INFICON HLD6000 User Manual

Translation of the original operating instructions

HLD6000

Leak detector

kina43e1-a, 1408

Order no.:
510-025, 510-027,	from software version:
510-028	1.11

No part of this manual may be reprinted, translated or duplicated without the expressed written consent of INFICON GmbH.

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Translation of the original operating instructions HLD6000, kina43e1-a, 1408

Table of Contents
1	About these instructions ............................................................................................................................................	7
1.1	Target groups .................................................................................................................................................................	7
1.2	Other applicable documents ....................................................................................................................................	7
1.3	Displaying information ...............................................................................................................................................	7
1.3.1	Warnings ..........................................................................................................................................................................	7
2	Safety .................................................................................................................................................................................	9
2.1	Intended use ...................................................................................................................................................................	9
2.2	Owner requirements ....................................................................................................................................................	9
2.3	Operator requirements .............................................................................................................................................	10
2.4	Dangers ..........................................................................................................................................................................	10
3	Shipment, Transport, Storage ................................................................................................................................	11
4	Description ....................................................................................................................................................................	13
4.1	Function .........................................................................................................................................................................	13
4.2	Basic unit ........................................................................................................................................................................	14
4.3	Sniffer line ......................................................................................................................................................................	16
4.4	Technical data ...............................................................................................................................................................	17
5	Installation .....................................................................................................................................................................	23
5.1	Setup ...............................................................................................................................................................................	23
5.2	Sniffer line .....................................................................................................................................................................	23
5.2.1	Connecting the sniffer line ......................................................................................................................................	23
5.2.2	Exchanging the sniffer line ......................................................................................................................................	23
5.3	Sniffer tip ........................................................................................................................................................................	24
5.3.1	Replacing the sniffer tip ............................................................................................................................................	24
5.3.2	Using the water conservation sniffer tip ............................................................................................................	25
5.3.3	Use flexible sniffer tips ..............................................................................................................................................	25
5.3.4	Using an extension hose for a sniffer tip ............................................................................................................	26
5.4	Insert or replace a COOL-Check calibration leak .............................................................................................	26
5.5	Connecting to the power supply system ...........................................................................................................	27
5.6	Using a USB stick .........................................................................................................................................................	27
5.7	Connecting a PC ..........................................................................................................................................................	27
6	Operation .......................................................................................................................................................................	29
6.1	Switching on the device ...........................................................................................................................................	29
6.2	Operating the device .................................................................................................................................................	30
6.2.1	Structure of the touch screen .................................................................................................................................	30
6.2.2	Measurement display elements .............................................................................................................................	32
6.2.3	Display on the sniffer line .........................................................................................................................................	33
6.3	Basic settings ...............................................................................................................................................................	34
6.3.1	Setting the language .................................................................................................................................................	34
6.3.2	Setting date and time ................................................................................................................................................	34
6.3.3	Adjust volume ..............................................................................................................................................................	34
6.3.4	Setting auto standby .................................................................................................................................................	35
6.3.5	Setting the display ......................................................................................................................................................	35

