A 100 Introduction to the Sensistor ISH2000 series
Sensistor ISH2000 can be purchased in one of three versions. A desktop model
(Sensistor ISH2000), a battery operated model (Sensistor ISH2000C), and a
panel mount model (Sensistor ISH2000P).
Figure A-1: Sensistor ISH2000
Sensistor ISH2000 is equipped with a number of powerful functions making it
very easy to integrate in a semi or fully automatic test system. The functions
range from output of all necessary status signals and printer/communication
port to an advanced Active Probe Control system (APC). This makes the detector capable of controlling advanced sample collecting devices down to simple
test fixtures.
Sensistor ISH2000C
Sensistor ISH2000P
Figure A-2: Sensistor ISH2000C
The battery operated model, Sensistor ISH2000C, has all the Sensistor ISH2000
features apart from the APC system. This means that only passive probes (for
example Hand Probe P50) can be used. The battery, a Li-ion battery at 14.8 V,
can not support the current required to operate external probes. Sensistor
ISH2000C will operate for 14 hours on a fully charged battery with screensaver
and mute function. One hour charging will give about one hour of operating
time.
Figure A-3: Sensistor ISH2000P
The panel mount model, Sensistor ISH2000P, has identical features of the Sensistor ISH2000.The difference is that the Sensistor ISH2000 can be installed in
the operator’s panel or any other flat surface. Also it operates on +24 VDC.
Mounting brackets and a panel rubber seal are delivered with the detector.
The Sensistor ISH2000 leak detector is using SENSISTOR sensor technology
inside. SENSISTOR sensor technology uses an extremely sensitive hydrogen gas
sensor based on a microelectronic field effect transistor (MOS-FET).
The gas sensitivity appears when hydrogen absorbs into the sensor through a
metal alloy (metal hydride) layer.
Only hydrogen can diffuse into the metal and this makes the sensors practically
insensitive to other substances that do not contain free hydrogen molecules.
The signals from the sensors are processed by a microprocessor which also controls the sensor temperature with high accuracy, and other sensor diagnostics in
order to ensure perfect functionality. It also automatically compensates for
background gas.
If all you wish to do is to detect the presence of a leak, that is, find out whether
there is a leak or not, then use the Detection Mode (or use the detection bar in
Combined Mode). The definition of Leak/No Leak will then simply be "A leak is
a leak when it can be detected by the detector, set to a specific sensitivity".
To set up:
The operation in Detection Mode is not quantitative. The audio and visual sig-
nal will increase and decrease with the gas concentration. Therefore, there is no
actual calibration to be done, but rather a setting of the sensitivity to a desired
level.
A typical set-up procedure for Detection Mode is:
• Set up a reference leak which corresponds to the smallest leak you wish to
detect.
• Put the probe close to the reference leak and note approximately what reaction you get (no reaction, small, medium, high, full scale) within the first few
seconds.
• Set the sensitivity. This can be done permanently under the menu Detection
Mode Settings or temporarily as a Direct Sensitivity Adjustment on the display
(unless you have set this function to OFF under the Detection Mode Settings
menu).
There is also an Auto ranging function which can be selected under the Detection Mode Settings menu.
Note: If the Detection Mode is used and the alarm function is required to be
activated at a particular calibrated level, then the unit must be calibrated in
accordance with the instructions, see "Calibrate the leak detector" on page 17.
The reason for this is that the alarm is based on the Analysis Mode when the
Detection Mode is displayed.
To Locate Leaks
Note: The Detection Mode (or use the detection bar in Combined Mode) is
used to locate leaks. This mode is semi-quantitative, that is, it gives an audio
and visual signal which increases as a leak is approached (a higher gas concentration) and decreases as you move the probe away from the leak. It does not
display figures. In this mode of operation leaks can easily be detected using a
sensitivity which can be preset.
Leaks can be located very accurately, even when there are other leaks nearby. If,
for example, you are trying to locate a leak on a product and the product has a
major leak, then you will get an audio signal as soon as the probe is placed
close to the product.
When the probe is moved around and over the product, the signal will increase
as the probe approaches the leak. If the signal goes out of scale, simply reduce
the sensitivity setting to bring the signal within the scale. Working with the sensitivity setting this way you will be able to locate multiple leaks that are in close
proximity to each other.
Note: Working inside a confined space such as, for example, a cabinet or a narrow passage on a combustion engine there is a risk that the background concentration accumulates to levels close to the upper detection limit of the
detector. In such case it will not be possible to locate leaks as easily as in open
spaces.
Hint: It is good practice to detect a leak, locate it, and immediately remove the
probe to avoid saturation. The probe is not damaged by the exposure but it will
recover more slowly. After excessive exposure it will be less sensitive for a short
period of time.
The Analysis Mode (or use the analysis figures in Combined Mode) is used for
measuring the size of a leak (or the concentration of a gas sample). To be able
to do this measurement and obtain correct values, the instrument must first be
calibrated using the calibration function.
In the Analysis Mode the detector determines the gas concentration from the
change, as the probe goes from being exposed to background to being
exposed to a certain gas concentration. The detector does not continuously
monitor the gas concentration but takes just one reading instead. Another suitable alternative name for this mode could be Sampling Mode. It is important to
keep this in mind when using the detector in this mode.
In Analysis Mode the probe should be moved directly from a background situation to the test point. The size of the leak in PPM, or any other selected units, is
shown on the display. The probe can and should be removed from the measuring point as the measured value steadies and remains on the display. The period
during which the measured value is displayed can be adjusted in the Analysis
Mode Settings menu.
When pure hydrogen gas is released in air its flammability range spans from 4%
to 75% of hydrogen in air. Below 4% there is insufficient chemical energy available for a flame to occur. Above 75% hydrogen there is not enough oxygen left
to support a flame. When, for example, a mixture of less than 5.5 % hydrogen
in nitrogen mixes with air there is not sufficient energy to support a flame, irrespective of the ratio of air-to-gas. When a mixture of more than 5.5 % hydrogen in nitrogen is released into air there is a region of ratios of air-to-gas where
the mixture is flammable. When, for example, a mixture of 10% hydrogen in
nitrogen mixes with air there is still very little energy available. Only in exceptional circumstances can a flame be self-supporting. However, such mixtures
cannot detonate.
