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INFICON
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T-Guard Leak Detection Sensor
User Manual
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INFICON T-Guard Leak Detection Sensor User Manual

TECHNICAL HANDBOOK
jina85e1-f (1112)
catalog no. 540-001 540-002
from software version 1.6
T-Guard™
Sensor for Leak Detection
Printed in Germany We reserve the right to alter the design or any data given in this handbook. This is
due to the fact that we are permanently developing ou r pr od u cts . The illustrations are not binding. If there are divergences between your product and the Technical Handbook, please contact us.
Reprint, translation and duplication need to be a pproved by INFICON GmbH. Please contact your sales people for an updated version of the Technical Handbook.
INFICON GmbH Bonner Straße 498
50968 Cologne Germany
2
Content
1 Operating instructions 4
1.1 How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Warning and danger symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Graphic conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Safety 7
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Requirements to be fulfilled by the user . . . . . . . . . . . . . . . . . . 7
2.3 Restrictions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Description 9
3.1 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Vacuum diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Wise Technology™ Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.1 Control unit for desktop operation . . . . . . . . . . . . . . . . . . . . . . 20
3.5.2 19" control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.3 Connection Cable for Control Unit, 5 m . . . . . . . . . . . . . . . . . 23
3.5.4 Connector set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.5 Fore Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.6 2m line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5.7 I•Stick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.5.8 Set of filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.6 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.7 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Installation 29
4.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Installing Mechanically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
4.3 Choosing a Fore Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 Installing Electrically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5 Connecting the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.6 Connecting a PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.6.1 Selection of functions assigne d to the PLC inputs. . . . . . . . . . 32
4.6.2 Electrical connection of the PLC inputs . . . . . . . . . . . . . . . . . 34
4.6.3 Selection of functions assigned to the PLC outputs. . . . . . . .35
4.6.4 Electrical connection of the PLC outputs . . . . . . . . . . . . . . . . 37
4.6.5 Overview of all settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.7 Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Content 1
5 Operation 39
5.1 Running up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.2 Calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5.2.1 Preparing Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5.2.2 Start Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
5.3 Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.3.1 Accumulation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
5.3.1.1 Hints for a good measurement: . . . . . . . . . . . . . . . . . . . . . . . .45
5.3.2 Carrier Gas Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
5.3.2.1 Hints for a good measurement: . . . . . . . . . . . . . . . . . . . . . . . .48
5.3.3 Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.3.4 Switching Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.3.5 Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.3.6 Helium contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.4 Controlling via PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
5.4.1 How to execute an accumulation measurement . . . . . . . . . . .51
5.4.2 How to execute a carrier gas measurement . . . . . . . . . . . . . .51
5.5 Controlling via RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
5.6 Configuring analog output . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
5.7 Using the I-Stick and the parameter sets . . . . . . . . . . . . . . . .53
5.8 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.8.1 Menu Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
5.8.2 Explanation of Menu Items . . . . . . . . . . . . . . . . . . . . . . . . . . .56
5.9 F.A.Q. - Frequently asked questions . . . . . . . . . . . . . . . . . . .63
6 Maintenance 66
6.1 Replacing the Inlet Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
6.2 Replacing Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
6.3 Replacing the Internal Fuses . . . . . . . . . . . . . . . . . . . . . . . . .68
7 Product Handling 71
7.1 Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
7.1.1 Transporting after Contamination . . . . . . . . . . . . . . . . . . . . . .71
7.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8 Technical Data 72
8.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
8.2 Weight / dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
8.3 Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
8.4 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
8.5 Assembly Drawing for built-in Control Unit . . . . . . . . . . . . . . .73
2 Content
9 Errors and Warnings 74
10 Service Centers World Wide 78
10.1 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Content 3

1 Operating instructions

Warning
Caution

1.1 How to use this manual

• Please read this manual before using the T-Guard™ Leak Detection Sensor.
• Keep the manual in a way that you can use it at any time.
The INFICON T-Guard™ Leak Detection Sensor has been designed for safe and efficient operation when used properly and in ac cord an ce with this Tec hn ica l Handbook. It is on the user's own responsibility carefully to read and strictly to observe all safety precautions described in this chapter and throughout this Technical Handbook. The T-Guard™ Leak Detection Sensor must only be operated under the conditions described in this Technical Handbook. It must be operated and maintained by trained personnel only. Consult local, state, and national authorities regarding specific requirements and regulations. In case you have any further queries on safety, operation and/or maintenance, please contact our office nearest to you.