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6.3.6	Set time interval for calibration request .............................................................................................................	36
6.3.7	Switching the request for replacing filters on or off ......................................................................................	36
6.3.8	I/O module ....................................................................................................................................................................	36
6.3.8.1	Create a connection between the device and the I/O module .................................................................	36
6.3.8.2	Configuring analog outputs ...................................................................................................................................	37
6.3.8.3	Setting the upper scale value for 10 V of the analog output ......................................................................	37
6.3.8.4	Setting up the I/O module protocol ....................................................................................................................	37
6.3.8.5	Configuring PLC outputs .........................................................................................................................................	37
6.3.8.6	Configuring PLC inputs ............................................................................................................................................	38
6.3.8.7	Setting the interface unit .........................................................................................................................................	38
6.3.9	Set up scope of error messages ............................................................................................................................	38
6.3.10	Access to the settings ...............................................................................................................................................	39
6.3.10.1	Protecting settings via PIN assign ........................................................................................................................	39
6.3.10.2	Switching between "supervisor" and "operator" modes .............................................................................	39
6.3.10.3	Changing parameter access levels .......................................................................................................................	40
6.3.11	Save parameters .........................................................................................................................................................	40
6.3.12	Load parameters .........................................................................................................................................................	40
6.4	Settings for the measurements ............................................................................................................................	41
6.4.1	Setting setpoints .........................................................................................................................................................	41
6.4.2	Setting up the sniffer probe ...................................................................................................................................	41
6.4.3	Setting up an alarm profile for setpoints ...........................................................................................................	41
6.4.4	Setting up the gas for the SMART sniffer line ...................................................................................................	42
6.4.5	Verifying R290 with the sniffer line for R600a/R290 .......................................................................................	43
6.4.6	Calibration .....................................................................................................................................................................	43
6.4.6.1	Time and type of calibration ..................................................................................................................................	43
6.4.6.2	Calibration with an internal COOL-Check ..........................................................................................................	44
6.4.6.3 Calibration with an external calibration leak ...................................................................................................		45
6.4.6.4	Checking the calibration with an internal COOL-Check ...............................................................................	45
6.4.7	Measuring ....................................................................................................................................................................	46
6.4.8	Measured data .............................................................................................................................................................	47
6.4.8.1	Recording measured data .......................................................................................................................................	47
6.4.8.2	Evaluating measured data .......................................................................................................................................	48
6.4.8.3	Transferring measured data from the internal memory to a USB stick ...................................................	48
6.4.8.4	Deleting measured data ..........................................................................................................................................	49
6.5	Standby .........................................................................................................................................................................	49
6.6	Diagnosis ......................................................................................................................................................................	49
6.7	Calling up information about the device ..........................................................................................................	49
6.7.1	Parameter list ...............................................................................................................................................................	50
6.8	Updating the software ..............................................................................................................................................	51
6.8.1	Updating the software of the basic unit ............................................................................................................	52
6.8.2	Updating the software of the operating unit ...................................................................................................	52
6.8.3	Updating the software of the sniffer line ...........................................................................................................	53
6.8.4	Updating the software of the I/O module .........................................................................................................	53
6.9	Switching off the device ..........................................................................................................................................	53
7	Warning and error messages .................................................................................................................................	55
8	Maintenance ................................................................................................................................................................	61
8.1	Basic unit ........................................................................................................................................................................	61
8.1.1	Replacing the filter plates ........................................................................................................................................	61

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8.1.2	Cleaning the calibration opening .........................................................................................................................	62
8.1.3	Replacing the fuses ....................................................................................................................................................	62
8.1.4	Cleaning the device ....................................................................................................................................................	62
8.2	Sniffer line ......................................................................................................................................................................	63
8.2.1	Replacing the filter holder .......................................................................................................................................	63
8.2.2	Changing the filter block ..........................................................................................................................................	64
8.3	Sending for maintenance or repairs .....................................................................................................................	64
9	Decommissioning the device .................................................................................................................................	65
9.1	Disposing of the device ............................................................................................................................................	65
9.2	Sending in the device ................................................................................................................................................	65
10	Appendix ........................................................................................................................................................................	67
10.1	Accessories and spare parts ....................................................................................................................................	67
10.2	Menu trees .....................................................................................................................................................................	68
10.3	CE Declaration of Conformity .................................................................................................................................	70
	Index ................................................................................................................................................................................	73

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6Table of Contents

1About these instructions

This document applies to the software version stated on the title page.

1.1Target groups

These operating instructions are intended for the operator of the HLD6000 leak detector and for technically qualified personnel with experience in leak detection technology.

