INFICON ILS500 User Manual

O P E R A T I N G M A N U A L

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Type no. ILS500.210.306

Sensistor ILS500

Hydrogen Leak Detection System

Content

1 General Information 9

1.1 About This Manual 9

1.2 Related Manuals 9

1.3 Introduction to the ILS500 9

1.4 Disposal 10

2 Equipment and Storage 11

2.1 Supplied Equipment 11

2.2 Required Equipment 12

2.3 Storage 12

3 ILS500 Description 13

3.1 Front View 13

3.2 Rear View (Electrical) 14

3.3 Configuring Ports and Interfaces (Electrical) 15

3.4 Rear View (Pneumatical) 16

3.5 Configuring Ports and Interfaces (Pneumatical) 17

3.6 Labels 17

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4 Hand Probe P50 19

4.1 General Information 19

4.2 Description 19

4.3 Calibration 19

5 System Examples 20

5.1 Simple Hand Probe System 20

5.2 Automatic Chamber Test 21

5.3 Chamber Test with Leak Locating Option 22

6 Setup 23

6.1 Placement of the ILS500 23

6.2 Electrical Connections 24

6.3 Pneumatic Connections 27

6.4 Set Up Test Area 31

7 Menu System 32

7.1 ILS500 Display 32

7.2 Passwords 34

7.3 Menu Overview 35

8 Using the ILS500 40

8.1 Test Sequence 40

8.2 Run a Test 41

Content 3

9 Recipes 44

9.1 Recipe Overview 44

9.2 Create a Recipe 45

9.3 Test Settings 46

9.4 Optimizing the Test Cycle 53

10 Calibration 58

10.1 About Calibration 58

10.2 Calibration Overview 58

10.3 How to Calibrate 60

11 Troubleshooting 62

11.1 Fault Symptoms 62

11.2 Perform Hardware Test 62

12 Maintenance Instructions 75

12.1 Software Update 75

12.2 Maintenance Plan 76

12.3 Maintenance 77

12.4 Functional Verification 83

13 Service 84

14 Technical Data 85

14.1 Electrical Specifications 85

14.2 Pneumatic Specifications 86

14.3 Other Data 87

14.4 Interfaces and Connectors 88

15 Spare Parts and Accessories 99

16 Support from INFICON 101

16.1 How to Contact INFICON 101

16.2 Returning Components to INFICON 101

17 Declaration of Conformity 102

18 Declaration by the Manufacturer 103

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Content 4

Appendix

A: Parameter Index 104

General Safety Precautions

Definitions of Warning, Caution and Notice

Warning

Indicates procedures that must be strictly observed to prevent hazards to persons.

Caution

Indicates procedures that must strictly be observed to prevent damage to or destruction
of the instrument

.

General Safety

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Notice

Failure to observe the following precautions could result in serious personal
injury:

Indicates special requirements the user must comply with.

Warning

Pure Hydrogen is a flammable gas. Use only ready-made Hydrogen Tracer Gas
comprising 5% Hydrogen in Nitrogen. This is a standard industrial gas mixture used
in a variety of industrial applications.

Warning

Since the tracer gas mix contains no oxygen, releasing large amounts of the gas in a
confined space may lead to asphyxiation.

Warning

Compressed gases contain a great deal of stored energy. Always carefully secure
gas bottles before connecting a pressure regulator. Never transport gas bottles with
a pressure regulator fitted.

5

Warning

Pressurizing objects at too high pressures can lead to the object bursting. This in
turn can result in serious injury or even death. Never pressurize objects that have
not previously been burst-tested or have otherwise been approved for the test
pressure you intend to use.

Failure to observe the following precautions could result in damage to the
equipment:

Caution

Do not open the detector! Service of this equipment may only be carried out by
service organizations authorized for this purpose by INFICON.

Caution

If the detector suffers external damage, it must be checked and repaired by a service
organization authorized by INFICON.

Caution

Do not expose the probe to a hydrogen concentration greater than 0.1% when the
instrument is not operating, as this could damage or destroy the probe sensor.

Caution

When the instrument is operating, the sensor can withstand temporary exposure to
hydrogen concentrations up to 100%. Avoid long exposures to high concentrations.

Caution

Always switch power off before connecting or disconnecting any cable.

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6

Notice

Whenever the word 'hydrogen' is used in this manual, it implies that the
hydrogen gas is safely mixed with nitrogen in the proportions
95% Nitrogen / 5% Hydrogen.

Before connecting the tracer gas, confirm that the connectors or test
object is designed for operating at the test pressure to be used.

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7

Safety ILS500

Warning

The ILS500 must never be introduced to pressures higher than that approved for the
object to be tested and never beyond the ILS500 specification.

Warning

Be sure to have a pressure relief valve in case of accidental tracer gas pressure
increase.

Warning

When dealing with high pressures, a blast protection is needed between the Test
Port and the Test Object.

Warning

When dealing with test objects that cannot stand high pressure increase, make sure
to mount a flow control valve on the Test Ports.

Warning

Make sure not to confound Compressed Air and Tracer Gas.

Notice

INFICON can not take any responsibility for the consequences arising from
inappropriate use of certain test pressures.

The ILS500 has no internal emergency stop circuit. ILS500 is prepared for
integration into an external emergency stop circuit.

Check that all relevant legislation and safety standards are complied with
before putting the ILS500 into service. See further information under
Installation.

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8

1 General Information

Please read this Operating Manual carefully before putting your Sensistor ILS500 into
service. When reading, please pay particular attention to the WARNINGS, CAUTIONS
and NOTICES found throughout the text.

1.1 About This Manual

The purpose of this manual is to:

• Describe the working principles of the ILS500 and its different parts

• Show examples of different types of test stations

• Teach the reader how to set up the ILS500 for different test purposes

1.1.1 Document History

Revision Date Remark

e 11-2013 New Tracer Gas Filler with New Hydrogen Leak Detector
f 10-2014 Updated version

1.2 Related Manuals

Extensive information about the Leak Detector can be found in the manuals for the
Sensistor ISH2000:

• Operating Manual Sensistor ISH2000

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• Technical Reference Manual Sensistor ISH2000

1.3 Introduction to the ILS500

The Sensistor ILS500 is an all-in-one Tracer Gas Leak Detection System.The purpose
of the ILS500 is to make it possible to set up a fully automatic leak test system quickly,
to a low cost.

1.3.1 Intended Use

ILS500 is designed for indoor use only.
All functions are accessible and programmable using a touch panel, a PC or via the

Internet. The test sequence is controlled by an integrated controller.
Different sets of parameters can be saved. Each set forming a specific recipe for a

specific test object.

General Information 9

1.3.2 Available Configurations

Sensistor ILS500

Sensistor ILS500

Standard For common tracer gas leak detection.
High Pressure (HP) When a higher tracer gas pressure is needed.

The actual configuration is shown on the ILS500 display during start-up and in the
menu when clicking Setup >> Info.

1.4 Disposal

Notice

Start-up time for the leak detectors can be up to 10 minutes, depending
on the condition.

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According to EU legislation, this product must be recovered for
separation of materials and may not be disposed of as unsorted
municipal waste.

If you wish you can return this INFICON product to the manufacturer
for recovery.

The manufacturer has the right to refuse taking back products that
are inadequately packed and thereby presents safety and/or health
risks to the staff.

The manufacturer will not reimburse you for the shipping cost.

Shipping address:
INFICON AB

Westmansgatan 49
582 16 Linköping
Sweden

10 General Information

2 Equipment and Storage

2.1 Supplied Equipment

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Notice

11

10

When receiving the equipment, check that it has not been damaged
during transport.

2

12

OM

ISH2000

OM

ILS500

WARNING

9

PAPER

1

8

7

3

4

5

6

Supplied Equipment

1 ILS500
2 Hand Probe P50
3 Probe Cable (3 m)
4 Power Cables (EU, UK, US)
5 Screw Terminal Connectors for External I/O Signals
6 Thread Converter Set (ISO to NPT Conversion)
7 Hose Connection Kit
8 Safety Override Loopback
9 USB flash drive with other relevant manuals
10 Operating Manual Sensistor ILS500 (this manual)
11 Operating Manual ISH2000
12 Warning Paper about use of Hand Probe

Notice

Accessories to the ILS500 can be found on page 99.

All pneumatic ports are plugged upon delivery. Store the removed plugs.
They are used for future hardware testing.

Equipment and Storage 11

2.2 Required Equipment

1

5 9

Required Equipment

2

6

7 8

3

4

2.3 Storage

1 Tracer Gas
2 Compressed Air
3 Two-Step Gas Regulator
4 Calibration Leak with Certificate (small or large) or
5 Calibration Gas with Certificate
6 Compressed Air Filter
7 Oil Separator (recommended)
8 Exhaust Hose
9 Emergency Stop Circuit (recommended)

For more information, see on page 99.

For prolonged storage, factors such as temperature, humidity, saline atmosphere etc.,
may damage the detector elements.

Please contact your local representative for more information.

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12 Equipment and Storage

3 ILS500 Description

ILS500 is manually controlled using the START and STOP buttons and the menu
system of the touch panel. The screen also shows the steps of the test sequence
graphically and in plain text.

3.1 Front View

3

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2

1

ILS500 Front View

1 Red lamp
2 Green lamp
3 ILS500 Touch panel
4 START button
5 STOP button
6 ISH2000

4

5

6

ILS500 Description 13

3.2 Rear View (Electrical)

13

12

11

10
9

8

Rear View (Electrical)

1 Leak Detector
2 Connection Port
3 Safety Interface
4 Fuses
5 Power Switch
6 Power Input
7 Probe Control Port
8 Control Output
9 Tooling Interface
10 Status Output
11 Inputs 1 and 2 (optional)
12 Ethernet
13 Printer Port/RS232

1

2

3

4
5

6

7

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14 ILS500 Description

For more information, see on page 85.

3.3 Configuring Ports and Interfaces (Electrical)

Port/Interface Connect

Leak Detector File Transfer Cable

(for downloading custom APC drivers)
Pin-to-Pin Cable

(for external mounting of ISH2000)
Connection Port Probe
Safety Interface Emergency Stop Circuit
Power Input Power Cable
Probe Control Port APC Units
Control Output Optional External Valves
Tooling Interface External Tools
Status Output Light Tower etc.
Input 1 (optional) Analogue Input

(not supported by std software)

Digital Input

(not supported by std software)

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Input 2 (optional) Active Holder for Hand Probe
Ethernet Ethernet

(remote view and control of touch panel)
Printer Port/RS232 Serial Printer

Logging Device

(e.g. PC)

Remote Control

(START, STOP etc.)

ILS500 Description 15

3.4 Rear View (Pneumatical)

9

8

7

6

5

4

Rear View (Pneumatical)

1 Optional Port
2 Test Port 2
3 Compressed Air Input
4 Tooling Valve Outputs 1-4
5 Vacuum Gauge Vent
6 Test Port 1
7 Tracer Gas Input
8 Plugged Port
9 Exhaust

1

2

3

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16 ILS500 Description

Notice

Do not remove the plug from the plugged port in pos. 8.