Hydrogen can be stored and transported as either a gas a cryogenic liquid.
The tracer gas is standard welding gas of industry quality, easy to obtain at low
For automatic leak testing of entire products or parts of products. Can also be used
for testing permeability of materials.
Part No: 590-035
AP57 Counter Flow Probe
For fast manual leak location in hard to-reach places. Active probe that sniffs the
sample air past the hydrogen sensor in the probe tip.
Part No: 590-550
For leak detection in enclosed spaces or in environments with a high background
level of tracer gas. An adjustable air flow from the probe tip provides a protective air
curtain against tracer gas in the surroundings.
The normal risks associated with working with all compressed gases must be
considered.
Indicates a potentially hazardous situation which, if not avoided, could result in
property damage.
Indicates a potentially hazardous situation which, if not avoided, could result in
moderate or minor injury. It may also be used to alert against unsafe practices.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or severe injury.
Indicates an imminently hazardous situation that, if not avoided, will result in death or
severe injury (extreme situations).
WARNING!
Pure hydrogen is a flammable gas. Only use readymade Hydrogen Tracer Gas of 5% Hydrogen in
Nitrogen. This is a standard industrial gas mixture
used in various industrial applications.
Note:
Whenever the word Hydrogen is used in
this manual it implies that the hydrogen gas is
safely mixed with Nitrogen in the proportions
- 95% N2.
5% H
2
Leak detector label
WARNING!
Since the tracer gas mix contains no oxygen,
releasing large amounts of 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 pressure regulator. Never transport gas
bottle with the pressure regulator fitted.
Before connecting tracer gas: confirm that the connectors or test object is designed
for working at the test pressure.
WARNING!
Pressurising objects at too high pressures can result
in a burst object. This in turn can result in serious
injury or even death.
Never pressurise objects that have not previously
been burst tested or otherwise approved for the
chosen test pressure.
Located at the back of the Sensistor ISH2000, a label indicates the electrical
specifications of the leak detector and its serial number.
B 300 Controlling the detector with the I/O
interface
The Sensistor ISH2000 is equipped with a parallel Probe Control port. This
Probe control port can be used for controlling active probes, feeding status signals to a supervising computer system, and for simple test fixture control.
Note: Battery operated model Sensistor ISH2000C does not have a Probe Control Port.
Pin configuration for the different detector models is described under Model
Specific Specifications below.
See "Sensistor ISH2000 Technical Specifications" on page page 23 for electrical specifications.
I/0 name on the screenSignal Name on the pinsFunction
Inputs 0 to 4In_0 to In_4Input signal
Outputs 0 to 6Out_0 to Out_6Output signal
Status ODET_ONWhen detector is on
Status WDET_WAITHigh during warm-up
Status SDET_SIGNALGas detected / Sensor not
recovered
Status RLEAK_ALARMLeak above Reject Level
detected
Status CCAL_CONFCalibration preformed
and ok
Status EDET_ERRORHigh if Probe, Sensor or
Cable is broken
DET_ERROR will go high for a short time (1-5 seconds) when the detector is
switched on. It will go low when the sensor has been checked. In normal operation, DET_ERROR = HIGH means that there is a problem with the sensor,
probe, or cable.
DET_WAIT is high when instrument is in warm-up mode after switching on
power. Instrument will also go into warm-up if there is a temporary fault in the
sensor or sensor connection.
The timing of the status signals in relation to different events is described by the
following two examples:
• Example: Input signals issued to control the APC system should have a pulse
length of at least 40 ms.
• Example: Output signals switch with a cycle time of 20 ms (0.02 s). This is the
cycle time of the APC system.
Note: Not valid for battery operated version of Sensistor ISH2000.
The RS 232 interface makes it possible to control the leak detector with a PC
compatible computer: it is installed on all leak detectors.
Commands available for your leak detector
RS232 interface commands
SettingNo printerPC printerData output
Data rate115200 baud1200 baud9600 baud
Data bits888
B 310
Stop bits
Parity
Flow control
Common used functions
CommandHeader
CalibrateK
MeasureM
Print RequestN
Stop MeasurementQ
Hand ProbeR
Active Probe (Installed AP)S
Analysis ModeX
Detection ModeZ
Combined ModeY
111
NoneNoneNone
NoneNoneNone
K = Calibration request
Starts calibration if the Sensistor ISH2000 has an active probe driver installed.
Sensistor ISH2000 answers with a "K" if an active driver containing a calibration routine was found and "F" if the calibration APC sequence not found. Calibration doesn’t start if Purge level is reached.
M = Measure Request
The active test cycle defined by the APC driver starts. “M” is returned if the
selected driver supports active test. “F” (failed) is returned otherwise.
Send parameters one by one; send the specific header and then send the data
(for example “1.00E+01”). String must be ended with a carriage return character, chr13 (dec).
Example: “CPPM” or “C PPM”, Carriage Return (chr 13). This sets Reject Level
Rate Unit to “PPM”.
B 320 Connecting the detector directly to a
printer or another device
For detailed information please refer to document RS 232 for leak detectors
users manual.
Printer port
The Sensistor ISH2000 is equipped with a serial printer port. This is the 9-pin Dtype connector. It is used for printer connection, RS232 commands and APC
driver installation.
Note: Always switch power off before disconnecting or connecting any cable.
Preparing the RS 232 link cable
Use INFICON cable, P/N: 103616, or make your own by following the pin connections specified below:
Use a Sub D9 pin, female connector (7 and 8 connections are necessary only if
RTS and CTS are used in an user software).
Connector pin configuration
B 320
Pin Signal Comment
1Not used
2RXReceived data
3TXTransmitted data
4(DTR)Not used
5SGSignal ground
6(DSR)Not used
7(RTS)Not used
8(CTS)Not used
9(RI)Not used
Only pin 2 (Received data), pin 3 (Transmitted data) and pin 5 (Signal ground)
are used.
For example, the user can communicate easily with the detector using the Terminal or Hyper Terminal program in Windows®.
Selectable printer types
Most PC-printers with serial interface can be connected to the 9-pin printer
port. Parallel (Centronics) interface printer can be used if connected through a
serial to parallel converter. The port can be set up for the following printer
types: PC Printer and Data Dump.
No printer
Printer output disabled. Incoming communication is enabled. Sensistor ISH2000
listens for incoming data but will not print/send test results.