1.2 Warning and danger symbols

Indicates procedures that must be strictly observed to prevent haza rd s to per sons.
Indicates procedures that must strictly be observed to prevent damage to, or destruction of T-Guard™ Leak Detection Sensor.
4 Operating instructions

1.3 Graphic conventions

Notice Points to very useful pieces of information.
1 Points to an operation that you have to perform.
⇒ Points to the result of an operation you accomplished. → Points to the button you have to press.
• Shows a listing.

1.4 Glossary

Sensitivity
Characterises the ratio of the helium signal to the measured signal.
I·Stick
Optional memory extension of the T-Gu ard™ Leak Detection Sensor.
Calibration
Measuring time
Parameter set
RS232
Purge
T-Guard
Equalisation of measured signal and leakage rate.
Time from the beginning of the measurement to the output of the results.
Group of parameters, e.g. measuring time, chamber volume, carrier gas, etc.
Interface standard for data communication between electronic devices.
Removal of excessive helium from the air.
Tracer (Gas) Guard
Operating instructions 5
Carrier Gas
Trigger
Background
Zero
Cycle time
Large gas flow which transports a small gas flow.
Limit value of the rejection leakage rate for th e detection of le aks of the test sa mple .
The air contains 5 ppm (0.0005%) of helium by nature. For goo d measurements with the T-Guard, the helium content in the air must be less than 10 ppm.
"Reset to Zero" is an automatic function of the T-Guard™ Leak Detection Sensor.
Time from the beginning of the measurement to the next possible measurement.
6 Operating instructions

2 Safety

Skilled personnel
Warning
Warning

2.1 Intended use

The T-Guard™ Leak Detection Sensor is a helium leak dete ction sensor which does not need any vacuum chamber. It can find leaks in test samples and quantify them when they are filled with helium under pressure.
Using the T-Guard™ Leak Detection Sensor, the chamber with the test sa mple does not have to be evacuated.
Measured at atmospheric pressure, the minimum detectable leak rate is 1×10 l/s. This depends on the chamber volume and the measuring time, the rejection l eak rate will mostly be between 1·10
Do not let water penetrate into the body or hoses of the T-Guard™ Leak Detection Sensor. Do not forget to use the external filters.
Only use accessories and spare parts from INFICON.

2.2 Requirements to be fulfilled by the user

-4
and 1·10-2 mbar l/s.
-6
mbar
The T-Guard™ Leak Detection Sensor must only be started and operated by properly trained staff.
Get used to the functioning of the device. Yo u may only use the device after reading and understanding the manual.

2.3 Restrictions of use

Disregarding the following precautions could result in serious injury:
For all contacts of the I/O port, a maximum voltage of 60 V DC or 25 V AC must not be exceeded or reached based on the protective cond uctor or the earthing devices. Please refer to the information given in the following chapters.
For maintenance work, disconnect the T-Guard™ Leak Detection Se nsor from the power supply.
Safety 7
Warning
Before replacing the fuses, the T-Guard™ Leak Detection Sensor must be
Caution
Caution
Caution
disconnected from the power supply.
Disregarding the following precautions could result in damage to the equip­ment.
The T-Guard™ Leak Detection Sensor must not be operated while standing in water or when exposed to drip water. The same applies to all other kinds of liquid.
The T-Guard™ Leak Detection Sensor should only be used inside rooms.
Avoid the T-Guard getting in contact with bases, acids, and solvents, as well as being exposed to extreme climatic conditions.
Do not suck up liquids into the T-Guard™.
8 Safety

3 Description

This chapter describes the exterior design of the T-Guar d™ Leak Detection Sensor, its accessories and how to use it.

