ILS500-Appendix - INFICONsensistor.com/wp-content/uploads/2015/05/TM-ILS500-200810.pdf · • Set the Pre-evacution Setpoint to half of the previous and repeat the test from step

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2 Adixen Sensistor - Technical Manual ILS500

Contents1. Optimising the Test Cykel ............................................................................................ 3 1.1 Optimising the Connection of Test Object ............................................................... 3 1.2 Optimising the Pre-Evacuation Step ......................................................................... 4 1.3 Optimising the Tracer gas Filling .............................................................................. 6 1.4 Adjusting the Parameters for internally regulated filling ........................................ 7 1.5 Push-Through filling ................................................................................................. 8 1.6 Optimising the Removal of Tracer gas ..................................................................... 9

2. Interfaces and Connectors ......................................................................................... 10 2.1 APC ......................................................................................................................... 10 2.2 HMI Panel ............................................................................................................... 11 2.3 External Control Panel ............................................................................................ 12 2.4 Printer and RS232 Interface .................................................................................... 13 2.5 H2000 Serial ............................................................................................................ 13 2.6 Option 1 ................................................................................................................. 14 2.7 Option 2 ................................................................................................................. 14 2.8 Option 3 ................................................................................................................. 14 2.9 Safety ...................................................................................................................... 15 2.10 Tooling .................................................................................................................. 16 2.11 ILS Printer / RS232 Specification ............................................................................ 17

3. Service Menu .............................................................................................................. 19 3.1 Outputs ................................................................................................................... 19 3.2 Inputs ...................................................................................................................... 19 3.3 Analogue Inputs Configuration ............................................................................. 20 3.4 System Reset ........................................................................................................... 21 3.5 H2000 Settings ........................................................................................................ 21 3.6 RS232 ...................................................................................................................... 22 3.7 Service Run ............................................................................................................. 23 3.8 Hardware Test ........................................................................................................ 23 3.9 Interpretation of hard ware results ........................................................................ 29 3.10 Hardware error messages ..................................................................................... 31 3.11 Pneumatic Components Overview ....................................................................... 32

4. Maintenance ............................................................................................................... 33 3.1 Toolkit ..................................................................................................................... 33 4.2 Maintenance plan .................................................................................................. 33 4.3 Venturi Pump ......................................................................................................... 34 4.4 Gas Valves ............................................................................................................... 36 4.5 Pilot Valves ............................................................................................................. 37

5. Technical Specification .............................................................................................. 38 5.1 Electrical Specifications ........................................................................................... 38 5.2 Pneumatic specifications ........................................................................................ 40 5.3 Evacuation and Filling capacity .............................................................................. 42 5.4 General ................................................................................................................... 43

3Adixen Sensistor - Technical Manual ILS500

The test cycle can be divided in six main blocks:

1. Connection of Tested Object.

2. Pre-Evacuation of Residual Air.

3. Filling with Tracer gas.

4. Tracer gas Leak Test.

5. Removal and Venting of Tracer gas.

6. Disconnection of Tested Object.

The different steps of the connection and disconnection

sequences, even if controlled by the ILS500 tooling

system, is a matter of fixture design for which we can

not give any general advice. Be aware, though, that the

faster the connection is made the higher the risk for

injury. Be careful and install guards etc, according to

local legislation and safety standards so that your fixture

is safe to use.

There are, however, details of how the test fixture is

connected to the ILS500 that affects the cycle time.

Installation factors affecting fill speed:

• Length of tubing between ILS500 and tested object.

• Inner diameter of tubing between ILS500 and tested

object. Consider the smallest diameter in the connection.

This section is a guide for optimising steps number 1,

2, 3 and 5.

The gas test step is not handled here. For optimising

this part refer to the application manual, “The Hydro-

gen Method”.

To obtain the full benefit from using the ILS500 you

should follow the rules below:

• Use both test ports. I.e. connect to two ports on the test

object.

• Smallest diameter in connection between test ports

and tested object (including fittings etc.) should not be

smaller than 8 mm (0.31”). Gas valve bore is 7 mm

(0.28”).