PC printer (with serial interface)
The PC Printer option can be used to print data on most standard PC printer
with serial interface. Parallel interface printers can be used if connected through
a serial to parallel converter.
Note: The output format has been chosen to be as simple as possible to ensure
that most printers will accept it. Therefore, the printer output does not use any
flow control. This means that some printers may delay printing until the input
buffer is full or a pre-defined timeout has elapsed.
Figure B-9:
B 320
SettingValue
Data rate1200 baud
Data bits8
Stop bits1
ParityNone
Flow controlNone
Note: Due to the large variety of printers available on the market, INFICON
AB does not take responsibility for the operation of a particular type of printer.
Printed data
The detector can print the following information:
1 Date and Time for Power on of detector.
2 Time of print.
3 Value of all gas signals above the Reject Level.
4 Test result: “Accept” or “Reject”.
5 Value of signal obtained during active test.
6 Result of calibration: “OK” or “Calibration Not saved”, Date and Time,
Parameter settings.
Printing of the current value can also be requested by an RS232 command or
ordered manually by pressing PRINT.
The Analysis Data Output option is intended for transferring test results to a
supervising computer system such as, for example, a PLC system.
Communication specifications.
SettingValue
Data rate9600 baud
Data bits8
Stop bits1
ParityNone
Flow controlNone
The data format for Analysis data output consists of nine ASCII characters.
Seven characters show the value in engineering format one character shows
the result of the test, and one character shows line feed (LF).
The character indicating the result of the test is one of the following.
CharacterResult of the test
AAccept. Previous test was below Reject Level alarm limit.
RReject. Previous test was above Reject Level alarm limit.
PRejected by Purging. Previous test was above purge limit
(and Reject level limit).
CCalibration approved. Previous cycle was calibration.
Calibration was approved.
FCalibration failed. Previous cycle was calibration.
ETest interrupted by “Error” that occurred during cycle
Example: 2.5E-04R (LF)
This example is a line feed (LF), R means that the test was above the Reject Level
alarm limit, and the value was 2.5E-04.
For passive probes (for example P50 and AP57*) data is printed when a signal is
detected above Reject Level or when the print button is pressed. Activate this
under Measure Button menu.
For active probes (e.g AP29) data is printed at end of measurement sequence.
Printing of the current value can also be requested by an RS232 command or
ordered manually by pressing PRINT.
* A custom APC program setting the MEAS flag prints as AP55/AP29 and an
APC program not using MEAS flag prints as P50.
Detection data output
The Detection Data Output option is intended for automated scanning of weld
seams etc.
Note: The Detection Data is expressed in arbitrary units. Detection Mode signal
is not affected by calibration!
Communication specifications.
SettingValue
Data rate9600 baud
Data bits8
Stop bits1
ParityNone
Flow controlNone
The data format for Detection data output contains of ten ASCII characters.
Nine characters show the value in engineering format, and one character shows
linefeed (LF).
• indicator bar in Detection Mode and the figures in Analysis Mode.
• seven main menus. Their positions are indicated on a horizontal scale. Change
from one menu to another using the < and > buttons.
• main menus have submenus, which are also indicated by horizontal scales
and can be selected using the < and > buttons.
• scales for setting numeric values, languages, etc.
• messages.
Sensistor ISH2000C:
• A battery status indicator in the upper right corner, where 13.5 V indicates
discharged state and 16.0 V indicates that the battery is fully charged.
• six main menus. Their positions are indicated on a horizontal scale. Change
from one menu to another using the < and > buttons.
LEDs
The two LEDs indicate the status of the instrument as follows:
• Green flashing slowly, during warming up phase.
• Green fixed light indicates that instrument is ready and hydrogen signal is
below Reject Level limit.
• Red fixed light together with Reject on display means the instrument has
detected a leak larger than the set alarm limit. Red flashing rapidly, check message on screen. (See “Trouble-shooting” on page 74.
The functions of the push-buttons are shown at the lower edge of the display.
In this manual the buttons are numbered, from left to right, 1, 2, 3, and 4. The
push-buttons are used to:
• Change from one menu item to another using the < and > buttons.
• Press Enter to move down to the nearest submenu.
• Press Save to save the set value.
• Press Undo to restore the previously set value.
Press Esc to move up to the nearest higher level(s).
Demo Mode is a demonstration mode, special designed for seller. All APC drivers for standard probes and filler will be selectable. The seller can easily swap
between the different drivers and won't need to download them.
To set the Detector in Demo Mode:
• Select: Menu/General Settings/Change Password
• Enter "DEMO"
• Confirm New Password "DEMO"
Select driver under menu: APC Settings/Probe Type
The word "DEMO" will be shown at start up.
To turn Demo Mode off repeat the list above.
The menu system is designed as a tree structure similar to that used in mobile
telephones. The display shows all the levels when browsing down through the
menus so that you can always see exactly where you are.
3
412
Figure C-2: Push-buttons
To enter the menus, press Menu (button 4). Press < and > (button 2 and button
3) to choose between main menus.
If no setting is made in a menu or its submenus within 60 seconds, the instru-
ment will revert to the Detection Mode/Analysis Mode.
The buttons may change functions in different menues. Always read the text,
just above the buttons in the display, for the button functions.
All changes in values are valid only when saved using the Save button (button
4).
Use the Undo button (button 1) to delete a change in value and revert to the
previous setting.
Use the Esc button (button 1) to browse backwards through the menus to the
start position Detection Mode/Analysis Mode/Combined Mode.
To change quickly from Detection Mode to Analysis Mode or vice versa, press
Choose the measuring method you will use in the menu Change Test Mode.
There are three different methods to choose:
• Analysis Mode
• Detection Mode
• Combined Mode
Figure C-4: Change test mode screen example
The instrument must be calibrated by using the integral calibration function to
ensure it displays the correct values in Analysis Mode/Combined Mode. After
calibration the instrument will show the correct measured values on the display.
The calibration parameters will be stored into the probe.
Detection mode settings
Analysis mode settings
Figure C-5: Calibration screen example
In Detection Mode, the signal is displayed in the form of a bar. The length of
the bar varies with the gas concentration.