1.2Other applicable documents

Interface description, document no. kira43e1-a

1.3Displaying information

1.3.1Warnings

Imminent threat of danger resulting in death or severe injuries

Dangerous situation potentially resulting in death or severe injuries

Dangerous situation resulting in minor injuries

Dangerous situation resulting in damage to property or the environment

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1 About these instructions

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81 About these instructions

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2Safety

2.1Intended use

The device is a leak detector for sniffer leak detection. Use the device to locate and quantify leaks on test objects. The HLD6000 sniffs for different gases depending on which sniffer line is connected. The following sniffer lines are available:

SMART sniffer line for R22, R32, R134a, R404A, R407C, R410A, R1234yf and 3 additional gases from the selectable gases that are verifiable by the device.

Sniffer line for R744 (CO2)

Sniffer line for R600a and R290.

A test object always contains gas under overpressure. Check the exterior of the test objects for escaping gas using a sniffer line (sniffing method).

►You must install, operate and service the device only in compliance with these operating instructions.

►Adhere to the restrictions of use (see "4.4 Technical data", page 17).

Unauthorized use

► Do not suck up liquids with the device.

►Never hold the sniffer probe into liquids but sniff only for gases.

2.2Owner requirements

Safety conscious operation

Personnel qualifications

►Operate the device only when it is in technically perfect working order.

►Operate the device only as specified in a safety-conscious and hazard-conscious manner and in compliance with these operating instructions.

►Comply with the following regulations and monitor their compliance:

–Intended use

–Generally applicable safety and accident prevention regulations

–International, national and local standards and guidelines

–Additional provisions and regulations that are specific to the unit

►Use only original parts or parts approved by the manufacturer.

►Keep these operating instructions available at the equipment location.

►Allow only qualified service technicians to work with and on the device. The qualified service technicians must have received training on the device.

►Allow personnel in training to work with and on the device only under the supervision of trained qualified service technicians.

►Make sure that the authorized personnel have read and understood the operating instructions and all other applicable documents, especially the information on safety, maintenance and repairs, before starting work (see "1.2 Other applicable documents", page 7).

►Define the responsibilities, authorizations and supervision of personnel.

2 Safety

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2.3Operator requirements

►Read, observe and follow the information in these operating instructions and the working instructions created by the owner, especially the safety instructions and warnings.

►Carry out any work only based on the complete operating instructions.

►If you have any questions regarding operation or maintenance that you cannot find answers to in these instructions, please contact INFICON customer service.

2.4Dangers

Dangers from electric power

Dangers from liquids and chemical substances

Dangers from strong exposure to light

The device was built according to the state of the art and the recognized safety regulations. Nevertheless, improper use can result in danger to life and limb of the operator or other persons and damage to the device and other property.

Considerable voltages arise inside the device. Touching parts where electrical voltage is applied can result in death.

►Disconnect the device from the power supply prior to any installation and maintenance work. Make sure that the electric power supply cannot be reconnected without authorization.

Contact of the sniffer tip with live parts may result in danger to life.

►Before starting the leak test, disconnect electrically operated test objects from the power supply. Make sure that the electric power supply cannot be reconnected without authorization.

The device contains electric components that can be damaged from high electric voltage.

►Before connecting the device to the power supply, make sure that the supply voltage specified on the device is the same as the local power supply.

Liquids and chemical substances can damage the device.

►Adhere to the restrictions of use (see "4.4 Technical data", page 17).

►Do not suck up liquids with the device.

►Never try to find toxic, caustic, microbiological, explosive, radioactive or other harmful substances with the device.

►Only clean the device using mild household detergents.

►Only use the device outside potentially explosive areas.

►No smoking. Do not subject the device to open fire and avoid sparking.

Eye exposure to LED light can lead to permanent eye damage.

►Do not look into the LEDs of the sniffer handle from a short distance or for longer periods of time.

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2 Safety

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3Shipment, Transport, Storage

Shipment	Table 1: Shipment
	Item	Quantity
	HLD6000 (Basic unit)	1
	Sniffer line with sniffer tip (100 mm)	1
	Power supply cable (EU and US version)	2
	Fuses	4
	Filter holder for sniffer tip	5
	Filter blocks for sniffer tip	4
	Operating instructions	1
	Interface description	1
	USB stick with instructions, software	1

► Check the shipment of the product for completeness after receipt. You can also order separately:

the COOL-Check calibration leak.