3.5 Configuring Ports and Interfaces (Pneumatical)

Port/Interface Port Thread

Exhaust Barb Fitting:

ID 25 mm (1 in.)

3.6 Labels

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Tracer Gas Input
Test Port 1
Test Port 2
Compressed Air Input

Tooling Valve Outputs 1-4 Hose Connectors:

BSP 3/8" (NPT 3/8" adaptor included)

BSP 3/8" (NPT 3/8" adaptor included)

BSP 3/8" (NPT 3/8" adaptor included)

BSP 3/8" (NPT 3/8" adaptor included)

OD 4 mm (0.16 in.)

Machine Plate

Tooling Plate

ILS500 Description 17

Pneumatical Plate Electrical Plate

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18 ILS500 Description

4 Hand Probe P50

4.1 General Information

Caution

Do not expose the probe to a hydrogen concentration greater than 0.1% when the
instrument is not operating, as this could damage or destroy the probe sensor.

Caution

Connection and disconnection of the sensor cable must be done with power OFF.
Sensor can be damaged if power is on.

4.2 Description

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1

2

3

4

Hand Probe P50 (Rigid Neck)

1 Hydrogen Sensor
2 Indicator LED lamps
3 Function Button
4 Lamps

The Hand Probe P50 is a non-sniffing probe. Gas analysis takes place in the
replaceable sensor located in the tip of the probe.

For more information about the Hand Probe P50, refer to the Operating Manual and
Technical Reference Manual for Sensistor ISH2000.

Notice

4.3 Calibration

The probe needs to be calibrated for optimal accuracy. Make sure it is calibrated when
it is used for the first time. For more information about calibration, see on page 58.

The probe can be ordered with a flexible neck. For more information, see
on page 99.

Hand Probe P50 19

5 System Examples

ILS500 is equipped with a large number of functions for connection and leak testing of
different kinds of objects. It is therefore possible to build a leak test station that suits the
tested object and the requirements on testing speed etc.

Three examples of test stations are given in the following sections.

5.1 Simple Hand Probe System

1

7

2

6

3

4

5

Simple Hand Probe System

1 Power Connection
2 Compressed Air Connection
3 Tracer Gas Connection
4 Evacuation and Gas Filling
5 Test Object
6 Hand Probe
7 Active Probe Holder (optional)

In this system the operator is manually handling the Hand Probe for the leak test and
the test fixture (Tooling).

ILS500 ensures that the tracer gas correctly fills the entire object.
Filling and Gross Leak Test (if desired) are performed automatically and the gas leak

test is conducted manually by the operator.
An Active Holder for Hand Probe (option) can be used to ensure that the selected

minimum test time is used.
ILS500 will indicate LEAK if any of the tests fails.

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20 System Examples

5.2 Automatic Chamber Test

1
2

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3

4

Automatic Chamber Test

1 Power
2 Compressed Air
3 Tracer Gas
4 Test Object
5 Test Chamber
6 Automatic Probe, AP29 ECO
7 COMBOX

6

7

5

This example is using the integrated tooling system for automatic connection of the
tested object. ILS500 will automatically fill the object with tracer gas, and maintain the
correct pressure.

An automatic gas leak test is performed after filling and accumulation of leaking gas in
the test chamber. The gas test is made using the Active Probe AP29. ILS500 will signal
LEAK if leakage above the set limit is registered.

The tracer gas is automatically removed after the test and the tooling system
disconnects the test fixture.

System Examples 21

5.3 Chamber Test with Leak Locating Option

1
2
3

4

Chamber Test with Leak Locating Option

1 Power
2 Compressed Air
3 Tracer Gas
4 Hand Probe
5 Test Chamber
6 Automatic Probe, AP29 ECO
7 COMBOX
8 Active Probe Holder (optional)

8

6

7

5

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In this system example the ILS500 includes an Active Holder for Hand Probe, a Hand
Probe and a Automatic Probe. This enables you to combine a leak test with a Active
Probe with leak locating with a Hand Probe.

The Active Probe first measures within the chamber. The extra Hand Probe will be
automatically activated if a leak is detected and the operator can immediately open the
chamber and locate the leak.

The Detector automatically switches over to locating mode when the probe is lifted
from the holder. The gas in the object under test is automatically removed when the
probe is replaced in the holder.

The operator can skip the locating process by pressing STOP instead of lifting the
probe.

22 System Examples

6 Setup

Caution

Check that you comply with all relevant legislation and safety standards before
putting your ILS500 into service.

6.1 Placement of the ILS500

Place the ILS500 on a flat surface, as close as possible to the test fixture and
ventilation system.

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Some free space must be provided around the ILS500 to enable maintenance and
service access.

≥350 mm (14 in.)

Ensure that there is at least 350 mm (14 in.) of free space behind the ILS500 to enable
removal of service hatches, connection of supplies, test fixture etc.

Notice

The front feet under the ILS500 can be flipped out to raise the front for a
better viewing angle.

Setup 23

Avoid to place the ILS500 close to hydrogen sources such as cigarette smoke,
combustion engines, aluminum machining, lead battery charging stations and
compressed air systems.

6.2 Electrical Connections

6.2.1 Setting Up an Emergency Stop

Caution

To short-circuit is not recommended and should only be made for preliminary testing
before connecting compressed gases or test tooling with moving parts.

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24 Setup

You have the following two options to prepare the ILS500 for start:

• Connect the ILS500 through an external emergency stop relay.

• Short circuit the SAFE SPLY terminal to “+24 V” on the Safety Connector.

Use the Safety Override Loopback delivered with the unit.

Notice

ILS500 will not start testing unless an emergency circuit has been
installed.

6.2.2 Connecting the Probe

1 Use the Probe Cable to connect the Probe to the ILS500.

Probe connectors are placed on the front and rear of the unit.

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6.2.3 Connecting to Mains

1 Plug the Power Cable into the Power Inlet of the ILS500 and into the nearest socket.

Notice

If you have purchased another type of probe than the Hand Probe P50,
refer to the manual for that probe. There may be other connections in
addition to the Probe Cable.

To disconnect the Probe, hold around the knurled part of the connector
and pull straight out.

Standard cable length is 3 m (10 ft.). Several different cable lengths are
available.
For more information, see on page 99.

6.2.4 Connecting Extra Features

When using the ports for Options, Status, Tooling and Control, make sure to mount the
connectors as shown below.

Setup 25

Top pin is number 1

For more information about the connection ports, see on page 85.

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26 Setup

6.3 Pneumatic Connections

6.3.1 Connecting Compressed Air

Caution

Make sure that compressed air is dry, well filtered and oil free. Recommended filter
grade is 5 μm or finer. Inadequate filtering will result in increased maintenance.

Caution

Make sure to use adequate pressure and flow. For more information, see on page

86.

1 Use the hose to connect the compressor and the ILS500.

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6.3.2 Connecting Tracer Gas

Pressurizing objects at too high pressures can result in a burst object. This in turn
can result in serious injury or even death. Never pressurize objects that have not
previously been burst tested or otherwise approved for the chosen test pressure.

Pure Hydrogen is a flammable gas. Only use ready-made Hydrogen Tracer Gas of
5% Hydrogen in Nitrogen. This is a standard industrial gas mixture used in various
industrial applications.

Warning

Warning

Setup 27

1 Secure gas cylinder safely.
2 Open the cylinder valve briefly to blow out dirt that may have collected in the outlet.
3 Install the two stage gas regulator on cylinder.

4 Turn regulator fully counter clockwise for zero output pressure.

5 Connect a regular welding gas hose or similar between the Tracer Gas Port and the

pressure regulator. Check that the hose is certified to withstand the maximum output
pressure of the regulator.

6 Open cylinder valve and set regulator to desired pressure. See warning banner!

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28 Setup

7 Open regulator outlet valve (if any).

6.3.3 Connecting Exhaust to Air Vent

Min 2 m (6.5 ft.)

Ø ≥100 mm (4 in.)

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Max 10 m (30 ft.)

Ø ≥25 mm (1 in.)

3

2

1

Exhaust Recommendation

1 ILS500
2 Exhaust Hose
3 Bleed Air

• The exhaust gas should be directed out of the building.

It is best placed on the roof of the building, far away from the fresh air intake of the
test station.

• It is recommend that a dedicated duct is installed. Install an electric duct fan and an

optional wind extractor.

• It is not recommended to use the general ventilation system to ventilate the exhaust.

If the ventilation system is equipped with energy recirculation there is a big risk that
large amounts of tracer gas will be carried back to the test room thus disturbing the
testing.

Notice

Inadequate exhaust installation is the most common reason for problems
with tracer gas leak testing.

Too narrow or too long exhaust line will result in reduced evacuation
capacity and thereby increased cycle time.

Setup 29

6.3.4 Connecting to Test Port 1 and 2

• Use both Test Ports if applicable.

• Hose ID ≥8 mm (0.31 in.).

• The hoses should be as short as possible.

Notice

6.3.5 Connecting Tooling

Warning

Be aware that the faster the connection is made, the higher the risk for injury. Be
careful and install guards etc, according to local legislation and safety standards so
that your fixture is safe to use.

The larger the test object, the more important to follow the
recommendations above.

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30 Setup

Tooling Valve Outputs 1-4 is available for connection of external Tooling.
If the test object has 2 or more ports, connect to ports on opposite sides of object.

6.4 Set Up Test Area

Large distance

2

1

Test Area Recommendation

1 Fresh Air Fan
2 Exhaust Fan
3 Test Area
4 Test Building

• Place fresh air intake on outer wall of building.

• Place air intake far away from tracer gas exhaust, cargo bays and other hydrogen

sources.

• Do not use compressed air as fresh air supply.

Industrial compressed air often contains varying and substantial amounts of
hydrogen.

4

3

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1

4

2

3

Fresh Air Curtain Recommendation

1 Fan
2 Local Air Jet
3 Test Object
4 Filter

• Try to create a laminar flow over the test area.

• Curtain should cover the entire test area (test hood or sample point) and extend at

least 0.5 m outside the area.

• Air speed in curtain should be rather low, typically 0.1 m/s.

• Additional small fan(s) can be set up within the curtain for directional purging of test

chamber etc.

Setup 31

7 Menu System

7.1 ILS500 Display

1

1 Status Bar
2 Main Display
3 Navigation Button Bar (varies depending on menu)

7.1.1 Menu Buttons

Use the menu buttons for quick navigation.

-0,70

- 0 +

Ready for Start

5,00

bar

2

3

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Calibrate Load Recipe

Settings Home

32 Menu System

7.1.2 Navigation and Other Buttons

Go Back Escape

Previous Page
(changes will be saved)

Activated Unactivated

Selected Deselected

Save
(only shown if USB is connected)

Open switch Closed switch

7.1.3 Entering Numbers and Text

To change a value:

1 Click on the value.

A numeric or alphanumeric on-screen keyboard will open.

