7.1 it will appear the request of the model
code that must be included in the showed test. (fig. 9.7.5)
If the model code introduced is valid and it exists in the test stock, the software shows the
effectuated test corresponding to the introduced model code. For the description of the test see the
section 9.7.5 (test)

Figure 9.7.5: introduction of the model code for the test research
BUTTON
OK
Cancel

ACTION
to show the effectuated test in the defined
period.
the software turn back to the screen of
figure 9.7.1.

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9.7.5 ALL TEST

Pushing the button ALL from the screen of fig. 9.7.1 it will appear a list of the entire effectuated
test (fig. 9.7.6).
Is further visible a window with the total number of test which are present in the showed list.

Figure 9.7.6: test effectuated from the plant

BUTTON
DIAGRAM
DELETE
EXIT

ACTION
To look the exit of the test with an
histogram graphic
To cancel the selected test.
Turn back to the stock test main manage
screen (fig. 9.7.1).

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Here follow is reported the meaning of the showed parameters in the test screen:
LABEL
TEST DATA
TEST HOUR
MODEL
DESCRIPTION
OPERATOR CODE
RESULT

COMMENT ON RESULT
NUMBER OF CHAMBER
CIRCUIT NUMBER
NITROGEN PRESSURE (PSI)
PRESSURE FALL (PSI)
HELIUM PRESSURE (PSI)
LEAK VALUE
ORDER

MEANING
Data of the effectuated test.
Hour of the effectuated test
Alphanumeric code of the tested
component.
Description of the model
User code of the user who made the test
Alphanumeric value corresponding to the
exit of the test: -1 means a test with
positive result, 0 a test with a negative
result
Short comment to the exit of the test.
Number of the chamber where the test is
made
Number of the junction where the test was
made.
Nitrogen pressure reached for the
mechanical resistance test.
Decay pressure value into the circuit.
Helium pressure reached for the test of
leakage research with mass spectrometer
Leak value measured during the test.
Order number.

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9.7.6 SAVE THE TEST

Pushing the SAVE button from the screen of fig. 9.7.1 it will appear a list of the entire files with
the memorized test. (fig. 9.7.7).

Figure 9.7.7:
BUTTON
SAVE
EXIT

screen to save the effectuated test

ACTION
The software will copy the selected file on
the disk.
Turn back to the stock manage main screen
(fig. 9.7.1)

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9.8 EXIT OF THE PROGRAM

Pushing the EXIT button from the main menu, the computer will prepare to the switch off.
It will be possible switch off the plant when on the screen of the PC it will appear the label it is
now possible to switch off the PC.
Warning

In case of temporary power supply failure can be lost the machines parameters
temporary stored in the pc ram.

Warning

Its necessary to do pc shut-down before switch off the power supply of the
machine.

9.9 CHANGE PASSWORD

All the functions, except to the automatic cycle manage are protected with password.
All the password are defined at 1234 from the manufacturer.
To change password proceed as follow:
1. Push the button corresponding to the function that you would like to modify the password.
2. From the screen of insert password push the button MODIFY in order to enter in the
modify password screen
3. Introduce the old password
4. Introduce the new password
5. Confirm the new password
6. Push the OK button to confirm the new password
7. Push the CANCEL button to not save the modifications.

9.10 SNIFFER CYCLE

Pushing SNIFFER CYCLE button from type of test, it will possible to start the sniffer cycle.

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Fig.9.10.1: sniffer cycle selection

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SECTION 10: MAINTENANCE

10.1 DAILY MANTENANCE
Check the rotary vane pump and the roots pump oil level. If necessary add adapt oil (type
GALILEO SH200). Please note that this is an important check for a good maintenance of
the plant.
Check the air service pressure, nitrogen and helium cylinder.
Clean the analysis chamber
Clean the seal packing of the chamber. We suggest to not use alcohol for this operation in
order to avoid to dry the seal itself. If necessary, after this operation, lubricate the seal.
Clean the connection joint to the component. .
Check the tightness of whips and joint making a cycle without components connected to the
whips.
Make the mass spectrometer and plant calibrations.