3.1 Housing

The housing of the unit consists of an oval cylinder. On top, there are several electrical connections and the ventilation opening. On the rear side, ther e are th ree hose connectors.
Fig. 4-1 Front view of the T-Guard™ Leak Detection Sensor
Fig. 4-2 Back view of the T-Guard™ Leak Detection Sensor
Description 9

3.2 Interfaces

The T-Guard™ Leak Detection Sensor has 5 interfaces for control and information exchange.
Fig. 4-3
Power Connector
Only two of the four pins are used for the power supply. The plus pole is marked with „1+“, the minus pole is marked with „2-“.
Fuse
The fuse reacts to reverse polarity and a current exceeding 7 A.
Item Description Item Description
1 Power supply connector 5 PLC-interface 2 Fuse 6 RS232 PC-interface 3 Interface for the control unit 7 Analog Recorder Output 4 I•Stick -connector 8 Status LEDs
10 Description
Interface for the control unit
Here, the INFICON control unit (Cat. No. 551-100 or 551-101) is connected via its connecting cable (Cat. No. 551-102 or 551-103) to control the T-Guard™ Leak Detection Sensor manually.
Notice The connection cable must only be plugged in or unplugged when the
supply voltage of the T Guard™ is turned off or disconnected.
I•Stick -connector
You can store 25 parameter sets on the INFICON-I-Stick and also download them from there.
PLC-interface
The T-Guard™ Leak Detection Sensor has 6 configurable digital PLC-Inputs and 8 configurable digital PLC-outputs. (Refer to 4.6.1 Selection of functions assigned to the PLC inputs. and 4.6.3 Selection
of functions assigned to the PLC outputs..)
RS232 PC-interface
Connect any RS232 capable device here with an uncrossed RS232 cable in order to control the T-Guard™ Leak Detection Sensor or to read out information. The latter takes less than 100 ms.
Analog Recorder Output
The T-Guard™ Leak Detection Sensor has two separately configurable analog recorder outputs (0 - 10 V).
They have a resolution of 16 bit and a hardware limited refresh rate of about 2 Hz. For a higher refresh rate, please use the RS232 interface. For detailed Information on how to use the analog output refer to chapter 5.6.
Description 11
Status LEDs
Certain operating conditions can be indicated by 5 status LEDs: The first LED : lights up during operation
The four remaining LEDsindicate the status of the configurable digital outputs 1-4.
LED No. 2 is red and in standard setting, it will light up to indicate an error or a warning. The desired output function can be set (refer to4.6.3).
Fig. 4-4 Status LEDs
12 Description