Figure C-6: Detection mode screen example
In Analysis Mode the measured value is displayed in figures. The default unit is
in PPM but it is possible to choose other units, See .“C 500 Factory configuration of the leak detector parameters” on page 65
APC is an abbreviation for Active Probe Control. The APC function is for the
control of an active probe that has a built-in alarm, valves or pumps via Probe
Control Port.
Different probes require controls therefore, it is possible to download different
drive routines for the instrument from a PC.
There is a possibility to adapt how to measure by adjusting the timers and Purge
Level.
Probe Type
Select the connected probe. Choose between “Hand Probe” and another
probe driver installed from the disc delivered with active probe (if ordered).
APC Time A-D
Adjustable timer used by the APC system. Select a APC timer and press “Enter”
to display specific use of this timer. APC timer can be used for general purposes
in a custom APC program.
Purge Level
Signal level controlling the Purge_Level APC Triggers. Standard probes that support active sampling use the Purge Level for fast interruption of sampling that
result in high gas signals.
Setting Purge Level equal to, or just above, Reject Level will give the fastest possible cycle times for those probes.
Quick purging also enhances signal repeatability.
Note: Purge level interrupts active sampling of APC probes. This means that
higher signals will be underestimated as the sensor is purged before full signal
has developed.
Reset Signal
Reset the sensor level in Analysis mode and Detection mode.
This section describes the different display settings of the Sensistor ISH2000.
Contrast
Contrast level of display. Higher value gives higher contrast. The contrast may
need adjustment if ambient temperature changes.
Brightness
Brightness of the display lamp. A lower brightness value saves energy and prolonges the lamp.
Invert Colors
Change the black to white and white to black. Useful in a dark environment to
keep a high readability.
Screen Save Timeout
Display lamp will dim to half brightness if instrument is left idle for the number
of minutes set by this parameter. The screen save timeout can be set between 1
and 60 minutes, the function is deactivated if set to OFF. The display lamp will
return to the set brightness if any of the display buttons are pressed, if a gas
signal is detected or an instrument error is detected.
This part describes the general settings of the Sensistor ISH2000.
Language
The Sensistor ISH2000 user interface contains the following languages:
• English
• French
• German
• Italian
• Spanish
• Swedish
Measure/Print Button
Setting this parameter to ON displays Measure or Print above the button 1.
Measure will be displayed for an APC-Probe or Print for a Hand Probe. Pressing
Measure will initiate a sample cycle. Pressing Print will send the values from the
hand probe measurement to the printer port.
Probe Button
This is for setting the different functions with the probe button. These functions
are as follows:
• Toggle Mode-makes it possible to switch between Analysis mode and Detection mode.
• Zero detection signal-in Analysis mode and Detection mode.
• Measure/Print-makes it possible to initiate sample cycles or send the values
from the hand probe measurement to the printer port.
• Probe Lamp-makes it possible to turn on and off the Probe Lamp.
Probe Lamp
Makes it possible to have the Probe Lamp on even if the other Probe Button
function is chosen.
Change Password
The user password is a text string (max 12 alphanumerical characters) used to
lock critical parameters. Setting password to an empty string (no characters)
means that no password is needed to modify the critical parameters. The
default is no password (“”).
Contact INFICON AB if you have lost your user password. If the Password Protected Calibration parameter is set to ON you will be prompted for a password
when starting a calibration.
Note: Setting Password Protected Calibration to ON has no effect if no password is set.
Note: APC controlled calibration can be started from the bus in both cases.
Audio Base Frequency
This sets the lowest audio base frequency tone in Search and Detection Mode.
Set Clock
Real time set as hh:mm:ss. Hours and minutes can be adjusted. Seconds will
automatically be set to 00 when hours and minutes have been set. Clock runs
even when detector is disconnected from the power supply.
Set Date
Real Time Clock date set as YY-MM-DD. Clock runs even when detector is disconnected from the power supply.
Printer Port
The Sensistor ISH2000 is equipped with a serial (RS232) printer port. See
“Printer port” on page 35.
Info
Contains information about software versions, Serial number, and Internet contact information.
Service settings
The Service Mode is reached by starting the instrument and at the same time
hold the right button down on the panel. After start a new main menu called
Service Settings will appear.
The user password is a text string (max 12 alphanumerical characters) used to
lock critical parameters. Setting password to an empty string (no characters)
means that no password is needed to modify the critical parameters. The
default is no password (“”).
Contact INFICON AB if you have lost your user password. If the Password Protected Calibration parameter is set to ON you will be prompted for a password
when starting a calibration.
Note: Setting Password Protected Calibration to ON has no effect if no password is set.
Note: APC controlled calibration can be started from the bus in both cases.
Do not expose the probe to a hydrogen concentration higher than 0.1
% when the instrument is not put into operation, this might damage
or destroy the probe sensor.
When the instrument is put into operation the sensor withstands temporary exposure to hydrogen concentration up to 100%. Avoid long
exposures to high concentrations.
If all you wish to do is to detect the presence of a leak, that is, find out whether
there is a leak or not, then use the Detection Mode (or use the detection bar in
Combined Mode).
The definition of Leak/No Leak will then simply be "A leak is a leak when it can
be detected by the detector, set to a specific sensitivity".
To set up:
The operation in Detection Mode is not quantitative. The audio and visual sig-
nal will increase and decrease with the gas concentration. Therefore, there is no
actual calibration to be done, but rather a setting of the sensitivity to a desired
level.
A typical set-up procedure for Detection Mode is:
• Set up a reference leak which corresponds to the smallest leak you wish to
detect.
• Put the probe close to the reference leak and note approximately what reaction you get (no reaction, small, medium, high, full scale) within the first few
seconds.
• Set the sensitivity. This can be done permanently under the menu Detection
Mode Settings or temporarily as a Direct Sensitivity Adjustment on the display
(unless you have set this function to OFF under the Detection Mode Settings
menu).
There is also an Auto ranging function which can be selected under the Detec-
tion Mode Settings menu.
Note: If the Detection Mode is used and the alarm function is required to be
activated at a particular calibrated level, then the unit must be calibrated in
accordance with the instructions. The reason for this is that the alarm is based
on the Analysis Mode when the Detection Mode is displayed.
To locate leaks
Note: The Detection Mode (or use the detection bar in Combined Mode) is
used to locate leaks. This mode is semi-quantitative, that is, it gives an audio
and visual signal which increases as a leak is approached (a higher gas concentration) and decreases as you move the probe away from the leak. It does not
display figures. In this mode of operation leaks can easily be detected using a
sensitivity which can be preset.