ESC

(changes will not be saved)

Next Page

Load

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2 Enter the desired digits or characters.
3 Click on the enter symbol to store the new value.

1 2

3

Esc a b c d e f Del

ghi jklmn

opqr stuv

wxy z, .?

Shift A..1

Ctrl

4

5

1 Escape
2 Delete
3 Enter
4 Control
5 Upper/Lower Case and Numbers

987

4

56

12

-0,

3

1

Esc

2

Del

3

Menu System 33

7.2 Passwords

To access the menus, use default password "1234" for "Service". The password can be
changed under Settings / Advance Settings / Password.

Passwords

Notice

7.2.1 Set Up New User

1 Click Settings >> Advance Settings >> Passwords to enter Passwords menu.
2 Click Log In and log in as Service.
3 Click Setup User.
4 Click Add.

Log In
Log Out

Setup User

Remember to change the passwords of all menus you want to protect.
Anyone using this manual can access the system if you keep the default
password.

Setup excl. Tooling

Adv. Setup excl. Service

Calibrate

Select Recipe

Service Menu

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5 Fill in user name and password for new user.
6 Click Next.
7 Select Security Group by checking the appropriate boxes.
8 Click Finish.

34 Menu System

7.3 Menu Overview

For information about parameter factory default settings, see on page 104.

Notice

The instrument is equipped with a Leak Detector ISH2000, which means
that some settings are blocked. These settings are accessed using the
ILS500 operator panel.

Calibration
Load Recipe
Settings Hardware Setup

Test Settings Tooling Connection

Pre Evacuation
Gross Leak Test Vacuum Decay Test

Pressure Decay Test
Tracer Gas Filling
Blockage Test
Tracer Gas Test
Gas Evacuation
Tooling

Disconnection

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Advanced Settings Timers

Pressures
Options
ISH2000
Service Menu Outputs

Inputs

Analog Inputs

System Reset

ILS500

RS232

Service Run

Hardware Test
Passwords
IP-Settings

Calibration Settings
Recipes
Statistics

Menu System 35

Settings Region Time Zone, Region

7.3.1 Settings

and Daylight
Time and Date
Language

Info

Hardware Setup

Hardware setup, one Probe connected.

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36 Menu System

Hardware setup, two Probe connected.

Test settings

For more information see chapter 9 on page 44.

Advanced Settings

Advanced Settings

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Timers

Pressures
Options

ISH2000

Advanced settings to fine tune the fill cycles and settings for service staff.

Service Menu

Passwords
IP-settings

Calibration Settings

For more information, see chapter 10 on page 58.

Menu System 37

Recipes

For more information, see chapter 9 on page 44.

Statistics

Statistics

Total:
Accepted:
Rejected:

Evacuation:
Vacuum Decay:
Blockage:
Gas Fill:
Pressure Decay:
Gas Test:

0
0
0

0
0

0
0
0

0

Print

Reset

Press 3 sec

Information about test statistics and number cycles events during a test period.
For more information see on page 88.

Region

Region settings.

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38 Menu System

Language

Language

English

Japanese

German

Language settings.

Info

Info

Type: ILS500
Serial number: 0
CPU software v 3.00.08
Display version: 3.00.09

Backup Battery Level (3,0 V)

Brightness display

Swedish

Italian

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Instrument information, software versions, battery status and display light settings.

Menu System 39

8 Using the ILS500

Warning

Ensure that the tracer gas supply pressure (feeding the ILS500 tracer gas inlet) is
set up properly.

Caution

To abort a test sequence and reset to standby, press STOP for 3 s.

Notice

8.1 Test Sequence

Step Comment

1 Standby ILS500 is idle waiting for Start Signal.
2 Tooling Connection Four Air Valves and four Proximity Switch Inputs can

3 Pre Evacuation

Gross Leak Test 1­Evacuation Timeout

The following description is an example for illustration only. The design of
the text fixture, the use of probe(s) and tooling functions etc. should be
adapted to suit your particular application.

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be set up to control moderate test fixtures. Controller
can be expanded for more demanding fixtures.

The air is evacuated from the test object and a first
gross leak test is made simultaneously. The Gross
Leak tests are used to detect larger leaks by pressure
changes.
Evacuation is often necessary to ensure that the
Tracer Gas reaches all parts of the tested object, and
to secure that the tracer gas concentration as high as
possible.

40 Using the ILS500

4 Gross Leak Test 2-

Vacuum Decay Test

Applicable for:

• very long objects (e.g. pipes or heat exchangers).

• low fill pressures (<1 atm).

Less appropriate:

• if the test object does not tolerate underpressure.

• at higher test pressures (Fill Setpoint).

Can be used to reveal leaks before filling with gas.
This minimizes spillage from gross leaks.

Step Comment

5 Tracer Gas Filling Tracer gas filling before gas test.
6 Blockage Test

7 Gross Leak Test 3-Gas

Pressure Decay Test

8 Tracer Gas Test The main leak test. This test can be manual using a

9 Gas Evacuation For fast removal of tracer gas after test. Can also

10 Tooling Disconnection Disconnection of test fixture.

• Reveals internal blockages in tested object.

• Ensures that connection lines and test fixture are

correctly connected.

The test object is filled through Test Port 1 while the
pressure is recorded in Test Port 2. Practical for
testing e.g. capillaries etc.

Performed in parallel with tracer gas test.

Can be used for integral testing in parallel with a more
sensitive gas test at selected points.

Hand Probe or fully automatic using an Active Probe.

include an efficient air purge.

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8.2 Run a Test

Notice

The ILS500 will communicate through the lamps and messages on the display.

Lamp Status Indication

Red ON Acknowledge a leak.

Green ON Test sequence is over and the tested object

Yellow
(START Button)

Several of the steps are optional and can be turned off.
Chosen settings can be saved as a Recipe. For more information, see on

page 44. It is also possible to combine two recipes in one test sequence.
Contact your local supplier for more information and individual settings.

Tested object rejected.
General error.

accepted.
Flashing ILS500 is in stand by.
ON The test sequence is running.

8.2.1 Start Up

1 Turn the ILS500 on.
2 Wait for Ready to Start to show on the display.
3 Click Load Recipe and choose a preset recipe, or follow the instructions in the

section on page 45.

Using the ILS500 41

8.2.2 Place the Test Object

1 Place the test object in the Test Chamber or connect it to one, two or more

connection ports.

2 Connect any extra equipment needed.

8.2.3 Perform a Test

Caution

Do not expose the probe to a hydrogen concentration greater than 0.1% when the
instrument is not operating, as this could damage or destroy the probe sensor.

Caution

When the instrument is put into operation the sensor withstands temporary
exposure to hydrogen concentration up to 100%. Avoid long exposures to high
concentrations.

Automatic Gas Test

1 Press Start on the ILS500 or wait approximately 4 seconds if automatic start is

activated.

2 When ready – Check the result on the display and lamps.

Manual Gas Test

1 Press Start on the ILS500.
2 Move the Hand Probe close to and along the pressurized test object.
3 A chime sound indicates the detection/location of a leak. A small leak can be more

precisely located by moving the probe over the leak again.

4 Remove the probe promptly.
5 Check the result on the display and lamps.

Notice

For more information about manual testing, refer to ISH2000 manuals and
manual(s) for chosen probe(s).

It is good practice to detect a leak, locate it, and then immediately remove
the Hand Probe to avoid saturation. The probe is not damaged by long
time exposure, but it will recover more slowly. After excessive exposure,
the probe will be less sensitive for a short period of time.

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42 Using the ILS500

8.2.4 Disconnect Test Object

1 Evacuate the gas or release the gas pressure.
2 Remove the test object from the fixture.

Notice

Exercise care in the handling of tracer gas after use. Released tracer gas
contaminates the surrounding air with hydrogen and can comprise
subsequent measurements for some time. Ensure that the tracer gas is
ventilated away from the target area, preferably to the outside of the
building.

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Using the ILS500 43

9 Recipes

A recipe is a collection of settings suited for a particular test setup. This is used to have
different settings for different test objects.

9.1 Recipe Overview

Click Settings >> Recipes to enter the three Recipe Setup menus.

Recipe Setup

Use Recipes
Choose at startup

Recipe Setup

Connect with recipe

Load Recipe
Save Recipe Delete Recipe

0

Use from list

Keep Tooling in Test Step
Keep Pressure in Test Step

Recipe Setup

Import from USB
Export to USB

Use Recipes Select the box to activate the recipe handling.
Choose at Startup When power is switched on, the ILS500 prompts

Load Recipe Loads the parameters of chosen recipe.

Save Recipe Saves the current settings under chosen recipe

Factory Default

USB Memory connected

the operator to choose recipe.

A new window will open.

name.
A new window will open.

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44 Recipes

Delete Recipe Deletes the chosen recipe.

Connect with Recipe Connects two recipes to form one test cycle.

Use from list Shows all saved recipes.

Keep Tooling in Test Step Excludes the disconnection step in the first recipe

Keep Pressure in Test Step Retains gas pressure between two recipes.
Import from USB Imports recipes from connected USB memory.
Export to USB Exports all recipes to a editable file on connected

9.2 Create a Recipe

9.2.1 New Recipe

A new window will open.

Write the name of the recipe to be included, or
choose one from the list in Use from list.

By clicking the blue button the recipe displayed is
added to Connect with recipe.

when two recipes are connected as described
above.

USB memory.

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9.2.2 Modify a Recipe

1 Click Settings >> Hardware to enter the Hardware menu.

Set the correct hardware.

2 Set all ILS500 settings for the test sequence.

For more information, see on page 46.

3 Click Settings >> Recipes to enter the three Recipe Setup menus.
4 Click Save Recipe.
5 Enter a name for the recipe.
6 Click Save.

1 Click Settings >> Hardware to enter the Hardware menu.

Set the correct hardware.

2 Click Settings >> Recipes >> Load Recipe.
3 Select the recipe to modify from the list and click Load.
4 Adjust the ILS500 settings to suit the new recipe.

For more information, see on page 46.

5 Click Settings >> Recipes >> Save Recipe.
6 Enter the name of the new recipe.
7 Click Save Recipe.

Recipes 45

9.3 Test Settings

1 Click Settings >> Test Settings to enter the two Test Settings menus.

Test Settings

Tooling Connection
Pre Evacuation

Gross Leak Test
Tracer Gas Filling

Test Settings

Blockage Test
Tracer Gas Test

Gas Evacuation
Tooling Disconnection

ON

ON

Setup

Setup

2 Set which steps to include in the test sequence by selecting the ON boxes.
3 Click Setup to the right of each selected step to enter the Setup menus.

Notice

9.3.1 Tooling Connection

Connection Sequence menu shows the settings made for Tooling Connection.

Connection Sequence

Stand by
Step
Step
Step

Test

For more information about each step, see on page 40.