• Place ILS500 close to test fixture to make length of

tubing between test ports and object as short as possible.

• If object has more than 2 ports. Connect to ports on

“opposite sides” of object. This minimises the need for

pre-evacuation.

1. Optimising the Test Cycle

1.1 Optimising the Connection of Test Object


First you should determine how deep the pre-evacuation

needs to be or if it can be skipped altogether. To do this

you must fully understand the role of pre evacuation.

See also last paragraph in this section describing an

alternative filling procedure that does not require pre-

evacuation.

When your test object is connected it holds one

atmosphere of ambient air. It is often necessary to

remove some or most of this air before filling with tracer

gas.

There are two effects of not removing the air (i.e. pre-

evacuating):

1) The actual hydrogen concentration will bereduced

Example: The fill pressure is 0.05 MPa (7.2 psi) above

atmosphere (gauge pressure). The object has 1 atm =

0.1 MPa of air before filling. Leaving this air in the

object means the average tracer gas concentration will

be:

I.e. the average hydrogen concentration is only a third

of that expected (5% x 33% = 1.7%).

Pre-evacuating down to –0.7 atm (–0.07 MPa) means

there will be 0.3 atmospheres (0.03 MPa) of residual

air in the object before filling. This gives the following

average concentration:

I.e. the average hydrogen concentration will be 0.8 x

5% = 4% which is almost twice of that achived with no

pre-evacuation.

2) The tracer gas does not reach all parts of theobjectThe air left in the object can not always be expected to

mix evenly with the injected tracer gas. This is especially

so for tube shaped objects such as pipes etc. The flow

inside a regular “tube” is predominantly laminar. This

means no or very little turbulence occurs. Air left in the

“tube” will therefore be pushed in front of the injected

tracer gas and end up in the remote end of the “tube”.

Example: The test object is an aluminium pipe for a

refrigerator with brazed copper ends. The joints between

copper and aluminium must both be tested. Fill pressure

is 0.5 MPa (72 psi). Length is 10 m (33 ft). Skipping

pre-evacuation we will have:

of air left in the pipe. This is equivalent to 1.7 m (5.7 ft)

of the total length if no turbulence occurs during filling.

There is an evident risk that there will be only air inside

one of the joints, which means that a leak there will

remain undetected.

Pre-evacuating down to –0.7 atm (–0.07 MPa) means

there will be 0.3 atmospheres (0.03 MPa) of residual air

in the pipe before filling. We will now have:

Of air left in the pipe. This is equivalent to 0.57 m (1.9

ft). This air volume is normally small enough to be mixed

into the tracer gas by turbulence and diffusion.

The fastest way to fill a pipe like object is often to use

the so called push-through filling, that does not require

pre-evacuation. See Section 1.5.

1.2 Optimising the Pre-Evacuation Step

=Fill pressure + Evacuation pressure(Fill pressure + 0.1 atm)

= 0.8 = 80%

0.05 + 0,07( 0.05 + 0.1 )

=

=Fill pressure(Fill pressure + 1 atm)

= 1/3 = 33%

0.05( 0.05 + 0.1 )

=

=0.3 atm(Fill pressure + 0.3 atm)

= 0.056 = 5.6%

0.03( 0.5 + 0.03 )

=

=1 atm(Fill pressure + 1 atm)

= 0.17 = 17%

0.1( 0.5 + 0.1 )

=


Testing need for pre-evacuation.By far the best way to establish the need for pre-

evacuation is to make a realistic test.

1. Find a test object with a small leak in a difficult posi-

tion. Difficult meaning far away from test connection

so that the tracer gas does not readily reach the leak.

2. Set the H2000 PLUS detector in Analysis Mode.

3. Set up ILS500 according to your test specification.

4. Set Pre-Evacuation Level to –0.07 MPa (–10 psi).

5. Purge the object thoroughly with compressed air.

6. Check with hand probe that there is no Hydrogen in

the part.

7. Connect the object.

8. Place the hand probe on the leak (no signal should be

heard).

9. Press Start on ILS500.

10. Register the Signal from the leak. The gas signal

should stabilise quickly and the maximum achieved sig-

nal should be attained in a maximum of 2 seconds after

that the fill setpoint has been reached.