Leaks can be located very accurately, even when there are other leaks nearby. If,
for example, you are trying to locate a leak on a product and the product has a
major leak, then you will get an audio signal as soon as the probe is placed
close to the product.
When the probe is moved around and over the product, the signal will increase
as the probe approaches the leak. If the signal goes out of scale, simply reduce
the sensitivity setting to bring the signal within the scale. Working with the sensitivity setting this way you will be able to locate multiple leaks that are in close
proximity to each other.
Note: Working inside a confined space such as, for example, a cabinet or a narrow passage on a combustion engine there is a risk that the background concentration accumulates to levels close to the upper detection limit of the
detector. In such case it will not be possible to locate leaks as easily as in open
spaces.
Hint: Do not expose the probe to more gas than is necessary, because it will
slowly saturate with time. It is good practice to detect a leak, locate it, and
immediately remove the probe to avoid saturation. The probe is not damaged
by the exposure but it will recover more slowly. After excessive exposure it will
be less sensitive for a short period of time.
The Analysis Mode (or use the analysis figures in Combined Mode) is used
for measuring the size of a leak (or the concentration of a gas sample). To be
able to do this measurement and obtain correct values, the instrument must
first be calibrated using the calibration function.
In the Analysis Mode the detector determines the gas concentration from the
change, as the probe goes from being exposed to background to being
exposed to a certain gas concentration. The detector does not continuously
monitor the gas concentration but takes just one reading instead. Another suitable alternative name for this mode could be Sampling Mode. It is important to
keep this in mind when using the detector in this mode.
In Analysis Mode the probe should be moved directly from a background situ-
ation to the test point. The size of the leak in PPM, or any other selected units,
is shown on the display. The probe can and should be removed from the measuring point as the measured value steadies and remains on the display. The
period during which the measured value is displayed can be adjusted in the
Analysis Mode Settings menu.
The leak detector operates in the range 0.5 - 2000 ppm H2 giving linearity
between 0.5 and 500 ppm. To obtain greatest accuracy over this range, follow
the calibration recommendation. See "Calibration of the leak detector" on
page page 57.
The leak detector is the instrument and the probe together. This section consists
of step by step examples about how to calibrate the detector in the most comman cases.
The instrument must be calibrated by using the integrated calibration function
to make sure it displays the correct values in Analysis Mode. After calibration
the instrument will show the correct measured values on the display in Analy-sis Mode and Combined Mode. The calibration parameters will be stored into
the probe.
There is a possibility to calibrate the detector by Reference Gas or Reference
Leak.
A Reference Gas contains a well-defined concentration of Hydrogen gas in ppm
mixed by air or some inert gas. A Certificate will normal follow the gas bottles.
Reference Gas can be ordered from local gas suppliers.
A Reference Leak is a well -defined gas leak, and should be feed by same gas as
using in the detection test and with a gas pressure that is defined in the Reference Leak certificate. Reference Leak can be ordered from the detector provider.
Choose a calibration reference size, as follows recommendations:
• Same or higher than the Reject Level (but maximum 10 times higher)
• In one of the following ranges:
- 5 to 1000 ppm H2
- 1x10-5 to 1x10-2 cc/s (mbarl/s) defined for air
- 3 to 300 g/a defined for R134a
Please contact the provider of the detector for help to select optimal calibration
Before calibration, the Reference Value in the Calibration Menu must be set.
See “With reference gas” and “With reference leak” below.
When calibrating, expose the probe to the background air then do the following steps:
1. First Menu then Calibration/Calibrate/Enter.
2. Push the Start button or push the probe button.
3. Expose the probe for the reference gas/leak
The probe does not have to be exposed to the to the calibration gas during the
whole Calibration Time ( the time set in the Calibration Menu while the bar
is moving). The instrument only measures the change as the probe goes from
the background air to calibration gas.
While the calibration time bar is moving, the probe should be exposed to the
calibration gas or referenece leak. Then the display shows Detecting Gas and
gives sound signals. Save or repeat the calibration routine until you can save the
calibration. If the calibration is not saved, the instrument will revert to the previous value after one minute.
Note: You will need to repeat the calibation 2-3 times to get Calibration OK
after changing setup or probe.
• Allow at least 30 seconds between each calibration for best accuracy!
• If the message “No Gas or Unstable Signal” is displayed repeatedly - go back
to Detetion Mode and check functionality.
• If Repeat Calibration is displayed then this means that the measured value
devated more than 10% from the previous calibration. Repeat the calibration
procedure.
Also set the Analysis Unit to the same as the Reference Value. If you want to
use another unit you have to put a recalculation number into Correlation Value
which describes the relationship between the different units.
Calibration intervals
Low sensitivity warning
Calibration is a natural part of leak measurement and an important factor in
quality assurance. It is impossible to specify an exact requirement for the interval between the calibrations becase the applications for which the instrument is
used can vary considerably.
There will be some oxidation of the probe sensor, which reduces the sensitivity,
if the probe sensor:
• is not subjected to gas for a lengthly period or
• is exposed to a very small gas concentration (less than 10 PPM) with long
intervals between exposure.
If the instrument is subjected to a very large gas concentration over a long
period, a certain amount of insensitivity can occur directly afterwards. This saturation can make it difficult to detectvery small leaks. Therefore, make it a habit
of removingthe probe from the measurig point as soon as the measured value is
displayed. This gives the detector an opportunity to recover.
The Detector will warn if sensitivity of sensor is too low to safely detect a leak
equal to the set Reject Level limit. The warning can be ignored and calibration
updated but the CAL_CONF output will not be set.
The Detector will warn if the calibration signal is unreasonably high. This can
occur, for example, if 5% tracer gas mix has been used instead of proper reference gas or if the reference leak has an extra non-intentional leak. The warning
can be ignored and the calibration updated but the CAL_CONF output will not
be set.
The indicator bar extends in length when the sensor is detecting reference gas.
This indicator can be used for an early warning as to when a sensor replacement will be needed.
The length of the bar shows the condition of the sensor. The bar will become
shorter if the sensor has lost some in sensitivity. The scaling of the indicator is
not precise enough to say at exactly what length the sensor must be replaced.
