INFICON ISH2000P User Manual
Hydrogen Leak Detector
Sensistor ISH2000
EN
Operating Instructions
Publication: INFICON AB - nina60e1-c (1204) - All information can be modified without prior notice
EN
Hydrogen Leak Detector Sensistor ISH2000 - Operating Instructions
2 OP-Sensistor ISH2000-EN
Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
Contents
1 User information........................................................................................................................... 3
1.1 Notes and safety notices..........................................................................................................3
1.2 Document outline.................................................................................................................... 3
1.3 Conventions used in this book.................................................................................................3
2 Description of equipment............................................................................................................. 4
2.1 Sensistor ISH2000.................................................................................................................... 4
2.2 Sensistor ISH2000C .................................................................................................................4
2.3 Sensistor ISH2000P..................................................................................................................5
3 Controls and connections............................................................................................................. 7
3.1 Display ....................................................................................................................................7
3.2 Push-buttons ........................................................................................................................... 7
3.3 LEDs ........................................................................................................................................ 8
3.4 Ports and connections .............................................................................................................8
4 Precautions .................................................................................................................................. 10
4.1 When working with gas ........................................................................................................10
4.2 Hydrogen Tracer Gas for leak detection ................................................................................. 11
4.3 Interferences .........................................................................................................................11
5 Working principle....................................................................................................................... 12
5.1 Gas Sensor Technology ......................................................................................................... 12
5.2 Condition for leak detection .................................................................................................. 12
5.3 Leak detection modes............................................................................................................ 12
6 Operating the detector............................................................................................................... 13
6.1 To Detect leaks.....................................................................................................................13
6.2 To Locate Leaks .................................................................................................................... 13
6.3 To Quantify Leaks .................................................................................................................14
7 Calibrate the leak detector......................................................................................................... 15
7.1 Introduction ..........................................................................................................................15
7.2 Calibration reference ............................................................................................................. 15
7.3 Calibration procedure............................................................................................................15
7.4 Reference value with reference leak....................................................................................... 16
7.5 Reference value with reference gas........................................................................................ 16
8 Reference section........................................................................................................................ 17
8.1 Menu system.........................................................................................................................17
8.2 Engineering format................................................................................................................ 17
8.3 Change Test Mode ................................................................................................................ 18
8.4 Calibration ............................................................................................................................18
8.5 Detection Mode Settings .......................................................................................................21
8.6 Analysis mode .......................................................................................................................23
8.7 APC Settings .........................................................................................................................25
8.8 Display Settings .....................................................................................................................26
8.9 General settings ....................................................................................................................27
8.10 Service Settings .....................................................................................................................28
8.11 Combined Mode ...................................................................................................................29
8.12 Probe ....................................................................................................................................29
8.13 Probe Control Port................................................................................................................. 30
8.14 Printer port............................................................................................................................33
8.15 Sensistor ISH2000P installation .............................................................................................. 38
8.16 Default parameters................................................................................................................40
9 Trouble-shooting......................................................................................................................... 42
10 Sensistor ISH2000 specifications................................................................................................ 43
11 Spare parts and accessories........................................................................................................ 45
12 Support by INFICON.................................................................................................................... 46
12.1 How To Contact INFICON ......................................................................................................46
12.2 Returning you instrument to INFICON....................................................................................46
13 Declaration of conformity .......................................................................................................... 47
14 Recycling...................................................................................................................................... 48
EN
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
EN
Welcome to Sensistor ISH2000
Dear customer,
You have just bought an INFICON Hydrogen Leak Detector Sensistor ISH2000. The
Sensistor ISH2000 is an extremely sensitive and selective detector for hydrogen gas (H2).
It is especially designed for leak detection using Hydrogen Tracer Gas (Hydrogen diluted
with Nitrogen down to a safe concentration) which is the most effective and economical
tracer gas for leak testing.
Sensistor ISH2000 detects hydrogen in air at atmospheric pressure with no need for
vacuum pumping. It is especially suitable for applications where high sensitivity and
selectivity is required in combination with simplicity, reliability and low cost.
This product complies with the requirements of European
Directives, listed in the Declaration of Conformity found on
page 47 in this document. These Directives are amended by
Directive 93/68/E.E.C (E.C. Marking).
Copyright/Intellectual property
The use of INFICON AB products are subject to copyright and
intellectual property rights in force in any jurisdiction.
