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ILS500
User Manual
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INFICON ILS500 User Manual

O P E R A T I N G M A N U A L
ninb63e1-f (1410)
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
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
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
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.
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.
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.
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
• 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.
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

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.
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
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
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)
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
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

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
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

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.
20 System Examples

5.2 Automatic Chamber Test

1 2
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
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.
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.
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.
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.
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.
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!
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.)
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.
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.
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