10.2 MONTHLY MAINTENANCE

Check the clean of pressure valves
Check the clean of pressure filters
Check the clean of vacuum valves
Check the clean of vacuum filters
Check the clean of movement chamber system.

10.3 EVERY SIX MONTH

Clean pressure valves
Clean pressure filter
Clean vacuum valves
Clean vacuum filters
Clean chamber movement system
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 Change rotary vane pump oil of the analysis pumping group

Clean filters of component gauges, PC, mass spectrometer
Change the o.rings of pneumatic couplers
Check the functionality of pneumatic couplers

10.4 ANNUAL
Change the oil of all the rotary vane pumps of the plant.
Change the seal of the test chamber
Change the seal of the vacuum circuit
Change the o-rings of the pneumatic valve
Helium check of the piping
Make calibration of the instruments (vacuum gauge, pressure switch, mass spectrometer,
flux measure) and calibrated leak.
Make revision of analysis rotary vacuum vane pump.
Clean the cell of the mass spectrometer
Clean and change the kit o-ring vacuum valve
Clean and change the kit o-ring pressure valve

10.5.1 EVERY 2.000 HOURS

Change the oil of all the rotary vane pumps of the plant
Calibrate the pressure and vacuum sensor

Change the filaments of the mass spectrometer

10.5.2 EVERY 6.000 HOURS
Greasing the bearing of the turbo molecular pump
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 Change filter and o-ring of the vacuum pump

10.5.3 EVERY 12.000 HOURS
Check the working of the mass spectrometer
Change the bearing of the turbo molecular pump
10.6 EVERY 3 YEARS
Change calibrated leak
REMARK:
The under reported are information of general validity which must be adapted, each time, to the real
working conditions of the plant.
In any case, we suggest consulting the specific manual of the component.

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SECTION 11: FAILURE ANALYSIS

FAILURE OR ANOMALY
The main switch doesnt switch on

POSSIBLE CAUSE
Switch QS1 breakdown
Not make the switch on of rotary movement

The white light (LINE) signal doesnt switch

on

Switch QS1 breakdown

Line signal lamp HL0 fulminate
Cut-out FU1 and FU2 interrupt
Converter TC1 24 Vac breakdown.
Doesnt work the auxiliary component
Cut-out FU1 interrupt
(24Vac)
Converter TC1 breakdown.
Cut-out FU2 interrupt
Doesnt work the auxiliary component
Cut-out FU3 interrupt
(24Vdc)
Converter GS1 breakdown
Cut-out FU4 interrupt
The drive of the pumping group doesnt work Failures to the PLC control
Main switch QS2 off
Failure to the motor protector QM
Emergency switch on
Pump thermal protection are switch off
One pump of the pumping group doesnt
Failure to the main relay KM
work
Failure to the motor protector QM or switch off
Failure to the motor
Maintenance switch off
PLC (CPU) doesnt work
Cut-out FU6 breakdown
Breakdown to the power supply GS2
Power supply GS2 in OFF position
CPU in STOP position
CPU or power supply breakdown
The PC/touch screen doesnt switch on
Cut-out FU5 breakdown
Plug not connected
PC/TOUCH switch off
PC/TOUCH breakdown
The mass spectrometer doesnt work
Cut-out FU8 breakdown
Mass spectrometer switch off
Plug not connected
Lock of the chamber lid
Sensor out of position or breakdown
Emergency cycle introduced
Plant lock in emergency with emergency
button switch off

Interruption of the cable connected to the

emergency button.
Not reset the emergency
Breakdown of the security module KF1
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Plant in stop cycle

Pushing the start button the automatic cycle

doesnt switch on

Interruption of the cable not connected to the

STOP CYCLE button.
Breakdown of the contact
Emergency connected
Breakdown to the contact of START CYCLE
button
Breakdown of the PLC input digital module

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SECTION 12: ALARM ANALYSIS

During automatic or manual cycle appear the alarm message and some information:
ALARM SIGNAL
Air pressure alarm
ID :1

Mass spectrometer
alarm
ID:5

Emergency activated
ID:6

MEANING

POSSIBLE CAUSE

The compress air necessary for the

pneumatic components doesnt
reach the system or reach it with not
enough pressure.