Tooling Outputs

2341

ON

1

ON

2

OFF

3

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46 Recipes

1 Click on the Settings symbol to edit the settings.

Notice

Up to four connection steps can be programmed.

Stand-By

STAND-BY

Go to next step with

Tooling Outputs

ON

and Tooling Inputs

1234

Start Button

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Delay

1 Click on the Tooling Outputs to be activated in stand-by (between tests).
2 Choose how to move on to the next step.

- Set action in list.

- Select Tooling Inputs.

3 Set desired delay time.

0.0

Connection Step 1 — 3

Connection Step 1

ON

Tooling Outputs

Go to next step with

and Tooling Inputs

Info

1234

ON

Auto

Delay

0.0

1 Select the ON check box to activate the step.
2 Click on the Tooling Outputs to be activated.
3 Choose how to move on to the next step.

- Set action in drop-down-list.

- Select the appropriate check box(es) for the Tooling Inputs.
Then set “Open” or “Closed” status for each switch symbol.

4 Enter a text to describe the step (click the Info field to activate the on-screen

keyboard).

5 Set desired delay time.

Recipes 47

Test Step

Test Step

Tooling Outputs

Condition for starting test

and Tooling Inputs

123 4

ON

1 See Connection Step 1 - 3 above and follow the instructions.

9.3.2 Pre Evacuation

Pre Evacuation

Info Delay

Pre Evacuation Setpoint
Extended Pre Evacuation

Gas Locate if gross leak
Locate if Evacuated below

-0.70
0,0

-0.40

0.0

bar
s

bar

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48 Recipes

Pre Evacuation Setpoint A value of -0.70 bar (-0.07 MPa, -10 psi) is

adequate for most applications. This creates 70%
vacuum.

Extended Pre Evacuation To ensure a complete filling. Evacuation will

continue for the set time after Evacuation Level has
been attained.

Gas Locate if Gross Leak If there is a need to locate a leak with a Hand

Probe even if pre evacuation fails. ILS500 will fill to
chosen pressure in Locating Pressure under
Tracer Gas Test.

Locate if Evacuated Below Gas will be filled only if at least set value is

reached. Limits gas spillage through gross leaks.

9.3.3 Gross Leak Tests

Gross Leak Test

Evacuation Timeout
Vacuum Decay Test

- before gas test
Pressure Decay Test

- during gas test

Evacuation Timeout Object will be rejected if Pre Evacuation Setpoint is

not attained within time set.

Vacuum Decay Test If to be included in the test sequence, select the

box and click the blue button to enter Pressure
Decay Test setup menu (see below).

Pressure Decay Test If to be included in the test sequence, select the

box and click the blue button to enter Pressure
Decay Test setup menu (see below).

10.0

s

V acuum Decay Test

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Vacuum Decay Test

s

Vacuum Stabilisation Time
Vacuum Decay Test Time
Vacuum Decay Limit

Gas Locate if gross leak

Vacuum Stabilisation Time Delay time before Vacuum Decay test begins.
Vacuum Decay Test Time
Vacuum Decay Limit Allowed pressure rise during test time.
Gas Locate if gross leak If there is a need to locate a leak with a Hand

Time during which pressure rise is recorded.

Probe even if pre evacuation fails. ILS500 will fill to
chosen pressure in Locating Pressure under
Tracer Gas Test.

5.0

5.0

0.10

s
bar

Recipes 49

Pressure Decay Test

Gas Pressure Decay Test

Pressure Stabilisation Time
Pressure Decay Test Time
Pressure Decay Limit

Gas Locate if gross leak

Pressure Stabilisation Time Delay time before Pressure Decay test begins.
Pressure Decay Test Time Time during which pressure drop is recorded.
Pressure Decay Limit Allowed pressure drop during test time.
Gas Locate if gross leak If there is a need to locate a leak with a Hand

9.3.4 Tracer Gas Filling

s

5.0

5.0

s

0.10

bar

Probe even if pre evacuation fails. ILS500 will fill to
chosen pressure in Locating Pressure under
Tracer Gas Test.

Warning

The ILS500 must never be introduced to pressures higher than that approved for the
object to be tested and never beyond the ILS500 specification.

Notice

Tracer Gas Filling

Ensure that the test object has time to become filled before Fill Time Out
expires. In particular long narrow objects, as pipes, may need long filling
time.

Fill Setpoint

Fill Timeout

External Fill Regulation
Pressure Unit

bar

5.00

10.0

bar
s

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50 Recipes

Fill Setpoint Desired tracer gas fill pressure.
Fill Timeout Object will be rejected if Pressure Setpoint has not

External Fill Regulation If selected, this is the setpoint of fill pressure alarm.

Pressure Unit Select desired unit.

9.3.5 Blockage Test

been attained within this time.
Cancels the fill if the test object has a major leak,

opens, or if there are loose connections.

Internal pressure regulation is disengaged and
pressure will be that of the gas supply line. ILS500
checks that fill pressure is above Pressure Setpoint
before proceeding to gas test step.

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Notice

Blockage Test

Blockage Test Pressure Minimum pressure to be attained at Test Port 2

Blockage Test Time Time within which Blockage Test Pressure must be

This test can only be performed if both test ports are used and connected
on either side of the possible blockage.

Blockage Test Pressure
Blockage Test Time

0.50

bar
s

2.0

during Blockage Test time.

attained at Test Port 2.

Recipes 51

9.3.6 Tracer Gas Test

Depending on hardware, the following windows will be displayed.

Tracer Gas Test

Reject Level
Measuring Unit

Correlation Value
Purge Level

Displayed Gas

Tracer Gas Test

Reject Level
Measuring Unit

PPM

95%N2/5%H2

10

1

100

APC Timers

A

10.0

B

0.0

C

0.0

D

0.0

ESC

10

cc/s

s
s

s
s

Correlation Value
Purge Level
Displayed Gas

95%N2/5%H2

1

100

For information about the Tracer Gas Test, refer to the manuals for Sensistor ISH2000.

Locating Options

Locate after Gas Leak
Switch probe Automatically

Locating Pressure

2.00

bar

Timer

The Locating Options window is only shown if a Hand Probe is connected. For
information about Locating Options, refer to the manuals for Sensistor ISH2000.

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52 Recipes

9.3.7 Gas Evacuation

Gas Evacuation

Gas Evacuation Setpoint

Extended Gas Evacuation Extends time for gas evacuation, after Gas

9.3.8 Tooling Disconnection

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Gas Evacuation Setpoint
Extended Gas Evacuation

Disconnection Sequence

Test
Step
Step
Step
Stand-by

1

OFF

2

OFF

3

OFF

-0,30

Set desired level of Gas Evacuation.

-30 kPa (-0.3 bar, -4.4 psi) creates 30% vacuum,
which is adequate for most applications.

Evacuation Setpoint has been reached.

Tooling Outputs

1234

0,0

bar
s

Same function as Tooling Connection but in revers order.
For information about this step, see on page 46.

9.4 Optimizing the Test Cycle

Test Cycle can be divided in six main blocks:

1 Connection of Tested Object
2 Pre Evacuation of Residual Air
3 Filling with Tracer Gas
4 Tracer Gas Leak Test
5 Removal and Venting of Tracer Gas
6 Disconnection of Tested Object

Recipes 53

This section is a guide for optimizing step 2, 3 and 5.

0

-

Notice

For optimizing the gas test step, refer to the application manual, the
Hydrogen Method.

9.5 Optimizing the Pre Evacuation Step

Notice

Begin to determine how deep the pre evacuation needs to be, or if it can be skipped
altogether. To do this it is important to fully understand the role of pre evacuation.

When the test object is connected it holds one atmosphere of ambient air. It is often
necessary to remove some or most of this air before filling with tracer gas.

There are two effects of not removing the air (i.e. pre evacuating):

1 the actual hydrogen concentration will be reduced
2 tracer gas does not reach all parts of the object

The fastest way to fill a pipe like object is to use push-through filling. That
does not require pre evacuation.

9.5.1 Calculate Hydrogen Concentration

Example:
The fill pressure is 0.05 MPa (7.2 psi) above atmosphere (gauge pressure). The object

has 1 atm = 0.1 MPa of air before filling.
Leaving this air in the object means the average tracer gas concentration will be:

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A = Fill Pressure
B = 1 atm
C = Tracer Gas Fill Factor

A

--------

AB+

------------

,05 0,1+

0,05

C=

0,33=

The average hydrogen concentration in this example is only a third (33%) of what
expected.

0.33 x 5% = 1.7%

Pre evacuating down to -0.7 atm (-0.07 MPa) means there will be 0.3 atmospheres
(0.03 MPa) of residual air in the object before filling. This gives the following average
concentration:

54 Recipes

A = Fill Pressure
B = 1 atm
C = Tracer Gas Fill Factor
D = Evacuation Pressure

AD+

--------

AB+

0,05 0,07+

---------------

0,05 0,1+

C=

0,8=

The average hydrogen concentration in this example will be 0.8 (80%).

0.8 x 5% = 4%
This is almost twice of that achieved with no pre evacuation.

9.5.2 Example - Calculate Tracer Gas Filling

The air left in the object can not always be expected to mix evenly with the injected
tracer gas. This is especially so for tube shaped objects such as pipes etc. The flow
inside a regular “tube” is predominantly laminar. This means no or very little turbulence
occurs. Air left in the “tube” will therefore be pushed in front of the injected tracer gas
and end up in the remote end of the “tube”.

Example:

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The test object is an aluminium pipe for a refrigerator with brazed copper ends. The
joints between copper and aluminium must both be tested.

Fill pressure is 0.5 MPa (72 psi). Length is 10 m (33 ft.). Skipping pre evacuation we
will have:

A = Fill Pressure
B = 1 atm
E = Air left in the object

B

--------

AB+

-----------

0,5 0,1+

0,1

E=

0,17=

of air left in the pipe. This is equivalent to 1.7 m (5.7 ft.) of the total length if no
turbulence occurs during filling. There is an evident risk that there will be only air inside
one of the joints, which means that a leak there will remain undetected.

Pre-evacuating down to -0.7 atm (-0.07 MPa) means there will be 0.3 atmospheres
(0.03 MPa) of residual air in the pipe before filling.

Recipes 55

We will now have:

B

--------

AB+

-------------

0,5 0,03+

0,03

E=

0,056=

of air left in the pipe. This is equivalent to 0.57 m (1.9 ft.). This air volume is normally
small enough to be mixed into the tracer gas by turbulence and diffusion.

9.5.3 Testing Need for Pre Evacuation

The best way to establish the need for pre evacuation is to make a realistic test.

1 Use a test object with a small leak far away from the test connection.
2 Set the ISH2000 in Locating Mode.
3 Set up the ILS500 according to the specific test specification.
4 Set Pre Evacuation Level to:

-0.07 MPa

-0.7 bar

-10 psi

5 Purge the test object throughly with compressed air.
6 Check with the Hand Probe that there is no Hydrogen in the part.
7 Connect the test object.
8 Place the Hand Probe on the leak.