All rights reserved, including copying this document in whole
or in any part without prior written authorization from
INFICON AB.
Though INFICON AB believes reasonable efforts have been
made to ensure the accuracy of the information contained in
the document, it may include inaccuracies or typographical
errors. INFICON AB reserves the right to change the
information inside the document without further notice.
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
1 User information
Read this user manual carefully before using the Sensistor ISH2000.
1.1 Notes and safety notices
This manual contains warnings and cautions concerning the safe use of the product.
See definitions below.
WARNING!
Warning indicates a hazardous situation which, if not
avoided, could result in death or serious injury. It is
important not to proceed until all stated conditions
are met and clearly understood.
CAUTION!
Caution indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury. It is
important not to proceed until all stated conditions
are met and clearly understood.
EN
NOTICE!
Notice indicates instructions that must be
followed to avoid damage to the Sensistor
ISH2000 or other equipment.
Note: A Note is used to indicate information that is important for trouble-free and
optimal use of the Sensistor ISH2000.
1.2 Document outline
The document is devided in two main parts:
• Getting started
• Reference section
The Getting started part consists of step by step case examples, explaining how to
use the Sensistor ISH2000 in a variety common situations. The Reference section
consists of in depth explanation and additional information, which completes the
user manual with all relevant information.
1.3 Conventions used in this book
In this user manual the following text style (hardware command) is used for
references to hardware commands or button labels, while this text style (
command) is used for references to software commands and menu choices.
software
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
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2 Description of equipment
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).
2.1 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.
Fig 2-1. The desktop model consists of seven parts.
1
3
2
Item Description
1
2
3
4
5
6
7
Detector unit
Hand Probe P50 (shown) or Active Probe with
sensor
Probe cable C21
Power cable (the power cable is country specific
and may differ)
User manual (not shown)
User manual CD (not shown)
Product return form (not shown)
2.2 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. This is due to power management control.
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
The battery, a Li-ion battery at 14.8 V, can not support the current required to
operate external probes.
On the display (in Detection and Analysis Mode) a symbol in the upper right corner
shows the battery charge status. Sensistor ISH2000C will operate for 14 hours on a
fully charged battery with screensaver and mute function. And 9 hours without
screensaver and mute function.
One hour charging will give about one hour of operating time. This can be done
when necessary, but it is important to regularly fully charge the battery.
Fig 2-2. The battery operated model consists of seven parts.
1
2
EN
Item Description
1
2
3
4
Detector unit
Hand Probe P50 (shown) or P50-Flex
Probe cable C21
Battery charger (the battery charger are country
specific and may differ, not shown).
5
6
7
User manual (not shown)
User manual CD (not shown)
Product return form (not shown)
2.3 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. See “Sensistor ISH2000P
installation” on page 38.
3
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
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Fig 2-3. The panel mount model consists of seven parts.
1
Item Description
1
2
3
4
5
6
7
Detector unit
Brackets (not shown)
Screws (not shown)
O-rings seal (not shown)
User manual (not shown)
User manual CD (not shown)
Product return form (not shown)
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
3 Controls and connections
The controls and connections are discussed and shown in this chapter.
Fig 3-1. Sensistor ISH2000 controls and indicators.
1
2
3 3 3 3
Item Description
1 Display
2 Loudspeaker
3 Control push-buttons
4 Earphone socket
1
4
EN
6
5
5 Probe connector
6 LEDs
3.1 Display
The display shows:
• 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.
3.2 Push-buttons
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).
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
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3.3 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 Reject Level limit.
• Red flashing rapidly, check message on screen. (See “Trouble-shooting” on
page 42.)
3.4 Ports and connections
The ports and connections are shown in Figure 3-2 below.
NOTICE!
Always connect all four wires to the Power connector to
24VDC in order to operate.
Sensistor ISH2000
Fig 3-2. Sensistor ISH2000 ports and connections.
Rear View
Item Description
1 Printer port
2 Probe control port
3 Fuse
4 Power switch
5 Power input, 100-240 VAC
6 Screw hole for mounting plate
6
3
3
1
1
2
2
4
4
5
5
6
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
Sensistor ISH2000C
Fig 3-3. Sensistor ISH2000C ports and connections.