Compress air input tube is broken or

close.
Valve on the input air line close
Air pressure not enough.
Air pressure switch break or not
calibrated
CPU of PLC is broken
Failure to the digital input module.
It doesnt reach the READY
Fore vacuum on spectrometer
conditions into the maximum value insufficent.
imposed or READY condition loss Failure to the mass spectrometer
and/or to one of its components.
Leak on analysis piping.
Emergency button switch on
Emergency button is pushed
Emergency button not reset

Chambers vacuum
pump thermal
protection
ID:7

A motor protector of a vacuum

chamber pump is tripped

Failure to the motor

Pump is locked
Failure to the thermal
Not correct cabling

Components vacuum
pump thermal
protection
ID:8

A motor protector of a vacuum

component pump is tripped

Failure to the motor

Pump is locked
Failure to the thermal
Not correct cabling

Spectrometer not
ready
ID:9

The mass spectrometer is not ready.

This indication is not an alarm
because after the switch on, it
needs a delay time to reach the
rating conditions.
The mass spectrometer have lose
the READY condition
The mass spectrometer have lose
the calibration

The mass spectrometer doesnt reach

the READY condition, already.

Spectrometer error
ID:10

Spectrometers
A motor protector of a vacuum
vacuum pump thermal chamber pump is tripped
protection
ID:11

Mass spectrometer is switch off

Failure to the mass spectrometer
and/or to one of its components.
Leak on analysis piping.
Fore vacuum on spectrometer not
good.
Failure to the motor
Pump is locked
Failure to the thermal
Not correct cabling
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Turbo pump alarm

ID:14

The turbo molecular have lose the

READY condition

Turbo molecular locked

Fore vacuum not good
Fore vacuum pump broken
Turbo pump not ready Alarm because after the switch on, Fore vacuum not good
ID:15
it needs a delay time to reach the
Fore vacuum pump broken
rating conditions.
Leak on analysis piping
Spectrometers reading The spectrometer value is not
Instrument calibration is not correct
error
correct with calibration setting.
Scale or range is not correct.
ID:16
Value of the instrument in drift
Spectrometers
The Pirani value is not correct with Pirani broken
vacuum reading error calibration setting.
Scale or range is not correct.
ID:17
Value of the instrument in drift
Spectrometers
The spectrometers vacuum doesnt Vacuum gauge broken/not calibrated
vacuum alarm
reach the value imposed into the
Pump analysis broken
ID:20
parameter.
Leak on the piping
Spectrometer switch
The signal of mass spectrometer
Spectrometer switch in off position
off
there isnt.
Power module of the spectrometer
ID:21
broken
Failure on the cabling
Helium recovery alarm The external recovery system is in Not correct cabling
ID:22
alarm.
Failure on the external recovery
system; check on the recovery system
the specific alarm
Roots vacuum pump
A motor protector of a vacuum
Failure to the motor
thermal protection
chamber pump is tripped
Pump is locked
ID:23
Failure to the thermal
Not correct cabling
Helium concentration The signal of the concentration of Not correct cabling
alarm ID:24
helium from the recovery system is Recovery system not in work phase
zero.
(stand-by or switch off)
Trouble on the sensor of the
measurement of helium concentration.
Chambers closing
The chamber is opened before the Error of the operator, failure of the
alarm
end of the cycle.
sensor.
ID:33
Chamber vacuum
The chamber doesnt reach the
Vacuum gauge break/not calibrated
alarm
vacuum value suitable for the
Break to the pumping group
ID:34
transfer, in the maximum imposed Break to the vacuum chamber valve
time defined in the parameter
Break of the seal chamber
screen.
Component is externally humid
The filter on the vacuum chamber line
are dirty
Nitrogen/Air discharge The circuit of component pressure Air discharge valves are break
alarm
doesnt reach the atmospheric
Air discharge line is close
ID:35
pressure in the imposed time
Pressure transducer is not calibrated
and/or broken
Component vacuum
The component doesnt reach the
Transducer broken/not calibrated
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alarm
ID:36

vacuum in the maximum imposed

time defined in the parameter

Helium charge circuit

1 alarm
ID:37

Stop cycle activated

ID:42

Helium discharge
alarm
ID:45
Chamber opening
alarm
ID:46
Chambers vacuum
reading error
ID:57
Circuit pressure
reading error
ID:58