No signal should be heard.

9 Press Start on the ILS500.
10Register the Signal from the leak.

The gas signal should stabilize quickly and the maximum achieved signal should be
attained in a maximum of 2 seconds after Fill Setpoint has been reached.

• Set Pre Evacuation Setpoint to half of the previous and repeat the test from step 5.

• The new pre evacuation is adequate if the gas signal is essentially the same and

develops at the same speed.

• Reduce Pre Evacuation Setpoint further and repeat test again to find the lowest

suitable Pre Evacuation Setpoint.

Pipes etc. will exhibit considerable pressure drop along its length during the
evacuation. This means the pressure in the pipe can be much closer to atmosphere
than what is registered by the ILS500. Set the ILS500 to evacuate through Test Port 1
only (this is done in the Advanced/Options Menu). In this way the vacuum will be
registered in the end of the pipe and the evacuation will be at least as deep as set by
the Pre Evacuation Setpoint.

If this is not possible, add some extra time by setting an Extended Evacuation Time.

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56 Recipes

9.6 Optimizing the Tracer Gas Filling

Regulation of the tracer gas pressure can either be controlled by:

• the ILS500

• an external pressure regulator

Notice

9.6.1 External Pressure Regulation

Notice

External regulation is recommended mainly for very small objects (<50 cc).

Tracer gas pressure is controlled by external regulator. ILS500 opens a path between
the gas feed line and the test object. The pressure will equate and the tested object will
attain the pressure delivered by the external regulator. ILS500 checks that the fill
pressure is above Fill Setpoint before proceeding to the next test step.

9.6.2 Internal Pressure Regulation

Tracer gas pressure is controlled by the ILS500. Internally regulated filling is generally
faster than externally regulated. The reason for this is that the feeding pressure can be

ninb63e1-f (1410)

set higher than Fill Setpoint which results in a higher fill flow.

The ILS500 is set to regulate internally as default.

External Pressure Regulation does not support recipes with different test
pressure (i.e. Fill Setpoints).

Recipes 57

10 Calibration

10.1 About Calibration

It is important to have a correct calibration when measuring the size of a leak in
Measure Mode and Combined Mode.

There are two ways to calibrate the probe:

• Calibration gas (recommended)

Has a known concentration of hydrogen (10 ppm recommended).

• Calibration leak

Has a fixed leak rate (flow or g/y).

Both methods take less than 2 minutes to perform.
Calibration can be performed automatically for the Active Probes. For Hand Probes the

ILS500 will display a reminder when the system is due for calibration.

Notice

If calibration fails you can still use the instrument. Last valid calibration
parameters will be used. However, you should check that the instrument
reacts to the gas.

10.1.1 Required Equipment

• Calibration Gas (recommended) or Calibration Leak

• Relevant Certificate

For more information, see on page 99.

10.2 Calibration Overview

Click Settings >> Calibration to get to the three Calibration Setup menus.

Calibration Settings

Calibration Value
Calibration Unit

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2.2E-05

cc/s

58 Calibration

Leak Gas

Air

Calibration Settings

Calibrate:

At Startup
After Recipe change

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Every test

Calibration Repeat Pause

Calibration Settings

Cal. Leak in test cycle
Cal. Leak Pressure
Set Cal. Leak Pressure
Prevent Start

Automatic (Active Probe only)

Max. Attempts

Calibration Value Set to the same as stated on the calibration

Calibration Unit Set to the same as stated on the calibration

Leak Gas Set the gas flow for which the Calibration Leak is

50

30 s

bar

1.00

5

certificate issued for the leak or gas.

certificate issued for the leak or gas.

defined.

Notice

Calibrate:
At Startup Calibration is performed or requested whenever

After Recipe Change Calibration is requested every time another recipe

Every “XX” Test Set number of tests between calibration requests.
Calibration Repeat Pause

Notice

For more information, refer to the manuals for Sensistor ISH2000.

the power is switched on.

is selected.

Set minimum time between calibrations (recovery
time for sensor).
The unit will signal the interval through a pulsating
sound indication together with the text "Calibrate!".

The best way to find optimal calibration for an application, is to test
different intervals and learn at what interval calibration is optimal for the
specific case.

Calibration 59

Cal. Leak in Test Cycle Select the box if the calibration leak is integrated in

a test object or in the chamber wall.
A complete test cycle will be performed during
calibration (Active Probes only).

Cal. Leak Pressure This option is only visible if Leak in Test Cycle is

selected.
Makes it possible to adjust the pressure for the
Leak, so that it complies with the Leak's feeding
pressure that is specified in the certificate.

Set Cal. Leak Pressure

Prevent Start

Automatic
(Active Probe only)

Max Attempts

This option is only visible if Leak in Test Cycle is
selected.
Indicates feeding pressure on Leak.
Test cycle can not be started if calibration is not
valid.
This option is only visible if Leak in Test Cycle is
deselected.
The Active Probe will be automatically calibrated at
set interval.
This option is only visible if an Active Probe is
connected, Automatic Calibration selected and
Leak in Test Cycle deselected.
Set maximum numbers of recalibration attempts if
calibration fails. System will stop trying after this
number of attempts and instead display the manual
calibration button.

Notice

10.3 How to Calibrate

10.3.1 Preparation

Calibration Gas

Is a high perception gas mix of well known content of Hydrogen in air, normally 10 ppm
Hydrogen in air.

1 Adapt a Probe tip Nozzle to the regulator on the gas bottle.
2 Open the regulator carefully so that very little gas is flowing out from the nozzle.
3 Close the regulator after use.

Calibration Leak

Notice

1 Fill the gas container to the indicated pressure.

Uncertain about the optimal calibration level for your application? Please
contact your local provider of the Leak Detector.

Do not open the fill valve. Use the purge valve on the leak to release any
air trapped inside the leak housing.

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60 Calibration

2 Purge the hose from air via the Purge Valve on the leak.

3 Replace it with Tracer Gas.
4 Attach it to the leak.

10.3.2 Calibrate the Probe

Hand Probe

1 Expose the probe to the background air.
2 Press cal. button on ISH2000.
3 Press Start Button or push Probe Button.
4 Expose the Probe to the Calibration Leak or Calibration Gas.
5 Wait while the Calibration Time bar is moving.
6 Remove the Probe when the display shows Detecting Gas and gives a sound signal.
7 Save, or repeat the calibration routine until you can save the calibration.

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Notice

Wait at least 30 seconds between each calibration.
If the calibration is not saved, the instrument will revert to the previous

value after one minute.
When changing setup or probe you will need to repeat the calibration 2-3

times to get Calibration OK.

Active Probe

1 If manual start, click on the Calibration symbol.
2 Click Calibrate button.
3 Wait, or abort the calibration by clicking the Abort button.
4 The result of the test will be shown on the screen.

Calibration 61

11 Troubleshooting

11.1 Fault Symptoms

Fault Symptom Fault Measures

Evacuation Failed Failed to reach vacuum

within the specified time.
Large leak on Test Object

or connections.

Gas Fill Failed Failed to fill to the right

pressure within the
specified time.

Large leak on Test Object
or connections.

Gas Refill Failed Failed to refill the object.

Large leak on Test Object
or connections.

Gas Evac Failed Failed to reach vacuum

within the specified time.

Detector Signal Detector is busy signaling,

wait until finished.

ISH2000 APC Driver Error ISH2000 failed to start

measurement during test.

Detector Not Configured! Hardware settings are not

correctly set.

Check the compressed air
supply.

Check the incoming gas
pressure.

Check the incoming gas
pressure.

Check the fresh air supply.

Check that ISH2000 APC is
correctly configured.

Go to Hardware Setup and
set the correct hardware.

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HW Error During Test Serious error has occurred

Test Timeout Maximum time for the test

11.2 Perform Hardware Test

Notice

Before performing the hardware test, carefully check that your tracer gas
and compressed air feed pressures are correct. Wrongly set pressure can
cause erroneous test results.

during test.

was exceeded.

Check external equipment,
e.g Active Probe.

Check that time is correctly
set.

62 Troubleshooting

Hardware Test

OUTPUTS

Press “TEST”

ILS500 plugged
ILS500 + Object

TEST STOP

• For troubleshooting and testing of the system, use Service menu.

• For remote troubleshooting, use Service Run menu.

• Venturi Pump and all Gas Valves can be tested automatically.

The hardware test is a diagnostic tool helping you in preventive maintenance as well as
service and repair. The test takes you through a number of steps testing all units that
are subject to wear and should thereby help you to find almost any problem in the
ILS500 system.

Notice

Run through the whole sequence to interpret the results correctly.
You will need the reference table at the end of this section to help you

interpret the test results correctly. Keep this manual at hand when
performing the test.

Vacuum:

Pressure:

0.00

0.00

bar
bar

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You can choose to test according to the limits of your specific application.

1 Setup all parameters for your test object (or load desired recipe) and connect a leak

free sample.

2 Set test selection switch to ”ILS500 + Object” for application specific hardware test.

You can also test the ILS500 against factory specification. In this case you should
plug both test ports using the plugs delivered with the unit.

3 Remove ISO to NPT converters if installed. Set test selection switch to ”ILS500

plugged” for factory specified hardware test.

4 The ”Continue” button will be displayed at the end of each test step. Press

”Continue” for next test step.

Troubleshooting 63

Pressure and V acuum Sensors

Hardware Test

Pressure and Vacuum Sensors

Zero Points are OK

Vacuum:

Pressure:

CONTINUE STOP

Zero points of pressure and vacuum sensors are tested.
Possible results:

• Zero Points are OK

• Vacuum Zero Point not OK

Offset zero point can result in:

• Incorrect gas filling

• Erroneous vacuum or pressure decay results

0.00

0.00

bar
bar

Evacuation V alve

Hardware Test

Evacuation Valve

No Internal Leakage

ninb63e1-f (1410)

Vacuum:

Pressure:

CONTINUE STOP

Evacuation valve is checked for internal leakage.
Possible results:

• No Internal Leakage

• Internal Leakage

Internal leakage can result in:

• False vacuum decay rejects

• Increased tracer gas consumption

-0.03

0.00

bar
bar

64 Troubleshooting

V enturi Pump

Hardware Test

Venturi Pump

Max Vacuum OK

ninb63e1-f (1410)

Vacuum:

Pressure:

CONTINUE STOP

Checking max vacuum of Venturi pump.
Possible results:

• Max Vacuum OK

• Poor Max Vacuum

Poor max vacuum can result in:

• Failed pre-evacuation

• Slower evacuation

Manifold Tightness (gross)

Hardware Test

Manifold Tightness

No Leakage from Outside

-0.88

0.00

bar
bar

Vacuum:

Pressure:

CONTINUE STOP

The overall tightness of the manifold is tested using the vacuum raise method.
Possible results:

• No Leakage from Outside

• Leakage from Outside

Leaks in the manifold can result in:

• False vacuum decay rejects

• Increased gas consumption

Minor external leakage will be found later during the
gas test step.