• Set the Pre-evacution Setpoint to half of the previous

and repeat the test from step 5.

• The new pre-evacuation is adequate if the gas signal

is essentially the same and develops at the same speed.

• Reduce Pre-evacution Setpoint further and repeat test

again to find the lowest suitable Pre-evacution Setpoint.

If you can not perform this test there are a few guide

lines:

• Higher test pressure (Fill Setpoint) means less need

for pre-evacuation.

• Round shapes like tanks require less pre-evacuation.

• Pipes etc need deeper pre-evacuation.

• Pipes etc will exhibit considerable pressure drop along

its length during the evacuation. This means the pressure

in the pipe can be much closer to atmosphere than what

is registered by the ILS500. Set the ILS500 to evacuate

through Test Port 1 only (this is done in the Advanced/

Options Menu). In this way the vacuum will be regi-

stred in the other end of the pipe and the evacuation

will be at least as deep as set by the Pre Evacuation

Setpoint.

If this is not possible, add some extra time by setting an

Extended Evacuation Time.

If still in doubt, play it safe and set pre-evacuation to –

0.07 MPa (–10 psi). this will evacuate 70% of the air

which should be adequate in almost every case.


HAZARDNever pressurise system or object aboveapproved pressure. Too high pressure canresult in death or serious injury!

Regulation of the tracer gas pressure can either be controlled

by the ILS500 or by an external pressure regulator.

The ILS500 is set to regulate internally as default.

In either situation it is important that the tracer gas supply

pressure (feeding the ILS500 tracer gas inlet) is set up

properly. This is primarily a safety issue.

Check the following:

• Feed pressure must never be above the maximum pressure

allowed for object to be tested.

• Feed pressure must never be above the maximum pressure

specified for the ILS500, 1.0 MPa (145 psi) for the stan-

dard model.

External Pressure Regulation: Tracer gas pressure is

controlled by external regulator. ILS500 simply opens a

path between the gas feed line and the test object. The

pressure will equate and the tested object will attain the

pressure delivered by the external regulator. ILS500 checks

that the fill pressure is above Fill Setpoint before procee-

ding to the next test step.

The tracer gas filling step will be failed if the

Fill Setpoint is not attained within the Fill Timeout.

External regulation is recommended mainly for very small

objects (<50 cc).

N.B. External Pressure Regulation does not support recipes

with different test pressure (i.e. fill setpoints).

Internal Pressure Regulation: Tracer gas pressure is

controlled by the ILS500.

Internally regulated filling is generally faster than externally

regulated. The reason for this is that the feeding pressure

can be set higher than the Fill Setpoint which results in a

higher fill flow.

The ILS500 regulation is a simple and robust ON/OFF re-

gulator controlled by the parameters listed below:

Fill Setpoint: The desired tracer gas fill pressure (i.e. test

pressure).

Fill Timeout: The object will be rejected if the Pressure

Setpoint has not been achieved within this time.

Supply Pressure: Pressure fed to tracer gas inlet port.

N.B. This is not a software parameter.

Pulse Fill from (%) of Fill Setpoint: Fill function will

switch from continuous filling to pulsed filling at this level.

Fill Pulse Open: Open time for gas fill valve during pulsed

filling.

Fill Pulse Closed: Closed time for gas fill valve during

pulsed filling.

Extended Gas Fill: Extends filling after the fill set-point

has been attained.

Refill Hysteresis: Hysteresis for gas refill. Gas refill will

start if pressure drops below setpoint minus Refill Hysteresis.

Refill Timeout: Maximum time for refill before object is

rejected. Refill occurs if pressure drops below Fill Setpoint

– Refill Hysteresis after a successful filling.

1.3 Optimising the Tracer gas Filling


Optimal filling is when:

• Filling is fast.

• Resulting pressure is within ±5% of the

Fill Setpoint.

• Number of fill pulses is 1 – 2.

Parameter

Supply pressure

Pulse Fill from (%)...

Fill Pulse Open

Fill Pulse Closed

Increasing

Faster filling.

Greater risk for over filling.