Component pump broken

Valve broken
Component is internally humid
The helium pressure of the circuit 1 Helium charge valve is close
doesnt reach the imposed value in Component isolation valve close
the imposed time
Helium charge line is close
Helium cylinder is empty
Helium pressure is not enough
Transducer (1) is broken
Component (1) is clog after the first
test phase
Information which follow the
Stop cycle button is pushed
pressure of the stop cycle button
Stop cycle button is broken
Stop cycle button contact is broken
Not correct cabling
The helium pressure doesnt reach Discharge helium valve is break
the imposed value of zero pressure Discharge helium line is close
in the imposed time
Pressure indicator is not
calibrated/break
The chamber doesnt open in the
Break to the open chamber sensor
maximum imposed time, defined in Chamber is lock
the parameters
The Pirani value is not correct with Pirani broken
calibration setting.
Scale or range is not correct.
Value of the instrument in drift
The value of transducer of circuit 1 Transducer (1) broken
is not correct with calibration
Scale or range is not correct.
setting.
Value of the transducer (2) in drift

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INFORMATION

MEANING

Push ACK button

After the negative test

Vacuum valve
maintenance

Appear then the vacuum valve

counter maintenance reached the
setting impose

Pressure valve
maintenance

Appear then the pressure valve

counter maintenance reached the
setting impose

Please wait

Appear every time the plant

require a long time for setting a
new parameter
Appear when the spectrometer
play the calibration phase
Appear when the calibration of the
spectrometer is fault.

ACTION
Push ACK (blue) for open the
chamber and unlocked the
component refuse.
Make a maintenance at the vacuum
valve and reset the counter

Make a maintenance at the pressure

valve and reset the counter

Wait a new message or the end of

work phase before continue your
work
Calibration ramp up
Wait the end of the calibration
phase
Calibration error
Repeat the calibration. Is necessary
have a positive calibration for exit
of this phase
Waiting for spectrometer Appear when is reached interval
Wait the end of automatic cycle
calibration
time setting into the parameter for and the next calibration phase
spectrometer calibration interval.
Calibration and
Appear when the interval time of Make a calibration and sensibility
sensibility request
this phase setting into the
cycle of the chamber. Is necessary
parameter is reached.
have a positive result for exit of
this phase
Filament 2 on
Appear when the spectrometer
Verify the cause. If changing the
working with the second filament filament because the first is broken
change it before have a stop the
plant
MDP not ready
Appear every time switch on the Wait the ramp up of turbo
plant.
molecular pump. When the pump
is READY this message switch off

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SECTION 13: SPARE PARTS

DESCRIPTIONS

GALILEO TP CODE

Pressure transducer
Vacuum head PIRANI
Pressure regulator
Two way valve
Electrovalve 3/2 24 v
Electrovalve 2/2 high pressure
Electrovalve 3/2 230 V
Spectrometer filament
Vacuum oil 25 lt
Vacuum pneumatic valve DN80
Vacuum pneumatic valve DN100
Vacuum pneumatic valve DN63
Kit o-ring vc300
Vc 50 exhaust filter
Vc 300 exhaust filter
Filament collector
Magnetic sensor d-73
Pneumatic cylinder
Kit filter zeoliti

5.501.0.072
5.025.0.109
5.016.0.067
5.004.0.190
5.005.0.004
5.005.0.150
5.005.0.058
5.026.0.190
5.023.0.014
5.004.0.251
5.004.0.252
5.004.0.250
5.001.1.205
5.007.0.071
5.007.1.206
5.026.0.0179
5.501.0.123
5.002.0.091
5.007.0.076

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SECTION 14: LAY-OUT and DIAGRAM

Vacuum lay-out Pressure lay-out component Electro valve lay-out side 1 Electro valve lay-out side 2 Electric diagram

7.001.0.168
7.001.0.168
7.002.0.255
7.002.0.255
7.002.0.255

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