-0.82

0.00

bar
bar

Troubleshooting 65

V acuum Sensor Valve

Hardware Test

Vacuum Sensor Valve

Valve works!

Vacuum:

Pressure:

CONTINUE STOP

This checks that the valve shuts to protect vacuum sensor before filling.
Possible results:

• Valve works

• Faulty!

Malfunction can result in:

• Damage to vacuum sensor

• Failed pre-evacuation

0.00

0.00

bar
bar

T racer Gas Fill Valve

Hardware Test

Tracer Gas Fill Valve

No Internal Leakage

ninb63e1-f (1410)

Vacuum:

Pressure:

CONTINUE STOP

The step tests the gas fill valve for internal leakage by registering pressure rise behind
the valve.

Possible results:

• No Internal Leakage

• Internal Leakage

Internal leakage can result in:

• Erroneous pressure decay results

• False vacuum decay rejects increased gas consumption

0.00

0.00

bar
bar

66 Troubleshooting

Test Port 2 Valve

Hardware Test

Test Port 2 Valve

Valve works!

Vacuum:

Pressure:

CONTINUE STOP

Notice

This step tests Test Port 2 valve for internal leakage by registering pressure rise behind
the valve.

Possible results:

• No Internal Leakage

• Internal Leakage

Internal leakage can result in:

• False blockage test accepts

This test will fail if both test ports are connected to a test object. Proceed
and then repeat the entire hardware test sequence with both ports
plugged to perform this test step.

0.00

0.00

bar
bar

ninb63e1-f (1410)

T racer Gas Fill Valve

Hardware Test

Tracer Gas Fill Valve

Valve works!

bar

Vacuum:

Pressure:

CONTINUE STOP

This step tests that tracer gas fill valve opens to fill gas. Test will fail if tracer gas feed
pressure is too low. If this is the case, adjust pressure and restart hardware test from
beginning.

Possible results:

• Valve works

• Faulty!

Malfunction will result in:

0.00

0.50

bar

• Failed gas filling

Troubleshooting 67

External Gas Leaks

Hardware Test

Check for Leaks with Hand Probe

Vacuum:

0.00

bar

Pressure:

CONTINUE STOP

The ILS500 is now prepared for a manual test for external leakage. Use the hand probe
to check for leakage

1 Start by checking all connections between the ILS500 and your test object. Follow

each test line carefully and check every joint.

2 Proceed to check around the gas valves and manifold inside the ILS500.

0.50

bar

Manifold Tightness (gross)

Hardware Test

Manifold Tightness

Internal Leakage

bar

Vacuum:

Pressure:

CONTINUE STOP

0.00

0.46

bar

ninb63e1-f (1410)

68 Troubleshooting

The overall tightness of the manifold is tested using the pressure decay method. This is
a complement to the gas test, revealing leakage out, through the exhaust etc.

Possible results:

• No Internal Leakage

• Internal Leakage

Internal leakage can result in:

• False pressure and vacuum decay rejects

• Increased tracer gas consumption

Evacuation V alve

Hardware Test

Evacuation Valve

Valve works!

Vacuum:

0.00

bar

ninb63e1-f (1410)

Pressure:

CONTINUE STOP

This step tests that evacuation valve opens to release tracer gas to exhaust. Same test
as previously but under pressure instead of vacuum.

Possible results:

• Valve works

• Faulty!

Malfunction will result in:

• Failure to terminate test cycle

0.00

bar

Troubleshooting 69

Indicator Lamps

Hardware Test

Lamp in Start Button

OK?

Vacuum:

0.00

bar

CONTINUE STOP

Hardware Test

Green Lamp (Top Left)

CONTINUE STOP

Hardware Test

Red Lamp (Bottom Left)

OK?

OK?

Pressure:

Vacuum:

Pressure:

Vacuum:

0.00

0.00

0.00

0.00

bar

bar
bar

bar

ninb63e1-f (1410)

Pressure:

CONTINUE STOP

This is a “manual” test. The ILS500 lights up one lamp at the time. Simply check that
the right lamp comes on.

1 Check function of each lamp by pressing “Continue”.
2 Remember to check lamps on both touch panel and external control panel (if

installed).

0.00

bar

70 Troubleshooting

START and STOP buttons

Hardware Test

Press Start Button (Top Right)

OK?

Vacuum:

0.00

bar

ninb63e1-f (1410)

Pressure:

STOP

Hardware Test

Press Stop Button (Bottom Right)

OK?

Vacuum:

Pressure:

STOP

This is a “manual” test. The test continues when the correct button is pressed. The test
checks the activated START and STOP buttons only. Use INPUT menu under Service
menu to check buttons that are turned off.

0.00

0.00

0.00

bar

bar
bar

Troubleshooting 71

11.2.1 Hardware Error Messages

Error Message Reason for Error Corrective Action*

Detector Power Off No power to the Leak

Detector.

Detector Error + Check
Probe and Cable**

Detector Error + Check
Sensor, Voltage Error**

Detector Error + Error
[Driver name]**

Hardware Error
Vacuum Sensor Error

Hardware Error
Pressure Sensor Error

Analog Inputs Power Off No power to AD module. Check power cable on left

Emergency Stop Activated Emergency Stop not

Probe cable disconnected. Connect cable.

Gas sensor damaged. Replace probe or sensor.

Active Probe error. Consult Active Probe

No power to vacuum
sensor.

Sensor not connected to
AD.

Damaged vacuum sensor. Send in for repair.
No power to pressure

sensor.
Sensor not connected to

AD.
Damaged pressure sensor. Replace sensor.

Reset.

Check the power cable to
the detector (internal or
external).

Manual.
Check cable to sensor.

Check connection to AD.

Check cable to sensor.

Check connection to AD.

side of AD module.
Pull out emergency Stop

Button to reset.

ninb63e1-f (1410)

ISH2000 Comm. Error ISH2000 printer mode

turned off manually.
ISH2000 serial cable

disconnected.

* Contact your supplier if the suggested action does not clear the error.
** Error message on ISH2000 display.

Restart system.

Connect cable
(internal or external).

72 Troubleshooting

11.2.2 Interpretation of Hardware Test Results

Use the table below, to correct errors detected by the hardware test routine.

Tested Unit Tested Feature Reason for Error Action

Evacuation Valve Internal leaks Dirty or worn valve seals. Replace clean evacuation

valve.

Venturi Pump Maximum vacuum Compressed air pressure

Gas Valve Manifold Leaks from outside Leaks to outside. Check for leaks with Hand

ninb63e1-f (1410)

Vacuum Sensor Protection
Valve

Adjust compressed air
too low or too high. See on
page 86.

Dirt inside Venturi. Remove and clean

Dirty or broken Venturi
pilot valves.

Dirty or broken Evacuation
pilot valves.

If no gas leaks. Check internal leaks in

If no internal leaks in tracer
gas valve.

Function No signal to pilot valve. Check ”Sensor Protect”

pressure.

Venturi.

Replace two upper valves

in pilot ramp. See on page

77.

Replace fourth valve from

bottom in pilot valve ramp.

See on page 77.

Probe (later in hardware

test sequence).

tracer gas fill valve.

Replace/clean vacuum

sensor protection valve.

output.

Send in for repair.
Dirty or broken pilot valve. Replace valve third valve

from bottom in pilot ramp.
Vacuum sensor protection

valve broken.

Replace valve.

Troubleshooting 73

Tested Unit Tested Feature Reason for Error Action

Tracer Gas Fill Valve Internal leaks Dirty or worn valve seals. Replace or clean tracer

gas fill valve.

Leaking pilot valve. Replace fourth valve from

bottom in pilot valve ramp.

Test Port 2 Valve Function Dirty or broken pilot valve. Replace third valve from

bottom in pilot ramp.

Test port 2 valve broken. Replace valve.

Tracer Gas Fill Valve Function Dirty or broken pilot valve. Replace fourth valve from

bottom in pilot ramp.

Tracer gas fill valve

Replace valve.

broken.

Gas Valve Manifold Leaks to outside Wrongly assembled gas

valve.

Remove leaking valve.
Clean and grease valve
seal before installing
again. See instructions.

Wrongly installed
connectors/plugs.

Remove leaking unit.
Clean and grease o-ring
Install again.
Units lacking o-ring seal

should be sealed with
Loctite 577 or similar.

Evacuation Valve Function Dirty or broken Evacuation

pilot valves.

Replace fourth valve from
bottom in pilot valve ramp.

Lamp Function Broken lamp. Replace lamp.

Send in for repair.

Tooling Valves Function Dirty or broken pilot valve. Replace first or second

valve from bottom in pilot
ramp.

Buttons Function Broken switch. Send in for repair.

ninb63e1-f (1410)

74 Troubleshooting

12 Maintenance Instructions

Caution

Do not open the detector! Service of this equipment may only be carried out by
service organizations authorized for this purpose by INFICON.

There are three different parts that needs regular maintenance:

• Venturi Pump

Needs regular cleaning.

• Gas Valves

Needs regular cleaning and wears out.

• Pilot Valves

Maintenance free if incoming compressed air is dry and filtered to 5 μm.

Changing Venturi Pump and all Gas Valves takes less than 15 minutes.

12.1 Software Update

12.1.1 APC Driver Installation

All standard APC drivers are installed in the detector. Customized APC drivers

can be downloaded from a PC.

ninb63e1-f (1410)

To install a customized driver you will need the following:

• APC Driver software. (Delivered with the active probe.)

• File transfer cable. (Delivered with the active probe.)

• PC computer with Windows XP with.NET Framework 2.0 or later.

1 Connect the cable between the PC and ILS500, trough the Leak Detector port.
2 Start APC Installer and follow the instructions.
3 Disconnect the cable when necessary.

Maintenance Instructions 75

12.2 Maintenance Plan

Part Interval Action

Venturi Pump 3 months Perform a Hardware Test.

Check Ultimate Vacuum.
Clean venturi nozzles when necessary.

Evacuation, Fill and
Test Port 2 Valves

Vacuum Sensor Valve 12 months Perform a Hardware Test.

Pilot Valves 12 months Set PLC in STOP position.

Gas Sensor 3 months Check sensitivity and response time.

*Depends on the amount of particulates in the objects tested. Metal burrs and other
sharp particles will wear the valves down, requiring shorter maintenance intervals.

3-6 months* Perform a Hardware Test.

Check condition of valves.
Replace or clean valves when necessary.

Check condition of valve.
Replace or clean valve when necessary.

Remove output hose from load side and
block with finger.

Change valve if pressure builds.

See manual for ISH2000 and/or active
probe used.

ninb63e1-f (1410)

76 Maintenance Instructions

12.3 Maintenance

12.3.1 Tools and Safety Equipment

When performing regular maintenance of the ILS500 the following equipment is
needed.