Accessory list: see "10.1 Accessories and spare parts", page 67

Transport

Damage from transport

Transport in unsuitable packaging material can damage the device.

►Store the original packaging.

►Only transport the device in the original packaging.

Storage	Always store the device in compliance with the technical data, see "4.4 Technical data",
	page 17.

Losses due to overly prolonged storage

The service life of a COOL-Check is limited.

►Do not create inventories.

►Store the COOL-Check in a cool, dry place.

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4Description

4.1Function

The HLD6000 comprises of a basic unit and a sniffer line.

The HLD6000 can, depending on the model, verify and quantify gases sucked in by the sniffer line with the help of an infrared gas analyzer.

The key assemblies of the HLD6000 are:

Sniffer probe with sensor assembly,

Basic unit with pump system, electric and electronic assemblies.

A source emits infrared light in an optical cell through which the sucked-in gas flows. This light is filtered such that only light with a certain wavelength drops onto an infrared sensor.

If there is a leak and gas gets into the chamber with the sucked-in air then part of the infrared radiation is absorbed by the gas.

This means that the intensity of the light which meets the sensor is reduced.

The change in light intensity is electronically amplified, digitalized and then optically and acoustically displayed by the microprocessor after evaluation.

The underground concentration of the sample gas or other interfering gases are taken into consideration and balanced out due to a reference measurement of the ambient air.

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4.2Basic unit

The basic unit is only called a “device” in the following as long as the meaning remains clear.

Fig. 1: Frontal view
a Touch screen	d USB port
b LED power indicator	e Calibration opening for internal calibration
c Speaker	f Sniffer line connection port
b LED power indicator
Operating display with 3 statuses:

–green = in operation

–flashing green = unit in operation, display switched off

–red = malfunction

d USB port

For use of a USB stick see "5.6 Using a USB stick", page 27.

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Fig. 2: Rear view
a Mains plug	d Carry handle
b M12 socket	e Power cable connection
c Ventilation slots	f Cover for fuse holder

a Mains plug

The mains plug is used to switch the device on and off.

bM12 socket, 8-pin

–For connection of the INFICON I/O module, available as an accessory see "6.3.8 I/O module", page 36.

–Length of the data cable: Max. 30 m

f Cover for fuse holder

For exchanging fuses see "8.1.3 Replacing the fuses", page 62.

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Fig. 3: View from below
a Rating plate with information regarding	c COOL-Check calibration leak behind the cover
supply voltage, serial number and
productio date.
b Filter plates

4.3Sniffer line

	You need a sniffer line to operate the device. There are sniffer lines for verification of a sin-
	gle gas or sniffer lines for the verification of several gases see "2.1 Intended use", page 9
	and see "10.1 Accessories and spare parts", page 67. The sniffer line which is delivered as
	standard is 4.8 m long.
	The sniffer line is made of a black line, a sniffer probe, and a sniffer tip. The filter holder at
	the end of the sniffer tip is made of plastic. This reduces the risk of scratching the surfaces
	to be sniffed.
Sniffer tip	There are rigid and flexible sniffer tips of different lengths, see "10.1 Accessories and spare
	parts", page 67.
Sniffer probe	During measurement it is possible to switch the setpoint using the button on the sniffer
	probe, provided that this function is activated, see "6.4.2 Setting up the sniffer probe",
	page 41.
	The button on the sniffer probe is also used during calibration, see "6.4.6.2 Calibration
	with an internal COOL-Check", page 44.

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Fig. 4: Handle: Display and functions
a Key	d Illumination LED
b Status LED	e Sniffer tip
c Name of gas or sniffer line

If the setpoint is exceeded, the display switches from green to yellow, see Table 7 on

Page 33.

You can also set the illumination LEDs to flash at the lower end of the sniffer probe, see "6.4.2 Setting up the sniffer probe", page 41.