You will learn when this happens for your particular application. The instrument
will also tell you in clear text when sensitivity is too low.
MessageExplanationRemedy
Expose to background...Prepare the probe for
calibration by holding it
in hydrogen free
background.
Detecting gasGas signal is detected.Normal operation, gas
Repeat calibrationCalibration was not
within 20% of last.
Calibration OKCalibration was within
acceptable limit.
No gas or unstable signal.No gas signal or no stable
signal detected during
calibration.
Signal when reference gas
is shut off. Happens for
reference gas only.
Sensitivity too low for
Reject level
Sensitivity of sensor is too
low to guarantee correct
response to a gas flow or
concentration equal to
the Reject level. The most
likely reason is that sensor is too old.
-
exposure can be
interrupted.
Wait 30 s and calibrate
again.
Press Save (button 4) to
store calibration in
memory.
Check reference. Gas
valve may be shut.
Check that probe tip is
not clogged.
Background is higher
than reference gas
concentration. Improve
ventilation.
Check reference. Gas
valve may be shut.
Check that probe tip is
not clogged.
Check setting of Reject
Level.
Replace sensor if problem
remains.
Note: If calibration fails you can still use the instrument. Last valid calibration
parameters will be used. You should, however, check that the instrument reacts
to the reference.
Your reference should have a concentration or flow equal to or slightly above
what you want to measure. See the examples below for specific recommendations.
Example for reference gas:
• Reject Level is set at 8 PPM
• For good accuracy, use a reference gas between 8-80 ppm hydrogen.
• 8 PPM hydrogen in synthetic air will give best results.
Example for reference leak
• Reject Level level is set at 2.0E-4 atm. cc/s
• For best accuracy reference leak within 2.0E-4 - 2.0E-3 atm cc/s.
• A reference leak calibrated to 2.0E-4 atm. cc/s will give best accuracy.
Reference signal is abnormally high.
Check that reference gas
mix is not replaced with
tracer gas mix.
Check condition of reference.
Check that reference leak
connections has no leaks.
Reference Unit
Calibration Time
The Reference Unit is set in the Calibration menu. Select PPM, cc/s, cc/min,
SCCM, g/a, oz/yr, mbarl/s, mm3/min, Pa m3/s or Custom. When you select Custom you can enter any unit as long as it contains a maximun of 12 characters.
Calibration can be performed with:
• a known hydrogen concentration
• a known flow leak
The following characters can be used: Upper and lower case Roman letters, the
numbers ü, Å, Ä,Ö, å,ä,ö,%,/,(,),and - (dash).
Note: The space (““) is not supported. The leak rate unit string will be cut short
at the first space found.
The calibration time decides how long time the detector looks for a reference
signal before giving up. If the calibration is set to, for example, 6 seconds the
detector will record the maximum signal during 6 seconds after that the operator (or external hardware) orders a calibration.
It is very important that all delays in gas exposure as well as reaction time of
sensor are taken into consideration when setting the calibration time. Calibration will not be correct if the maximum signal comes after that the calibration
time has terminated.
This parameter sets the lowest possible Calibration Time that can be set under
the Calibration menu. Default is 5 seconds.
Minimum calibration time should be set to safeguard so that the following two
requirements are fulfilled:
1 The hydrogen from the reference leak or gas line must reach the sensor
before end of calibration time.
2 The sensor must have time to reach its maximum signal before end of calibration time.
Setting Min Calibration Time too low will have the following effects:
• Calibration will fail if calibration time is set too low.
• Calibration might pass but be incorrect.
Setting a high Min Calibration Time will have the following effects:
• Calibration takes longer time than necessary.
• Calibration gas consumption is higher than necessary.
Note: Correct calibration is an essential parameter in quality testing. We, therefore, recommend that careful consideration is paid to setting an appropriate
Min Calibration Time. This will inhibit personnel, lacking detailed knowledge
about calibration, from jeopardising quality by setting a too short Calibration
Time.
Password protected calibration
If desired, the calibration can be set under the general password to prevent the
operator from calibrating by mistake. In this case you will have to enter the
password to start the calibration routine. Setting password protection on calibration is done in the General Settings menu. Note that you must also set a
password. The instrument is delivered with no password set.
If you want to use another unit you have to put a recalculation number into
Correlation Value which describes the relationship between the different
units.
This might be necessary when you want to display Reject Level unit other than
the reference leak rate unit.
Useful also for correct the value when volume and time affect the measure
value result in accumulation test.
Example:
To use mbarl/s as an calibrate reference unit and mm3/s as a analysis Unit you
When measuring leak flow you will, in normal cases, calibrate the detector with
a reference leak.
Set the Reference Value equal to the calibrated flow of your reference leak.
This value can be found on the calibration certificate issued for the leak. Also
set the Reference Unit to the same unit as that used to express the leak rate of
the reference leak.
Example: Reference leak rate is 4.2E-5 mbarl/s.
1- Set Reference Value = 4.2E-05.
2- Set Reference Unit = “mbarl/s
Reference value with reference gas
When measuring hydrogen concentration (instead of leak flow) in most cases
you will calibrate the detector to a reference gas with a known concentration.
Set the Reference Value equal to the Hydrogen concentation in your reference
gas. This can be found on the certificate of analyis issued for the gas. Also set
the Reference Unit to the same unit as that used to express the leak rate of
the reference leak.
Example: Reference gas contains 10 PPM Hydrogen in synthetic air.
1- Set the Reference Value = 10
2- Set the Reference Unit = “PPM”
Real Time Clock date set as YY-MM-DD. Clock runs even when detector is disconnected from the power supply.
Real time set as hh:mm:ss. Hours and minutes can be adjusted. Seconds will
automatically be set to 00 when hours and minutes have been set. Clock runs
even when detector is disconnected from the power supply.
The Sensistor ISH2000 user interface contains the following languages:
The detector is equipped with a service setting to help in trouble shooting and
diagnostics.
IMPORTANT! The normal operator should not enter this mode.
The service mode menu option is therefore normally not shown in the menu
system and most of the functions in the service mode are protected by a special
password.
IMPORTANT! We strongly recommend that the service mode log in procedure
is kept secret from all personnel not fully trained in the details of all functions of
the detector.