Description Note

Allen Keys (Hexagonal 3 and 4 mm)
Torx Key (T25)
Screwdriver (Philip 1 or Pozidrive 1
Protective Eyewear When performing tooling output

Protective Ear Plugs When performing tooling output

12.3.2 Interior View

test.

test.

ninb63e1-f (1410)

10

1 2 3

9

8

4

5

6

7

1 Pilot Valve 6
2 Pilot Valve 1
3 Venturi Pump (Ejector)
4 Evacuation Valve

Maintenance Instructions 77

5 Tracer Gas Fill Valve
6 Test Port Valve 2
7 Vacuum Sensor Control Valve
8 Pressure Sensor (HP model only)
9 Vacuum Sensor
10 Pressure Sensor

Pilot V alve Ramp

Position

5A+6A Main Air Valve
5B+6B Venturi Pump Supply
4A Evacuation Valve
4B Tracer Gas Fill Valve
3A Test Port 2 Valve
3B Sensor Protection Valve
2A Tooling Valve 1
2B Tooling Valve 2
1A Tooling Valve 3
1B Tooling Valve 4

12.3.3 Removing the Cover

1 Use a T25 key to remove the two screws holding the right hand cover (next to gas

ports).

2 Slide the cover back and lift it off. Rock the rear end of the cover up and down a few

times to loosen. See below.

Valve

ninb63e1-f (1410)

78 Maintenance Instructions

12.3.4 Replacing the Venturi Pump

1 Remove the exhaust hose from the barbed hose fitting
2 Unscrew and remove the barbed hose fitting and the plastic washer.

3 Use a 4 mm Allen key to remove the four screws holding the Venturi pump.

ninb63e1-f (1410)

4 Remove the o-ring under the Venturi. Remove the hose from Venturi inlet.

Push hose into connector and press orange ring down to release hose, then pull
hose out.

5 Remove the hose fitting from the Venturi.

Maintenance Instructions 79

6 Install new Venturi or use compressed air jet and a cotton bud, pipe cleaner or small

brush to clean the nozzles inside the Venturi.

7 Replace hose fitting on Venturi inlet.
8 Reconnect inlet hose.
9 Clean o-ring and install in groove on valve manifold.

10Reinstall and tighten the four screws.
11Put plastic washer inside Venturi outlet and reinstall barbed fitting. Tighten with

spanner.

12Reconnect the exhaust hose.
13Run through the hardware test again to test that the Venturi delivers adequate max

vacuum.

ninb63e1-f (1410)

80 Maintenance Instructions

12.3.5 Replacing Gas Valves

1 Use a 3 mm Allen key to remove the four screws holding the valve to be changed.

2 Lift the old valve out and put the new valve in. Notice the correct orientation in the

picture below.

ninb63e1-f (1410)

3 Tighten the screws 2-3 mm (0.08-0.12 in.) at a time moving the key from screw to

screw so that the valve doesn’t tilt much.

4 Tighten the screws and replace the cover.
5 Run through the hardware test again to test that the changed/removed valve(s)

perform as required.

6 Use hand probe to check that there is no external leakage (this part of Hardware

Test is routine).

Maintenance Instructions 81

12.3.6 Replacing Pilot Valves

1 Use small screw driver to loosen the screw holding the valve. You must back the

screw all the way out until you feel it “jumping” in the thread entrance.

2 Push down on the LEDs while pressing the screw down until you feel the locking

mechanism “snap”.

3 Lift the old valve out from the coil side. If the valve does not come off, repeat steps 3

and 4 making sure the screw is completely backed out.

4 Push the screw in while inserting the new valve. Insert the end facing the screw first

and then push the coil side down.

5 Tighten the screw.

ninb63e1-f (1410)

6 Replace the cover.

82 Maintenance Instructions

12.3.7 Replacing Sensors

Caution

Service of the sensors may only be carried out by service organizations authorized
for this purpose by INFICON.

12.4 Functional Verification

See Perform Hardware Test on page 62.

ninb63e1-f (1410)

Maintenance Instructions 83

13 Service

Caution

Do not open detector! Service of this equipment may only be carried

out by service organizations authorized for this purpose by INFICON.

Caution

If the detector suffers external damage, it must be checked and repaired by a
service organization authorized by INFICON.

ninb63e1-f (1410)

84 Service

14 Technical Data

294 mm (11.6 in.)

275 mm (10.8 in.)

14.1 Electrical Specifications

Electrical Supply

Mains Voltage Single Phase

Current 1.0 A at 100 VAC

Power Rating 120 W max

ninb63e1-f (1410)

Inrush Current Max 40 A
Mains Connector IEC/EN 60320-1/C14
Recommended Fuse Rating 2 A slow

I/O Port Signals

364 mm (14.3 in.)

110-240VAC 50/60 Hz

0.45 A at 230 VAC

33 W typical average

6.3 x 32 mm, 0.2 x 1.3 in. (2 needed)

Signal Specification 24 VDC logic
Output Voltage
Output Capacity Max 0.5 A

Input Voltage HI Min 16 VDC
Input Voltage LO Max 4 VDC
Input Current Consumption approximately 7 mA at 24 VDC

Communication Ports

Ethernet RJ45, 10/100 Mbit/s, TCP/IP
RS232

23 ±1 VDC

Output (max 2.5 A total)

Male, 9 pin, D-sub (x2)

Technical Data 85

Communication Ports

Data rate 1200-115200 baud
Data bits 8
Stop bits 1
Parity None
Flow control None

14.2 Pneumatic Specifications

Compressed Air Supply

Pressure Std Model 0.35–0.7 MPa

(3.4–6.9 bar)
(50–100 psi)
Reduced vacuum capacity below:

0.5 MPa
(4.8 bar)
(70 psi)

HP model 0.5–0.7 MPa

(4.8–6.9 bar)
(70–100 psi)

Peak Consumption
at 6 bar (87 psi)

Quality Oil free and filtered to 5 μm
Dew point Max 10°C (50°F)

Tracer Gas Supply

Composition 95% N2 and 5% H
Pressure Std Model 0.005–1.0 MPa

HP model 0.02–4.5 MPa

Quality Industrial grade purity (>95% purity)

240 l/min (508 SCFH)

2

(0.05–10.0 bar)
(0.72–145 psi)

(0.2–45.0 Bar)
(3–652 psi)

ninb63e1-f (1410)

86 Technical Data

Exhaust

Capacity in Exhaust Duct Min 30 m3/h (1000 SCFH)
Dimensions of Hose Leading to

Duct

ID 25 mm (1 in.)

Pneumatic

Valve bore* 7 mm (0.28 in.)

*Capacity is given for 500 mm (20 in.) of ID 10 mm (0.4 in.) hose between ILS500 and
test volume.

Evacuation

Max vacuum -85 kPa (-12.3 psi)
Capacity 0.4 s/l to -50 kPa (-7.2 psi)

1.5 s/l to -80 kPa (-11.6 psi)

Filling

Capacity at 1 MPa supply 0.1 s/l to 0.6 MPa (87 psi)

Tooling Output Valves

Valve type Normally closed, 3/2 valve

ninb63e1-f (1410)

14.3 Other Data

Q

n

C

v

Gas and Air Connection

Ports Female ISO 3/8″

Hose connector 4 of OD 10 mm (0.4 in.) connectors included

General Data

Dimensions 295 x 275 x 330 mm (12 x 11 x 13 in.)
Weight 17.6 kg (38.8 lb.)
Ambient temperature 10–40°C (50–100°F)
Ambient humidity 85% RH (non condensing)
Protection IP30

160 std l/min

0.16 USGPM/psi

(ISO to NPT 3/8″ adapter included)

Physical Data

Please refer to ISH2000 documentation

Technical Data 87

14.4 Interfaces and Connectors

All interfaces signals except the serial. Communication interfaces are discrete 24 VDC
logic signals.

Output signals (OUT) are sourcing transistor outputs. Input signals (IN) are transistor
inputs.

Max current of each signal is given in the tables below. Total current (sum) must,
however, be within instrument specification.

Caution

Outputs are not relay types. Do not connect external drive source such as 24 V or 100/
230 VAC.

14.4.1 Printer Port/RS232

Connector: 9 pin male D-sub
Purpose: Connection of serial printer or logging device (e.g. PC or PLC)
Cable: Standard female to female file transfer cable (null modem)
Baud Rate: 9600 default (1200 - 115200 selectable)

Pin Signal Specification

1 Not used Standard RS232C
2 RD Data rate 9600 baud
3 TD Data bits 8
4 Not used Stop bits 1
5 SG Parity none
6 Not used Flow ctrl none
7 Not used
8 Not used
9 Not used

ninb63e1-f (1410)

88 Technical Data

Printing of results

The printer port prints the result of every test. In hand probe mode the result printed is
“ACCEPT” or “REJECT” followed by date & time and recipe name (if used) and end
Char New Line (0A, LF).<09> (Char Tab, 09) is used as a separator.

For Example: "TEST_ACCE<09>2013-09-04 13:23:03<09>Factory Default<0A>"
After an active probe test cycle the gas analysis value from the ISH2000 is printed. The

printout can be “2.4E+00A<09>2013-09-04 13:23:03<09>Factory Default<0A>”.
See the ISH2000 manual. If the test cycle is rejected by any other test this will be

printed. Followed with date, time and recipe name. Hardware error prints “ERROR”.
For example: “ERROR<09>2013-09-04<09>Factory Default<0A>”.

On the ILS500 (Service/RS232), you can choose if you want to include time and date in
every result from the ILS500 or not. If it’s on the result will be:

"TEST_ACCE<09>2013-09-04 13:23:03<09>Factory Default<0A>"And if it’s
off:“TEST_ACCE<0A>"

Results from ILS500

Results Explanation

TEST_ACCE Test accepted
TEST_REJE Test rejected

ninb63e1-f (1410)

USER_FAIL User has pressed stop
EVAC_FAIL Evacuation failed
VDEC_FAIL Vacuum decay test failed
FILL_FAIL Tracer gas filling failed
PDEC_FAIL Pressure decay test failed
BLOC_FAIL Blockage test failed
REFI_FAIL Tracer gas refill failed
COMM_FAIL Communication with ISH2000 failed
TEST_STRT Test cycle started
TEST_DONE Test cycle finished
FILL_DONE Filling completed
CALI_STRT Calibration started
CALI_FAIL Calibration failed
CALI_DONE Calibration successful
RECH_DONE Recipe change done
RECH_FAIL Recipe change failed
ERROR Hardware error on ILS500

Technical Data 89

Commands

The printer port can also be used to control the ILS500. The most commonly used
functions can be started/configured over the RS232 interface. Always use New Line
(0A,LF) as end character.