Increase for large objects.

Faster filling.



Bigger pressure steps



Better accuracy

Slower filling.

Decreasing

Better pressure accuracy.

Slower filling.

Decrease for small objects

Better pressure accuracy.

Slower filling.

Decrease for small objects

Better fill accuracy.

Increased number of fill pulses.

Do not set <20 ms.

Faster filling

Reduced accuracy.

Use the table below when adjusting the parameters to

achieve optimal filling. Start with the default settings

and then adjust the parameters in the order given from

top to bottom. The supply pressure and the “Pulse Fill

from (%) of Pressure Setpoint” parameter are normally

the only parameters you need to adjust.

1.4 Adjusting the parameters for internally regulated filling

Set Pulse Fill from (%) of Pressure Setpoint to 100 in order to disable pulse

filling.


Push-through filling is an alternative filling method for

filling elongated objects quickly. Cycle times can be

significantly reduced at the expense of an increased tracer

gas consumption.

An elongated object here means a pipe or other long

tube shaped object. This type of object normally requires

deep pre-evacuation since the gas will flow in laminar

fasion and not mix with air in the object. The residual

air will simply be pushed in front of the injected gas.

In push-through filling this air is pushed through the

“pipe” and into an additional volume. This added volume

is placed between the object and Test Port 2 (See figure).

ILS500 must be set to fill through Test Port 1 only. This

option can be found under Advanced Setup / Parameters

/ Options, Section 8.4.9.

The added volume should be:

V2 >

Where

V2

is added volume

V1

is sum of volumes of object

and connection tubing/piping.

Pfill

is fill pressure (Fill Setpoint)

given in atmospheres

(see example below).

1.2 is given for margin.

Example: The test object is an aluminium pipe. Fill

pressure is 0.5 MPa (72 psi) = 5 atm. Length is 10 m

(33 ft) with an internal volume of 280 cc. Internal volume

of connections is 120 cc in total:

V > = 96 cc

Add a 100 cc volume between the object and Test Port

2.

As mentioned above this procedure saves a considerable

amount of cycle time. The disadvantage is a higher

consumption of tracer gas.

- 0 + 5

-0.7 bar

1.2 x V1

P fill

Added volume

Long tube shaped object

1.2 x (280 + 120)

5

1.5 Push-through filling.


The main reason for removing the tracer gas is to

minimise the amount tracer gas in the ambient around

you test station. Leaving large amounts of gas in the

tested object can cause interference with the testing.

This is especially true for automatic testing. An opera-

tor testing manually can normally interpret spurious

signals as irrelevant. The computer controlling an

automatic test does not have that capability and back-

ground “noise” can result in false leak signals.

The optimum tracer gas removal is therefore always a

balance between cycle time and risk for false rejects.

The Air Purge function is normally the quickest and

most efficient way of removing the tracer gas from the

tested object. See further under tooling.

An alternative to removing all gas is to use a ventilation

hood above the “box” or pallet where the objects are

placed after testing.

As a start we recommend that you activate After

Evacuation and set the After Evacuation Setpoint to –

0.03 MPa (–4.4 PSI).

Use the Air Purge function if you are using the tooling

function.

Set the Purge Object timer so that there is only very

little gas left in the object after the test. Use the hand

probe to check.

1.6 Optimising the Removal of the Tracer gas.


The ILS500 is equipped with a number of interfaces forinteraction with indicating, supervising and registeringequipment.

The details of these are specified below. All interfaces sign-als except the serial communication interfaces are discrete24 VDC logic signals. Output signals (OUT) are sourcing transistor outputs.Input signals (IN) are transistor inputs.

Max current of each signal is given in the tables below.Total current (sum) must, however, be within instrumentspecification.

N.B. that outputs are not relay types. Do not connectexternal drive source such as 24 V or 100/230 VAC.