4.4	Technical data
		Table 2: Technical data
		Mechanical Data
		Basic unit
		Dimensions (height; diameter)	365 mm; 260 mm (14.4 in.; 10.25 in)
		Weight	4.1 kg (9 lb.)
		Length of sniffer line	4.8 m (15.5 ft.)
		Weight of sniffer probe	280 g (0.6 lb.)
		Ambient conditions
		Permissible ambient temperature (during operation)	5 °C up to 50 °C (40-122 °F)
		Permissible storage temperature	0 °C up to 50 °C (32-122 °F)
		Max. relative humidity up to 31 °C (87.8 °F)	80 %
		Max. relative humidity from 31 °C to 40 °C (87.8 °F-104 °F)	linearly decreasing from 80% to 50%
		Max. relative humidity over 40 °C (104 °F)	50 %
		Pollution degree	II
			(According to IEC 61010/ Part 1: “Usually, only non-con-
			ducting pollution may occur. However, temporary conduc-
			tivity caused by condensation is permissible at times.“)
		Max. altitude above sea level	2000 m

4 Description

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Table 2: Technical data (Contin.)

Electrical data
Supply voltages and frequencies	100 … 240V 50/60 Hz
Power consumption	55 VA
Protection class	IP 30
Overvoltage category	II
Mains fuse	2 x 1 A slow-blowing (Ø 5 × 20 mm)
Power supply cable	2.5 m (8.2 ft.)
Length of the data cable on the M12 plug	Max. 30 m (98.4 ft.)
Noise level without signal tones	< 54 dBA
Physical Data
Minimum detectable leak rate
R744 (CO2)	1.0 g/a (0.04 oz/yr)
R600a/R290	1.0 g/a (0.04 oz/yr); for R600a/R290 see "6.4.5 Verifying
	R290 with the sniffer line for R600a/R290", page 43
SMART	0.5 g/a (0.02 oz/yr); see "6.4.4 Setting up the gas for the
	SMART sniffer line", page 42
Measurement range of sniffer probes
Individual gases	0 - 100 g/a (3.57 oz/yr)
SMART	0 - 300 g/a (10.7 oz/yr)
Time constant of the signal from the leakage rates	< 1 s
Gas flow
Measured at 1 atm (1013 mbar) at sea level. The flow rate	320 sccm
changes with the geographical height and barometric pres-
sure.
Time until ready for operation	< 30 s
Response time	< 1 s

Table 3: General factory settings

(For current device settings see "6.7.1 Parameter list", page 50)

Analog output upper limit	100 g/a
Display off after	1 h
Display brightness	100 %
Display maximum value (log.) exponent	+3
Display maximum value (lin.)	20.0 g/a
Display upper limit (lin.)	300.0 g/a
Display upper limit (log.) exponent.	+3
Display unit leakage rate	g/a
Auto scale	on
Screen tap sound	Soft
Bus module address	126
Data record	Off
Diagram of the leakage rate	Line graph
User Gas Factor 1	0.0
User Gas Factor 2	0.0
User Gas Factor 3	0.0

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Table 3: General factory settings (Contin.)