Sensistor ISH2000C Rear View
Item Description
1 Power switch
2 Printer port
3 Battery charger
4 Screw hole for mounting plate
EN
1
2
4
3
Sensistor ISH2000P
Fig 3-4. Sensistor ISH2000P ports and connections.
1
Sensistor ISH2000P Rear View
Item Description
1 Probe connection
2 Ground screw
3 Power connector
4 Probe control port
5 Printer port
3
2
4
5
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
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4 Precautions
Read this user manual carefully before using the instrument. Hydrogen Leak
Detector Sensistor ISH2000 is extremely selective. Only Hydrogen Sulphide
(extremely toxic) gives a comparable response to hydrogen.
4.1 When working with gas
The normal risks associated with working with all compressed gases must be
considered.
WARNING!
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.
Note: Whenever the word Hydrogen is used in this
manual it implies that the hydrogen gas is safely
mixed with Nitrogen in the proportions 5% H2 95% N2.
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.
Note: INFICON AB can not take any responsibility for the consequences arising from the
inappropriate use of certain test pressures.
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
Pressure shocks might cause strong sounds which can cause impairment of hearing.
Check that all relevant legislation and safety standards are complied with before
putting Sensistor ISH2000 into service.
4.2 Hydrogen Tracer Gas for leak detection
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-togas.
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.
WARNING!
Hydrogen/nitrogen mixtures containing
approximately more than 15% hydrogen can
detonate when mixed in certain proportions
with air.
EN
NOTICE!
Never make your own mixtures. Only use readymade mixtures or use a certified hydrogen/
nitrogen mixture mixer installed by your gas
supplier.
4.3 Interferences
Most tracer gas methods suffer from some sort of interference. Either the detector is
sensitive to other gases or vapors, or there are other sources of the gas present to
which the detector is sensitive.
Some examples of possible hydrogen sources:
• Engine exhaust
• Battery charging stations
• Cigarette smoke
• Breathing air
• Human flatulence
• Scratching on aluminum surfaces
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
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5 Working principle
5.1 Gas Sensor Technology
The Sensistor ISH2000 leak detector is using 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.
5.2 Condition for leak detection
To use the leak detector the test object must be filled and pressurized by tracer gas
(95% N
welding gas of industry quality, easy to obtain at low cost. The generic name is
Forming Gas. Appropriate gas filling equipment can be obtained from the leak
detector supplier.
/ 5% H2) to get a gas flow through the leak. The tracer gas is a standard
2
Be careful of how tracer gases are handled after use. Released tracer gas
contaminates the surrounding air with hydrogen and can complicate the following
measurements for a time. Ensure that the tracer gas is ventilated away from the
target area, preferably to the outside of the building.
5.3 Leak detection modes
The detector operates in three modes:
• The leak locating mode (Detection Mode), mainly used for detecting and locating
leaks but not quantifying them.
• The hydrogen measurement mode (Analysis Mode) measures the concentration of
hydrogen.
• The Combined Mode, (default mode) which is a combination of Detection and
Analysis mode.
The Detection Mode operates continuously while the Analysis Mode determines the
hydrogen concentration (and calculates a corresponding leak rate) in a step
measurement. Detection Mode gives no numbers. It therefore needs no actual
calibration. The sensitivity of the sound signal and the moving bar on the display is
set manually or automatically, see below.
When using the instrument in Analysis Mode, it must be calibrated as described. See
“Calibrate the leak detector” on page 15 in order to give correct figures.
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
6 Operating the detector
6.1 To Detect leaks
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 signal
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.
EN
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 15. The reason for this is that the alarm is based on the Analysis Mode
when the Detection Mode is displayed.
6.2 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. See “Sensitivity” on page 25 and
“Direct Sensitivity Adjustment” on page 25.
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.
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Hydrogen leak detector Sensistor ISH2000 - Operating Instructions
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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.
6.3 To Quantify Leaks
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.
The leak detector operates in the range 0.5 - 2000 ppm H
giving linearity between 0.5
2
and 500 ppm. To obtain greatest accuracy over this range, follow the calibration
recommendation. See “Calibrate the leak detector” on page 17.
CAUTION!
• Do not open detector! Service of this equipment may only be carried out by service organisations authorised therefore by INFICON, Sweden.
• If the detector gets outer damage it must be controlled and repaired by service
organisation authorised by INFICON.
• 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.
14 OP-Sensistor ISH2000-EN-201203
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