Pin Signal Type Load Comment1 COM GND -1A Common GND for outputs2 COM GND -1A Common GND for outputs3 COM GND -1A Common GND for outputs4 IN_0 IN -0.5 mA Input of H2000 APC system5 IN_1 IN -0.5 mA Input of H2000 APC system6 IN_2 IN -0.5 mA Input of H2000 APC system7 IN_3 IN -0.5 mA Input of H2000 APC system8 IN_4 IN -0.5 mA Input of H2000 APC system9 CAL_CONF OUT 0.5A Output of H2000 APC system10 OUT_6 OUT 0.5A Output of H2000 APC system11 COM GND -1A Common GND for outputs12 COM GND -1A Common GND for outputs13 COM GND -1A Common GND for outputs14 DET_ERROR OUT 0.5A Output of H2000 APC system15 LEAK_OUT OUT 0.5A Output of H2000 APC system16 DET_ON OUT 0.5A Output of H2000 APC system17 DET_SIGNAL OUT 0.5A Output of H2000 APC system18 DET_WAIT OUT 0.5A Output of H2000 APC system19 OUT_0 OUT 0.5A Output of H2000 APC system20 OUT_1 OUT 0.5A Output of H2000 APC system21 OUT_2 OUT 0.5A Output of H2000 APC system22 OUT_3 OUT 0.5A Output of H2000 APC system23 OUT_4 OUT 0.5A Output of H2000 APC system24 OUT_5 OUT 0.5A Output of H2000 APC system25 24 VDC OUT OUT 0.5A Supply for switches etc. connecting to inputs.

Do not feed 24V here!

2.1 APC (Two ports)Connector: 25 pin female D-Sub.

Purpose: Connection of APC units.

For further information about APC system refer to Technical Manual of H2000 (TM-H2000).

APC Ports

2. Interfaces and Connectors


1 24V SPLY 200 mA Power supply for switches and touch panel.

2 24V SPLY 200 mA Power supply for switches and touch panel.

3 nc No connection

4 INTSTART IN -5 mA Panel Start button. Normally open switch.

5 INTSTOP IN -5 mA Panel Stop button. Normally open switch.

6 RUNNING OUT 50 mA Yellow lamp (LED) in Start button.

7 ACCEPT OUT 50 mA Green Accept (LED) lamp.

8 REJECT OUT 50 mA Red Reject (LED) lamp.

9 ERROR OUT 50 mA Summing Error signal

10 ESTATUS OUT 50 mA Emergency relay status. On when relay is in stop position.

11 EOT/FILLED OUT 50 mA End of Test or Test Object Filled signal (selectable).

12 RJ45-1 Internal Ethernet bridge.








20 RS232GND Internal RS232 bridge.

21 RS232TX Internal RS232 bridge.

22 RS232RX Internal RS232 bridge.

23 RS422 Internal RS422 bridge












35 nc No connection

36 COM SPLY -0.5 A Common GND for switches and touch panel.

37 COM SPLY -0.5 A Common GND for switches and touch panel.

Pin Signal Type Load Comment

2.2 HMI PanelConnector: 37 pin female D-Sub

Purpose: For external connection of HMI panel.

Do not connect to anything other than Adixen Sensistor original HMI panel.


1 +24VDC SUPPLY 250 mA Supply for emergency circuit contacts, start and stop buttons.

2 no -

3 EXTSTART IN -7 mA Start button return (NO contacts)

4 EXTSTOP IN -7 mA Stop button return side (NO contacts).

5 no -

6 RUNNING OUT 50 mA Cycle running.

7 ACCEPT OUT 50 mA Tested part accepted.

8 REJECT OUT 50 mA Tested part rejected.

9 ERROR OUT 50 mA Summing error.

10 ESTOP1 - * Emergency relay control: Terminal 1 of channel 1 input




14 SAFESUPPLY SUPPLY 250 mA 24V supply through internal emergency stop relay.

15 no -

16 no -

17 EAUTOR1 * Emergency relay control: Short to pin 18 for auto-reset

18 EAUTOR2 * Emergency relay control: Short to pin 17 for auto-reset.

19 EMANR1 * Emergency relay control: Short to pin 20 for reset.

20 EMANR2 * Emergency relay control: Short to pin 19 for reset.

21 no

22 no

23 FILLED OUT 250 mA Gas filled indicator.

24 ESTATUS OUT 50 mA Emergency circuit stopped. Reset lamp.

25 COM GND 0.5 A Common GND for reset switch lamp.

2.3 External Control PanelConnector: 25 pin male D-Sub

Purpose: Interace for External Control Panel (90650) or External Control Panel with

Emergency Stop (90660)

Connect to original Adixen Sensistor control panel only!