Logging in to Service settings
Service Mode Log In Procedure
1. Switch power OFF.
2. Press and hold the right display button.
3. Switch power ON.
4. Release right button when text appears. During warm up the display will
show software revision numbers and date and time of the real time clock.
C 580
Service mode
When in service mode the display will show a service info screen as shown
below.
To get to Service Mode: Choose Menu / Service Settings / Service Mode
The Service Menu has two screens. Toggle between them by using APC and
Back.
• First screen (Service Mode) show electrical parameters and sensor signals.
Figure C-8: Sevice mode screeen example
• Second screen (APC I/O) show APC program status, APC I/O:s input, outputs
and some internal flags.
Do not enter this mode. Debug mode is for the manufacturer's use only. Entering debug mode will set the detector to continuously dump debugging data on
the printer port.
IMPORTANT! Setting the detector in debug mode will inhibit normal use
of the printer port.
If you have accidentally entered the debug mode, you can exit by choosing the
"Debug Mode" menu option again.
Debug Mode get to Debug Mode: Choose Menu / Service Settings / Debug
Mode/Enter the code: SEN
Print Port output:
• Time (ms) counted from power up
• Raw Sensor Signal (mV)
• Numeric value of the Detection Mode signal
• Analysis Value
All values are presented with three digits and tabs between. Printer rate: 50 Hz
(20 ms).
As the Sensistor ISH2000 does not contain any mechanical parts there is no
need for preventive maintenance. However it is recommended to keep some
spare parts ready.
Error messages: “Error”Error in Active ProbeSee Probe Manual.
Error messages: “Check Sensor, Voltage Error”
Error messages: “Check Sensor, Temp.”
No sound in Detection
Mode and
Analysis Mode.
Broken connection
between probe and
instrument
Software problemsInstall the software
Broken Main PCBReplace Main PCB
Broken Probe PCBReplace Probe PCB
Sensor voltage from the
gas sensor out of the
range 300 - 3500 mV
Diode voltage from the
gas sensor out of the
range 544 - 612 mV
Sound set lowPress the + button repeat-
Check that the probe
cable is properly connected to the probe and
the instrument. If the fault
persists, replace the
probe/cable.
Check that the sensor is
properly connected to the
probe. If the fault persists,
replace the sensor.
Check that the sensor is
properly connected to the
probe. If the fault persists,
replace the sensor.
edly.
No picture on display, no
sound
No picture but only sound
when exposed to gas.
Loss of spots or black lines
on screen
Bad sound out of the
speaker
Broken speakerReplace the speaker
Fuse brokenCheck the fuse.
Broken Main CableReplace the Main Cable
Discharged battery
Broken Main PCBReplace the Main PCB
Display setting may be
wrong
Display or Inverter Cable
loose
Display Lamp brokenReplace the display
Internal contact to LCD
broken
Broken speakerReplace the speaker
Watch the display from
the side at a low angle
and aim a lamp at the
screen. Try to see the text
so that you can enter the
Display Settings menu and
adjust contrast and
brightness.
It is very important that we advice the end user to carefully study the manuals
for how to take best care and handle the reference leaks.
Here are a couple of mistakes a user can make:
1 The small leaks with a gas container (E, F and G) are delivered at atmospheric
pressure due to transportation limitations. This means that the end user has to
start by filling the gas container to the indicated pressure. This filling MUST be
conducted according to the included instructions to ensure you get as close as
possible to a 5%H2/95%N2 gas mix inside the container. Otherwise you risk
having an undefined gas mix in the container, and what is on the certificate is in
that case no longer valid.
2 The smaller leaks that have a gas container are sometimes emptied by the
new user, simply because he sees the fill valve and "have to try what it is for".
This way you empty the container quite effectively. After this you need to refill
the container. See above in point 1 for possible problems.
3 When users connect leak A, B, C to the gas line they sometimes forget that
the hose from the bottle may be full of air to start with. If they do this the leak
will appear to be very difficult or impossible to pick up by the detector simply
because there is mainly air passing through the leak to start with. What they
should do is purge the hose from air before attaching it to the leak. Also
remember to use the purge valve on the leak itself to release any air trapped
inside the leak housing, and replace it with tracer gas.
To a greater or lesser extent aIl contact between objects, separation of one item
from another, or sliding of one thing on another, causes a disturbance of electrical charge. When charge disturbances take place faster than charge redistribution, static charge accumulates.
Amongst the greatest generators of static electricity are people. It can be readily
shown how in ordinary ambient conditions a person's electrical charge, measured in Volt, is constantly changing. It can move up or down at every step, as
they sit or rise, when they touch things, or as another person passes nearby.
Consequently if people handle electrostatic discharge sensitive devices (ESD)
without appropriate precautions, there is a real risk they will unwittingly
damage them.
Electrostatic discharge (ESD) has been recognized as a potential hazard for
semi-conductors and integrated circuits.
To protect devices from the unwanted effects of ESD, two key measures must
be taken and applied at aIl times:
1. devices must be handled exclusively in an ESD Protected Area (EPA). ln
essence, an EPA is a defined space within which aIl surfaces, objects, people
and devices are kept at the same potential.
2. devices must be transported from one EPA to another only in ESD shielding
packages.
Safety instructions
Icons used
The issue is to save defects on customer sites for the integrated electronic
boards in leak detector, drytels, controllers and accessories.
The ESD reduce the useful life of the electronic boards. There is no immediate
consequences during the assembly of the electronic devices but there is a premature aging of components.
All the Service Centers must be equipped to protect the INFICON products
against the ESD during repair process.
On Customers site, during exchange or maintenance of electronic card, the
engineer must wear the ESD coat and use disposable wristband.
To achieve this goal, we invite you to order the “ESD KIT” and install it in your
Service Center as soon as possible.
E 120 Sending the leak detection for repair
to a service center
See “How To Contact INFICON” on page 103.
WEEE directive:
INFICON products like portable helium leak detectors, gauges or vacuum measurement devices fall within the scope of the WEEE directive.
INFICON AB provides a collection and recycling service for used electrical and
electronic products.
Any obligation of the manufacturer to take back such equipment shall apply
only to complete not amended or modified equipment, using Alcatel Vacuum
Technology original spare parts, delivered by Alcatel Vacuum Technology, containing i.e. all its components and sub-assemblies. This obligation will not cover
the shipping cost to an INFICON AB take back facility.
