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ILS500F
User Manual
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INFICON ILS500F User Manual

O P E R A T I N G M A N U A L
ninp69e1-a (1410)
Type no. ILS.210.306
Sensistor ILS500 F
Leak Detection Filler
Content

1 General Information 8

1.1 About This Manual 8
1.2 Introduction to the ILS500 F 8
1.3 Disposal 9

2 Equipment and Storage 10

2.1 Supplied Equipment 10
2.2 Required Equipment 11
2.3 Storage 11

3 ILS500 F Description 12

3.1 Front View 12
3.2 Rear View (Electrical) 13
3.3 Configuring Ports and Interfaces (Electrical) 14
3.4 Rear View (Pneumatical) 15
3.5 Configuring Ports and Interfaces (Pneumatical) 16
3.6 Labels 16

4 Setup 18

4.1 Placement of the ILS500 F 18
4.2 Electrical Connections 19
4.3 Pneumatic Connections 21
4.4 Connect External Leak Detector 25
4.5 Set Up Test Area 25

5 Menu System 27

5.1 ILS500 F Display 27
5.2 Passwords 29
5.3 Menu Overview 30

6 Using the ILS500 F 35

6.1 Test Sequence 35
6.2 Run a Test 36

7 Recipes 38

7.1 Recipe Overview 38
7.2 Create a Recipe 39
7.3 Test Settings 40
7.4 Optimizing the Test Cycle 46

8 Troubleshooting 50

8.1 Fault Symptoms 50
8.2 Perform Hardware Test 50

9 Maintenance Instructions 62

9.1 Maintenance Plan 62
Content 3
9.2 Maintenance 63
9.3 Functional Verification 69

10 Service 70

11 Technical Data 71

11.1 Electrical Specifications 71
11.2 Pneumatic Specifications 72
11.3 Other Data 73
11.4 Interfaces and Connectors 74

12 Spare Parts and Accessories 84

13 Support from INFICON 85

13.1 How to Contact INFICON 85
13.2 Returning Components to INFICON 85

14 Declaration of Conformity 86

15 Declaration by the Manufacturer 87

Appendix
A: Parameter Index 88
Content 4
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
Tracer Gases can be flammable or asphyxiating. Use only ready-made Tracer Gas mixtures.
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
If the tracer gas filler suffers external damage, it must be checked and repaired by a service organization authorized by INFICON.
Caution
Always switch power off before connecting or disconnecting any cable.
Notice
Before connecting the tracer gas, confirm that the connectors or test object is designed for operating at the test pressure to be used.
6
Safety ILS500 F
Warning
The ILS500 F must never be introduced to pressures higher than that approved for the object to be tested and never beyond the ILS500 F 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 Ports 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 F has no internal emergency stop circuit. ILS500 F 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 F into service. See further information under Installation.
7

1 General Information

Please read this Operating Manual carefully before putting your Sensistor ILS500 F 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 F and its different parts
• Show examples of different types of test stations
• Teach the reader how to set up the ILS500 F for different test purposes

1.1.1 Document History

Revision Date Remark
a 10-2014 First edition

1.2 Introduction to the ILS500 F

1.2.1 Intended Use

The Sensistor ILS500 F is a stand alone tracer gas filler with all necessary functions integrated in one very compact housing.The purpose of the ILS500 F is to make it possible to set up a fully automatic leak test system quickly, to a low cost.
The ILS500 F can also be combined with both hydrogen and helium INFICON leak detectors.
If a ISH2000 Hydrogen Leak Detector is connected to the ILS500 F, via the Probe Control Port and Leak Detector Port, the ILS500 F has the same functionality as ILS500. For information on how to setup this configuration, please contact INFICON.
Notice
ILS500 F 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.
ILS500 F is not compatible with AP29, AP55, and AP57.
General Information 8

1.2.2 Available Configurations

Sensistor ILS500 F

Sensistor ILS500 F
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 F display during start-up and in the menu when clicking Setup >> Info.

1.3 Disposal

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
9 General Information

2 Equipment and Storage

2.1 Supplied Equipment

Notice
8
7
6
When receiving the equipment, check that it has not been damaged during transport.
2
OM
ILS500 F
1
3
4
5

Supplied Equipment

1 ILS500 F 2 Power Cables (EU, UK, US) 3 Screw Terminal Connectors for External I/O Signals 4 Thread Converter Set (ISO to NPT Conversion) 5 Hose Connection Kit 6 Safety Override Loopback 7 USB flash drive with relevant manuals 8 Operating Manual Sensistor ILS500 F (this manual)
Notice
Accessories to the ILS500 F can be found on page 84.
Some pneumatic ports are plugged upon delivery. Store the removed plugs. They are used for future hardware testing.
Equipment and Storage 10

2.2 Required Equipment

1
5 6

Required Equipment

1 Tracer Gas 2 Compressed Air 3 Two-Step Gas Regulator 4 Compressed Air Filter 5 Exhaust Hose 6 Emergency Stop Circuit (recommended)
2
3
4