3.3 Vacuum diagram

On top of the vacuum diagram, there are the measurement inlet "IN" and the reference inlet "Ref". Both inlets are equipped with an external filter to protect T­Guard™ Leak Detection Sensor from sucking in dust or fluids. Three valves are integrated in the T Guard™ Leak Detection Sensor (see Fig. 4-5). Valve V1 opens and closes the measurement inlet. Valve V3 opens and closes the reference inlet. Valve V2 opens and closes the connection between V1 and V3. These three valves are connected to two flow-restricted capillaries which lead to the Wise Technology™ Sensor. The upper inlet of the Wise Technology™ Sensor is the fine inlet, the lower one is the gross inlet, which is less sensitive to helium than the fine inlet. The Wise Technology™ Sensor detects the heliu m in the gas stream, which passes by. The total pressure, which is applied to the Wise Technology™ Sensor is detected by the Pressure Gauge p1. The fore pump, which provides the gas stream inside T-Guard™ Leak Detection Sensor is also throttled to produce constant pressure and flow for the Wise Techno­logy™ Sensor.
Fig. 4-5 Vacuum diagram of the T-Guard™ Leak Detection Sensor
Item Description Item Description
1 Inlet “IN” 8 Pressure gauge p1 2 Reference “Ref” 9 Pump 3 Filter 2 10 Pump connector “OUT” 4 Valve V 5 Valve V 6 Throttle 2 13 Valve V 7 Wise Technology™ Sensor 14 Filter 1
3 2
11 Throttle 3 12 Throttle 1
1
Description 13
When the T-Guard™ Leak Detection Sensor is not measuring at the moment or is READY , V2 and V3 are open, V1 is closed (refer to Fig. 4-6). Only gas from the reference inlet gets to the sensor.
Fig. 4-6 Valve position in READY mode.
Item Description Item Description
1 Inlet “IN” 8 Pressure gauge p1 2 Reference “Ref” 9 Pump 3 Filter 2 10 Pump connector “OUT” 4 Valve V 5 Valve V
3 2
6 Throttle 2 13 Valve V 7 Wise Technology™ Sensor 14 Filter 1
11 Throttle 3 12 Throttle 1
1
14 Description
In Standby mode, all valves except V2 are closed and the pressure before the Wise Technology™ Sensor is equal to the base pressure of the fore pump. (refer to Fig. 4-7)
Fig. 4-7 Valve configuration in S
TANDBY mode.
Item Description Item Description
1 Inlet “IN” 8 Pressure gauge p1 2 Reference “Ref” 9 Pump 3 Filter 2 10 Pump connector “OUT” 4 Valve V 5 Valve V
3 2
6 Throttle 2 13 Valve V
11 Throttle 3 12 Throttle 1
1
7 Wise Technology™ Sensor 14 Filter 1
Description 15
In the rare event that the sensor is contaminated with helium, only the valve V3 to the reference inlet "Ref" is open, to purge the sensor. In this case, highly pure nitrogen or external air has to be led to the reference inlet to decontaminate the sensor as fast as possible.
Fig. 4-8 Valve configuration during decontamination
Item Description Item Description
1 Inlet “IN” 8 Pressure gauge p1 2 Reference “Ref” 9 Pump 3 Filter 2 10 Pump connector “OUT” 4 Valve V 5 Valve V 6 Throttle 2 13 Valve V 7 Wise Technology™ Sensor 14 Filter 1
3 2
11 Throttle 3 12 Throttle 1
1
16 Description
In FINE measurement mode, V1 and V2 are open, V3 is closed (see Fig. 4-9). The sensor receives only gas from the measurement inlet and shows the highest sensi­tivity to helium from the measurement line.
Fig. 4-9 Valve configuration in FINE mode
Item Description Item Description
1 Inlet “IN” 8 Pressure gauge p1 2 Reference “Ref” 9 Pump 3 Filter 2 10 Pump connector “OUT” 4 Valve V 5 Valve V
3 2
6 Throttle 2 13 Valve V 7 Wise Technology™ Sensor 14 Filter 1
11 Throttle 3 12 Throttle 1
1
Description 17
In GROSS measurement mode, V1 and V3 are open, V2 is closed (see Fig. 4-10). This way, the Wise Technology™ Sensor only receives little helium from the measu­rement line and normally even less helium from the reference line.
Fig. 4-10 Valve configuration in GROSS mode
Item Description Item Description
1 Inlet “IN” 8 Pressure gauge p1 2 Reference “Ref” 9 Pump 3 Filter 2 10 Pump connector “OUT” 4 Valve V 5 Valve V 6 Throttle 2 13 Valve V 7 Wise Technology™ Sensor 14 Filter 1
3 2
11 Throttle 3 12 Throttle 1
1
Other valve configurations than described above are not used by the software and cannot be set by the user.
18 Description

3.4 Wise Technology™ Sensor

The helium detector (Wise Technology™ Sensor) consists of a closed glass container with a measurement device for the precise determination of the pressure inside the glass housing and a membrane chip with a large number of small quartz windows.
The membrane is permeable only for helium; the membrane avoids all other co mpo­nents of air from entering the glass housing.
The quartz membrane is heated so that the permeation for helium is sufficie ntly high and fast.
Inside of the glass housing, the total pressure is measur ed precisely. As only helium can enter the glass housing, the total pressu re is equa l to the pa rtial pressure of helium.
The determined total pressure inside the housing is p roportional to the helium partial pressure outside the sensor.
Description 19

3.5 Accessories

1
9
12
11
2 3 4 5
14
6
7
8
10
13
In addition to the main unit, two different types of the control panel and the corres­ponding connection cables are available.