Error information operator	No. and text
Error information supervisor	No., text and info
Filter change request	On
Gas in the SMART sniffer line	R134a
I/O module protocol	ASCII
Interval for auto standby	2 min.
Interval for calibration request	60 min.
Calibration factor	15.0 (Calibration factor during initial setup. The calibration
	factor cannot be reset to factory settings. It can be changed
	by the service team.)
Config. Analog output 1	Leakage rate linear
Config. Analog output 2	Leakage rate linear
Configuration PLC Output 1	Setpoint 1 (inverse)
Configuration PLC Output 2	Setpoint 2 (inverse)
Configuration PLC Output 3	Open
Configuration PLC Output 4	Open
Configuration PLC Output 5	Measuring
Configuration PLC Output 6	Error (inverse)
Configuration PLC Output 7	CAL request (inverse)
Configuration PLC Output 8	Open (inverse)
Configuration PLC Input 1	No function
Configuration PLC Input 2	No function
Configuration PLC Input 3	Start/Stop (inverse)
Configuration PLC Input 4	No function
Configuration PLC Input 5	CAL external
Configuration PLC Input 6	No function
Configuration PLC Input 7	Delete
Configuration PLC Input 8	No function
Configuration PLC Input 9	No function
Configuration PLC Input 10	No function
Volume	5
LR setpoint 1	5.0 g/a
LR setpoint 2	10.0 g/a
Display measured value	On
Module on the M12 socket	I/O
Phase	20 (Phase during initial setup. The phase cannot be reset to
	factory settings. It can be changed by the service team.)
Calibration leak external	10 g/a
Interface unit leakage rate	g/a
Sniffer light alarm config.	Flashing
Sniffer light brightness	4
Probe key configuration	Setpoint
Setpoint audio alarm	Setpoint
Record interval	500 ms
Memory location	USB

4 Description

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Table 3: General factory settings (Contin.)

Language	English
Value axis decades	3
Value axis grid	Linear
Time axis scale	30 s
Table 4: Factory settings for access authorization
Parameter Access Ctrl.
Analog output upper limit	Supervisor
Display off after	Operator
Display brightness	Operator
Display maximum value (log.) exponent	Operator
Display maximum value (lin.)	Operator
Display upper limit (lin.)	Operator
Display upper limit (log.) exponent	Operator
Display unit leakage rate	Operator
Auto scale	Operator
Screen tap sound	Operator
Bus module address	Supervisor
Data record	Operator
Date	Supervisor
Diagram of the leakage rate	Operator
User Gas Factor	Supervisor
Error information operator	Supervisor
Error information supervisor	Supervisor
Filter change request	Supervisor
Gas in the SMART sniffer line	Supervisor
I/O module protocol	Supervisor
Interval for auto standby	Supervisor
Interval for calibration request.	Supervisor
Calibration factor	Service
Config. Analog output	Supervisor
Configuration PLC Output	Supervisor
Configuration PLC Input	Supervisor
Volume	Operator
LR setpoint	Supervisor
Display measured value	Operator
Module on the M12 socket	Supervisor
Phase	Service
Calibration leak external	Supervisor
Interface unit leakage rate	Supervisor
Sniffer light alarm config.	Supervisor
Sniffer light brightness	Supervisor
Probe key configuration	Supervisor
Setpoint audio alarm	Supervisor
Record interval	Operator

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Table 4: Factory settings for access authorization (Contin.)

Memory location	Operator
Language	Operator
Time	Supervisor
Value axis decades	Operator
Value axis grid	Operator
Time axis scale	Operator

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Description 4 22

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5Installation

5.1Setup

Danger from moisture and electricity

Moisture penetrating the device can lead to personal injury from electric shocks and to material damage from short circuits.

►Only operate the device in a dry environment.

►Operate the device away from sources of liquid and moisture.

Material damage from overheated device

The device heats up during operation and can overheat without sufficient ventilation.

►Please note the technical data, see page 17.

►Ensure sufficient ventilation, especially on the ventilation slots: at least 20 cm of free space on the sides, at least 10 cm in the front and rear.

►Keep heat sources away from the device.

►Do not expose the device to direct sunlight.

5.2Sniffer line

5.2.1Connecting the sniffer line

Connect the sniffer line before you start up the device.

If the sniffer line is not connected then the device reports an error.

If you remove the sniffer line during operation, the device also reports an error.

1Align the red marking on the sniffer line plug with the red marking on the socket of the device (see Fig. 1 on Page 14).

2Push the sniffer line plug into the socket on the device until it locks into place. The plug may no longer be easy to move.

5.2.2Exchanging the sniffer line

1 Select the sniffer line of the gas you wish to detect.

2 Switch the device off.

3To release the plug on the sniffer line from the socket of the device, pull the grooved ring on the plug until the lock is opened.

4 Pull off the sniffer line.

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