2.3 Storage

For prolonged storage, factors such as temperature, humidity, saline atmosphere etc., may damage the detector elements.
Please contact your local representative for more information.
11 Equipment and Storage

3 ILS500 F Description

ILS500 F 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 F Front View

1 Red lamp 2 Green lamp 3 ILS500 F Touch panel 4 START button 5 STOP button
4
5
ILS500 F Description 12

3.2 Rear View (Electrical)

12
1
11
10
9
8
7
6

Rear View (Electrical)

1 Leak Detector (for connection of ISH2000 or T-Guard) 2 Safety Interface 3 Fuses 4 Power Switch 5 Power Input 6 Probe Control Port (for connection of ISH2000) 7 Control Output 8 Tooling Interface 9 Status Output 10 Inputs 1 and 2 (optional) 11 Ethernet 12 Printer Port/RS232
2
3 4
5
13 ILS500 F Description
For more information, see on page 71.

3.3 Configuring Ports and Interfaces (Electrical)

Port/Interface Connect
Leak Detector ISH2000 or T-Guard. Safety Interface Emergency Stop Circuit. Power Input Power Cable. Probe Control Port Pin-to-pin cable
(for external mounting of ISH2000 Leak Detector). Control Output Optional External Valves. Tooling Interface External sensors for tooling control. Status Output Light Tower etc. Input 1 (optional) Analogue Input
(not supported by std software).
Digital Input
(not supported by std software). Input 2 Active Holder for Hand Probe
(if ISH2000 Leak Detector is connected).
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 F Description 14

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
15 ILS500 F 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.)

Device Label

Tooling Label

ILS500 F Description 16

Pneumatical Label Electrical Label

17 ILS500 F Description

4 Setup

Caution
Check that you comply with all relevant legislation and safety standards before putting your ILS500 F into service.
Notice
Start-up time for the leak detectors can be up to 10 minutes, depending on the condition.

4.1 Placement of the ILS500 F

Place the ILS500 F on a flat surface, as close as possible to the test fixture and ventilation system.
Some free space must be provided around the ILS500 F 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 F to enable removal of service hatches, connection of supplies, test fixture etc.
Setup 18
Notice
The front feet under the ILS500 F can be flipped out to raise the front for a better viewing angle.

4.2 Electrical Connections

4.2.1 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.
You have the following two options to prepare the ILS500 F for start:
• Connect the ILS500 F 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 F will not start testing unless an emergency circuit has been installed. This is ordered separately. For more information, see on page
84.
19 Setup

4.2.2 Connecting to Mains

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

4.2.3 Connecting Extra Features

When using the ports for Options, Status, Tooling and Control, make sure to mount the connectors as shown below.
Top pin is number 1
For more information about the connection ports, see on page 71.
Setup 20

4.3 Pneumatic Connections

4.3.1 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
72.
1 Use the hose to connect the compressor and the ILS500 F.

4.3.2 Connecting Tracer Gas

Warning
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.
Warning
Tracer Gases can be flammable or asphyxiating. Use only ready-made Tracer Gas mixtures.
21 Setup
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 counterclockwise 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!
7 Open regulator outlet valve (if any).
Setup 22

4.3.3 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 F 2 Exhaust Hose 3 Bleed Air
• The exhaust gas must 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.
23 Setup

4.3.4 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.
If the test object has 2 or more ports, connect to ports on opposite sides of object.

4.3.5 Connecting Tooling

Notice
The larger the test object, the more important to follow the recommendations above.
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.
Tooling Valve Outputs 1-4 is available for connection of external Tooling.
Setup 24

4.4 Connect External Leak Detector

Notice

Connect External ISH2000

External ISH2000 is connected to the Probe Control port and Leak Detector port. For more information about the connections and cables, see on page 81.

Connect External T -Guard

External T-Guard is connected to the Leak Detector port. For more information about the connection and cable, see on page 81.

4.5 Set Up Test Area

When external leak detector is connected, some settings must be updated. These settings are made in the Hardware Setup menu.
Start-up time for the leak detectors can be up to 10 minutes, depending on the condition.
Large distance
4
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 tracer gas
sources.
• Already tested objects may contain small amounts of tracer gas, which may interfere
with next measurement.
• Do not use compressed air as fresh air supply when a hydrogen mixture is used as
tracer gas. Industrial compressed air can contain varying and substantial amounts of hydrogen.
3
25 Setup
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 26

5 Menu System

5.1 ILS500 F Display

1

5.1.1 Menu Buttons

- 0 +
-0,70
5,00
bar
Ready for Start
1 Status Bar 2 Main Display 3 Navigation Button Bar (varies depending on menu)
Use the menu buttons for quick navigation.
Home Load Recipe
2
3
Settings
Menu System 27
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