RoHS directive:
The RoHS directive aims to limite the use of certain substances (lead, mercury,
cadmium, hexavalent chromium, PBDE and PBE), commonly used in designing
electrical and electronic equipment.
INFICON products do not fall within the scope of the RoHS directive, but as we
wish to protect the environment, many actions have already been launched:
• Inventory of all items which include these substances
• Action to eliminate these substances
• Qualification of new materials, new parts, etc.
All INFICON products are RoHS compliant since December 2007.
Sensitivity Test has been designed to help to double-check Hand Probe sensors
and H65 sensors for Sensistor ISH2000 before delivery to end customers. Every
sensor has been tested thoroughly before delivery from the factory. It happens,
however, that sensors lose sensitivity while kept in stock.
By following these instructions the user will get the information you need to
accept or reject a new sensor before delivery. The test is done using a reference
gas containing 10 ppm H2 in synthetic air.
You need the following equipment:
• Leak Detector (Sensistor ISH2000) with probe cable and hand probe.
• Reference gas 10 ppm H2 in synthetic air.
IMPORTANT:
A sensor can be calibrated using reference gas or a reference leak. There are
some fundamental differences between these two methods:
• When using a reference leak you add Hydrogen to the background.
• When exposing the sensor to reference gas you replace the background
(ambient) with the reference gas.
It is important, in both cases, to calibrate in a non-polluted background (i.e.
typically 0.5 ppm Hydrogen).
When using a reference gas this is essential. If the background is close to the
concentration in the reference gas you will get no signal. If the background
concentration is higher than the reference you will even get a negative signal
(i.e. signal appears when reference gas is removed).
When using a reference leak the problem is less pronounced as the leak adds
gas to the background. The calibration will however be significantly affected if
background is higher than the resulting concentration added by the leak.
Calibrating in a high background will, however, always result in making the
detector more sensitive. This means quality is not affected. Some “good” products may be rejected but no bad products will be passed.
On the following page are detailed instructions for testing the sensor with 10
ppm Reference Gas.
Using Reference Gas
1. Preparing the Reference Gas
a. Check the reference gas type ( must be 10 ppm Hydrogen in synthetic
air)
b. Connect pressure regulator to the gas bottle. IMPORTANT! Never use a
regulator that has previously been used for the 5% tracer gas. This may
contaminate the reference gas bottle and alter the concentration!
c. Connect a hose to the gas regulator complete with mouthpiece or a
piece of 11-15 mm inner diameter hose to slide over probe tip.
d. Purge the hose with low flow of reference gas (1-5 cc/s). If you put the
hose in a glass of water it should NOT "boil" the water but only release a
gentle stream of bubbles.
2. Preparing the Hydrogen Sensor
a. Switch power OFF on Sensistor ISH2000
b. Connect the probe and probe cable according to Manual
c. Start Sensistor ISH2000 in service mode by doing the following:
i. Press and hold the right button while switching power ON.
ii. Release button when text screen appears. (If logo appears you
released the button too late - try again)
iii. Go to service mode display after warm up period.
d. Remove probe tip protection cap!
e. Wait minimum 10 minutes more to stabilize sensor.
3. Sensitivity Test with Reference Gas 10 ppm
a. Make absolutely sure there is no abnormal increase of Hydrogen in the
background ( i.e. avoid: smoking in the room, releasing tracer gas in big
clouds, flatulence etc). Make sure you have as normal background of H2 as
possible (0.5 ppm).
b. Check that the Signal is 0.00E+00 (see See Figure E-3:"Service mode
screen")
Probe tip
Figure E-3: Service mode screen
c. Open a gas flow of about 1-5 cc/s.
d. Wait until you are sure there is only the 10 ppm gas in the hose.
e. Insert the probe tip (without protection cap) minimum 1 cm into the
open end of the hose. See See Figure E-2:"Connect a hose to the gas regulator". There must be no pressure on the sensor.
f. Wait until the signal has stabilized (takes a few seconds).
g. Read the Signal and then remove the probe. Close gas flow. The Signal
is given in scientific (engineering) format.
Examples:
The Service Mode is reached by starting the instrument and at the same time
hold the right button down on the panel. After start a new main menu called
Service Settings will appear.
Shows the chosen password in case the customer has forgotten the password.
Contact INFICON AB to have the code sent to you.
Resets all parameters to default settings, stored in the detector and the prob if
it is connected. Contact INFICON AB to have the code sent to you.
The Detector Signal Level is the level below which the sensor is considered to
have recovered from the last gas signal. It decides when the DET_SIGNAL output will come on. This signal can be used to block the start of a calibration or
new test cycle in semi and fully automatic testers.
If DET_SIGNAL is high then this means that the sensor has detected hydrogen
and has not yet recovered.
Detector Signal Level can be adjusted in the Service Settings menu. You can
increase Detector Signal Level if you have many small disturbing signals. A high
setting of Detector Signal Level gives better tolerance to “noise” gas signals at
the expense of accuracy. A low setting gives best accuracy but lower tolerance
for “noise” gas signals. The Detector Signal Level is set as 1 to 100% of the
Reject Level. Default is 20%.
NOTICE! Increasing the Detector Signal Level may give poorer accuracy.
Trigg Level
Minimum Calibration Time
Battery Mode
Number of Significant Digits
Debug Mode
Upper Limit setting for Peak hold in analysis mode.
Lower limit setting for the timer which is used during calibration. Contact INFICON AB to have the code sent to you.
Selection of battery power. Only used to adapt software for the battery model.
Choice of a number of significant numbers in Analysis and Combined Mode. It
is used when a more exact measurement is needed. A good control of the environment and calibration is required to be useful. Contact INFICON AB to have
the code sent to you.
This mode is used during service and software development. Service Mode This
mode contains useful information to analyse the gas sensor behavor. If the
instrument starts in the Service Mode then it is possible to reach APC Service
Mode.Under APC Service Mode is useful information to check timers, I/O on
the Probe Control Port, and other.
errors appeared
because of use of too
short variable type at
timeout control.
Result print format
using ”Analysis Data
Output” corrected.
(Log-a-Leak works
now). “n.nnE+ee”.
Probe connection and
reconnection,
approved user interface (quicker respons
at disconnect and connect of probe).