3.5.1 Control unit for desktop operation

Install the control panel on a flat workbench to avoid slipping. It is used to control all functions and read all values of the T-Guard™ Leak Detection Sensor.
The control panel contains an LC Display, START, S and also 8 soft keys to navigate in the menu on the display and to enter values.
TOP, ZERO and MENU buttons
Buttons
20 Description
Fig. 4-11 Soft keys of the control unit
Item Description Item Description
1 LC Display 8 Soft key No. 5 2 Soft key No. 1 9 Soft key No. 6 3 Soft key No. 2 10 Soft key No. 7 4 Soft key No. 3 11 Soft key No. 8 5 Soft key No. 4 12 MENU button 6 START button with LED 13 STOP / VENT button with LED 7 Control Unit 14 Z
START button
Notice All 3 LEDs in the buttons are inactive with T-Guard™ Leak Detec tio n
ERO button with LED
Sensor.
Press the START button to start a measurement using the selected method. The measurement will then finish automatically.
STOP button
Press the STOP button to cancel the measurement immediately.
MENU button
In order to change the settings or to read information about T-Gua rd™ Leak Detec­tion Sensor, open the menu by pressing the MENU button or the Soft Key (No.4) with the MENU symbol ( ). You will go back to the position in the menu you left before.
By pressing the M
ENU button again you will get back to the m easurement menu. By
pressing the MENU button for two seconds you will get into the main menu.
Fig. 4-12 Main Menu appearance
Soft Keys
The functions of the 8 soft keys depend on the currently opened menu.
Soft key No. 1 Description
1 and 8 very often have the functions B 4 often has the function to completely leave the menu ( )
ACK / ESC and OK, in this order,
MENU button Enter/Leave the menu
Entering values and units
The numerical values are entered in the the MENU page as follows:
Soft key No. 1 Description
SC-button)
1 (E 2( ↑ ) increments the numerical value.
3( ↓ ) decrements the numerical value. 6 and 7( ↑ and ↓ ) changes the unit 8 (OK) saves the entered value.
leave this menu page and return to the previous menu page. The value will not be changed.
Description 21
Fig. 4-13 You can change the value and the unit on this menu page
Entering the Menu-PIN
1 Press the ESC-button (soft key No.1) to leave this menu page and to return to the
previous menu page. The Menu-PIN will then neither be changed nor be entered.
2 Pressing a number button opens a submenu where you can select one of these two
numbers. After that, the cursor moves to the next digit to the right.
3 You can move the cursor to the left or to the right using the soft keys No. 4 and 8.
( ← and → ).
4 OK appears for soft key No. 8 when the last digit has been reached. 5 Pressing OK causes the PIN to be stored.
Status Line in the Display
22 Description
Fig. 4-14 Entering the Menu-PIN
The lowest line of the display is the status line. It shows general information, for instance, the actual measurement mode.

3.5.2 19" control unit

You can insert this control unit in a 19’’ rack or in a panel cut-out as shown in Section
8.5.
This control panel is used in the same way as it is for the desktop control unit, only the START, STOP and ZERO buttons are at other positions.
Fig. 4-15 Control unit for the installation in a 19"-rack
On its front side, the 19"-control unit refers to protection class IP40.

3.5.3 Connection Cable for Control Unit, 5 m

This cable connects the control unit and the T-Guard™ Leak Detection Sensor.
Fig. 4-16 Connection cable for control unit, cat. No. 551-102
Description 23

3.5.4 Connector set

The connector set includes all Phoenix connectors for connecting the electrica l inter­faces.
Fig. 4-17 Connector set, cat. No. 551-110

3.5.5 Fore Pump

24 Description
Fig. 4-18 Fore pump, cat No. 200 002 929 This fore pump has two stages, is brushless and runs with a supply voltage of
24 V DC.
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