Command Action

M<0A> Starts a test cycle.
Q<0A> Stop
N<0A> Print request
K<0A> Starts a calibration. If the function is busy, the ILS500 prints the

time remaining for the ongoing calibration in seconds. For
example, if two seconds remains the printout is as follows: WAIT

2 <0A>
S<0A> Statistics (see table below)
RS<0A> Reset statistics
R<09> Factory Default<0A> Loads a recipe. For example

“R<09>Factory Default” loads the recipe Factory Default. When

the recipe is loaded the recipe name is echoed back. If a recipe

name isn’t in the ILS500 the answer from the ILS500 will be “Not

a recipe name!”

Statistics Printed data Explanation

REC:AP29 - recipe name. Printed if recipes is activated
TOT:00031 - total
ACC:00009 - accepted
REJ:00022 - rejected
EVA:00001 - evacuation
VDE:00000 - vacuum decay
BLO:00006 - blockage test
FIL:00001 - gas filling
PRE:00000 - pressure decay
GAS:00014 - gas detector

ninb63e1-f (1410)

90 Technical Data

14.4.2 Input 1 (Optional)

Connector: 5 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal

Purpose: Options port 1. Optional analogue or digital input (not supported by

Pin Signal Type Load Comment

1 +24 VDC SUPPLY 250 mA Option supply.
2 VIN1 IN -60 mA Voltage input:Digital 24 VDC or

included.

std software).

analogue 0-10 VDC.

14.4.3 Input 2 (Optional)

ninb63e1-f (1410)

3 IIN1 IN +/-30 mA Current input: 0-20 mA.
4 COM1 IN -250 mA Signal common (GND).
5 COM/SHLD GND +/-30 mA Shield/screed connection.

Connector: 5 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal

included.

Purpose: Options port 2. Used for “Active Holder for Hand Probe” (90630).

Pin Signal Type Load Comment

1 +24 VDC SUPPLY 250 mA Option supply.
2 VIN2 IN -60 mA Voltage input:Digital 24 VDC or

analogue 0-10 VDC.
3 IIN2 IN +/-30 mA Current input: 0-20 mA.
4 COM2 IN -250 mA Signal common (GND).

Technical Data 91

Pin Signal Type Load Comment

5 COM/SHLD GND +/-30 mA Shield/screed connection.

14.4.4 Status Output

Connector: 6 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal

Purpose: Test Status Outputs. Sourcing 24 VDC transistor outputs.

Pin Signal Type Load Comment

included.

1 RUNNING OUT 0.5 A Cycle running.
2 ACCEPT OUT 0.5 A Tested part accepted.
3 REJECT OUT 0.5 A Tested part rejected.
4 ERROR OUT 0.5 A Summing error.
5 EOT/FILLED OUT 0.5 A End of test or gas filled indicator

6 COM GND -2.0 A Common GND for status signals.

Notice

14.4.5 Tooling Interface

ninb63e1-f (1410)

(selectable).

Gas filling status is available on the ST A TUS connector (pin 5) on the back
of the unit. Connect to a lamp for easy notification of “End of test” status.

92 Technical Data

Connector: 8 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal

included.

Purpose: Electrical tooling interface.

Pin Signal Type Load Comment

1 +24 VDC SUPPLY 300 mA Tooling switch supply (e.g. proximity

switch).
2 TS1 IN -7 mA Tooling switch 1.
3 TS2 IN -7 mA Tooling switch 2.
4 TS3 IN -7 mA Tooling switch 3.
5 TS4 IN -7 mA Tooling switch 4.
6 MARKER* OUT 0.5 A Marker output. Selectable mark on

REJECT or ACCEPT.
7 COM GND -1.0 A Common GND.
8 COM GND -1.0 A Common GND.

* MARKER output (Tooling Connector, pin 6) can be used to send a start pulse to

marking equipment such as an engraving machine or a valve controlling a simple
pneumatic stamp. Function and length of pulse is set by the following two
parameters:

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14.4.6 Control Output

Marker Output: Length of marker output pulse.

Output will go high at end of gas test and stay
high for the given time.

Marker Output High if Leak: Decides function of marker pulse.

To mark rejected part set to OFF.
To mark accepted part, set to ON.

Connector: 8 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal

included.

Purpose: External start and stop. Control of optional external valves.

Pin Signal Type Load Comment

1 +24 VDC SUPPLY 2.0 A Start and stop switch and supply.
2 EXTSTART IN -7 mA Start button return (NO contacts) or

contact to +24 VDC.

Technical Data 93

Pin Signal Type Load Comment

3 EXTSTOP IN -7 mA Stop button return side (NO contact) or

4 EVAC1 OUT 0.5 A Venturi valve output.
5 EVAC2 OUT 0.5 A Evacuation valve output.
6 GASFILL OUT 0.5 A Fill valve output.
7 OPTOUT OUT 0.5 A
8 COM GND -1.0 A Common GND for outputs.

14.4.7 Probe Control Port

contact to +24 VDC.

Connector: 25 pin female D-sub
Purpose: For external connection of ISH2000.

Pin Signal Type Load Comment

1 COM GND -1 A Common GND for outputs.
2 COM GND -1 A Common GND for outputs.
3 COM GND -1 A Common GND for outputs.
4 IN_0 IN -0.5 mA Input of ISH2000 APC system.
5 IN_1 IN -0.5 mA Input of ISH2000 APC system.
6 IN_2 IN -0.5 mA Input of ISH2000 APC system.
7 IN_3 IN -0.5 mA Input of ISH2000 APC system.
8 IN_4 IN -0.5 mA Input of ISH2000 APC system.
9 CAL_CONF OUT 0.5 A Output of ISH2000 APC system.
10 OUT_6 OUT 0.5 A Output of ISH2000 APC system.
11 COM GND -1 A Common GND for outputs.
12 COM GND -1 A Common GND for outputs.
13 COM GND -1 A Common GND for outputs.

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94 Technical Data

14 DET_ERROR OUT 0.5 A Output of ISH2000 APC system.
15 LEAK_OUT OUT 0.5 A Output of ISH2000 APC system.
16 DET_ON OUT 0.5 A Output of ISH2000 APC system.
17 DET_SIGNAL OUT 0.5 A Output of ISH2000 APC system.

Pin Signal Type Load Comment

18 DET_WAIT OUT 0.5 A Output of ISH2000 APC system.
19 OUT_0 OUT 0.5 A Output of ISH2000 APC system.
20 OUT_1 OUT 0.5 A Output of ISH2000 APC system.
21 OUT_2 OUT 0.5 A Output of ISH2000 APC system.
22 OUT_3 OUT 0.5 A Output of ISH2000 APC system.
23 OUT_4 OUT 0.5 A Output of ISH2000 APC system.
24 OUT_5 OUT 0.5 A Output of ISH2000 APC system.
25 24 VDC OUT OUT 0.5 A Supply for switches etc. connecting to

For further information about APC system refer to the Technical Reference Manual for
Sensistor ISH2000.

14.4.8 Power Input

Specification

AC mains voltage 110-240 V 50/60Hz.

inputs. Do not feed 24 V here.

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14.4.9 Safety Interface

AC mains current Typically 1 A (2 A pulse at power on).

Caution

Risk assessment is the sole duty of the user of the ILS500

Connector: 6 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal

included.

Purpose: Emergency stop interface.

Technical Data 95

Pin Signal Type Load Comment

1 +24 VDC SUPPLY 2.5 A
2 AUX1 - +/-1-5 A* Terminal 1 of safe relay contacts for

auxiliary external use.

3 AUX2 - +/-1-5 A* Terminal 2of safe relay contacts for

auxiliary external use.
4 Not used - - ­5 SAFESPLY** SUPPLY -2.5 A 24 VDC supply from EXTERNAL

emergency stop circuitry.
6 COM GND 1.0 A Common GND.

* 250 VAC 5 A cosj =1

30 VDC 5 A L/R = 0 ms
240 VAC 2A cosj = 0.3
24 VDC 1A L/R = 48 ms

** SAFESPLY feeds risk associated loads inside the ILS500. These include all gas

and tooling valves.

14.4.10 Connection Port

Connector: Probe connector.
Purpose: For connection of probe.
Cable: C21 Probe Cable.

14.4.11 Leak Detector

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96 Technical Data

14.4.12 USB Port

Connector: 9 pin male D-sub.
Purpose: For downloading of APC drivers.
Cable: Standard female to female file transfer cable (null modem) for

downloading APC drivers.

Pin Signal Specification

1 Not used Standard RS232C
2 RD Data rate 115200 baud
3 TD Data bits 8
4 Not used Stop bits 1
5 SG Parity none
6 Not used Flow ctrl none
7 Not used
8 Not used
9 Not used

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Connector: USB
Purpose: Used for import and export of recipes.

To access the USB port, remove the cover. See Removing the Cover on page 78.

Technical Data 97

USB is connected

Recipe Setup

USB Memory connected

Import from USB
Export to USB

An icon for USB is shown when installing the USB flash drive.

Import Recipe from USB

Importing database table Recipe1 from csv-file...

USB Memory connected

Import from USB
Export to USB

When importing recipes all recipes are imported from a file named Recipe1.csv.

Export Recipe from USB

Exporting database table Recipe1 to csv-file...

USB Memory connected

Import from USB
Export to USB

When exporting recipes all recipes are exported to a file named Recipe1.csv.

ninb63e1-f (1410)

98 Technical Data

15 Spare Parts and Accessories

1 2 43

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5

11 13

6 7

98 10

12

Pos. Part Type Description Part no.

1 Hand Probe P50 With a rigid neck. 590-780

P50-FLEX With a flexible neck. 590-790

2 Hand Probe Sensor For sensor replacement on P50

Hand Probe.

Spare Parts and Accessories 99

590-292

Pos. Part Type Description Part no.

3 C21 Probe Cable 3 m 590-161

6 m 590-175
9 m 590-165
4 m (Helical) 590-163
6 m (Helical) 590-164

4 Power Cables EU 591-146

UK 591-147
US 591-853

5 No-Stop Maintenance Kit Standard Model 590-680

HP Model 590-685

Venturi 1 pcs
Fill valve 4pcs
Pilot valve 1 pcs
Fuse 2 pcs
Necessary tools

6 Probe Tip Protection Cap for

Set of 500

590-625

Hand Probes P50 and
P50-FLEX

591-273
591-234
591-578

7 Probe Tip Filter
8 Fuse, 2 A slow for Sensistor

Set of 50
Set of 50

ISH2000

9 O-ring seal for Hand Probe 591-528

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10 Calibration Leak with

Certificate (small or large)

For calibration and function test of
the probes. Generic name is
Forming Gas. The tracer gas (95%

see

separate

Data Sheet

Nitrogen / 5% Hydrogen) is best
ordered from your regular gas

supplier.
11 Active Probe Holder 590-636
12 Active Probe AP29 ECO Sniffer flow 1 cc/s 590-036

Sniffer flow 3 cc/s 590-035

AP55 590-550
AP57 590-555

13 COMBOX To connect ILS500 to AP29 ECO. 590-820

For a complete list of all spare parts and accessories, please contact:

[e-mail]

100 Spare Parts and Accessories