Pin Signal Type Load Comment

* Connections are designed for safety relay included in Adixen Sensistor original part:

External Control Panel with Emergency Stop (90660)

HMI Panel and External Control Panel connector


Connector: 9 pin male D-SUB

Purpose: Connection of serial printer or logging device (e.g.

PC)

Cable: Standard female to female file transfer cable (null

modem).

BaudRate: 9600 default (1200 selectable)

Pin Signal Specification

1 Not used Standard RS232C

2 RD Data rate 9600 baud

3 TD Data bits 8

4 Not used Stop bits 1

5 SG Parity none

6 Not used Flow ctrl none

7 Not used

8 Not used

9 Not used

Connector: 9 pin male D-SUB

Purpose: Used for downloading APC drivers and for external mounting of H2000 PLUS

Cable: Standard female to female file transfer cable (null modem) for downloading APC drivers.

Pin-to-pin cable for external mounting of H2000 PLUS

Pin Signal Specification

1 Not used Standard RS232C

2 RD Data rate 9600 baud

3 TD Data bits 8

4 Not used Stop bits 1

5 SG Parity none

6 Not used Flow ctrl none

7 Not used

8 Not used

9 Not used

Printer and H2000 Serial connector

2.4 Printer and RS232 Interface

2.5 H2000 Serial


Connector: 5 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal included.

Purpose: Options port 1.Optional analogue or digital input (not supported by std software).

Pin Signal Type Load Comment1 +24VDC SUPPLY 250 mA Option supply2 VIN1 IN -60 mA Voltage input: Digital 24VDC or analogue 0-10 VDC.3 IIN1 IN +/- 30 mA Current input: 0 - 20 mA4 COM1 IN -250 mA Signal common (GND)5 COM/SHLD GND +/- 30 mA Shield/screen connection.


Purpose: Options port 2. Used for ”Active Holder for Hand Probe” (90630).

Pin Signal Type Load Comment1 +24VDC SUPPLY 250 mA Option supply2 VIN2 IN -60 mA Voltage input: Digital 24VDC or analogue 0-10 VDC.3 IIN2 IN +/- 30 mA Current input: 0 - 20 mA4 COM2 GND -250 mA Signal common (GND)5 COM/SHLD GND +/- 30 mA Shield/screen connection.


Purpose: Test Status Ouputs. Sourcing 24VDC transisor outputs.

Pin Signal Type Load Comment1 RUNNING OUT 0.5 A Cycle running.2 ACCEPT OUT 0.5 A Tested part accepted.3 REJECT OUT 0.5 A Tested part rejected.4 ERROR OUT 0.5 A Summing error.5 EOT/FILLED OUT 0.5 A End of test or gas filled indicator (selectable).6 COM GND -2.0 A Common GND for status signals.

IMPORTANT: Mount the 5, 6 and 8-pinfemale connectors for Options, Status,Safety, Tooling and Control as shownin the picture below.

Top pin is number 1

2.6 OptIn 1

2.7 OptIn 2

2.8 Status


* 250VAC 5A cosj = 1 / 30VDC 5A L/R = 0ms / 240VAC 2A cosj = 0.3 / 24VDC 1A L/R = 48ms. It is

possible to run the ILS500 without emergency stop circuit. Before doing this, make sure that there are no

risks involved.

Risk assessment is the sole duty of the user of the ILS500.

Connect jumper from SAFETY:1 to SAFETY:5 to run ILS500 without emergency stop circuit, see picture

below.

** SAFESPLY feeds risk associated loads inside the ILS550. These include all gas and tooling valves.

IMPORTANT! Read Safety Section carefully before installing your ILS500.


Purpose: Emergency stop interface.

Pin Signal Type Load Comment1 +24VDC SUPPLY 2.5 A2 AUX1 - +/-1-5 A* Terminal 1 of safe relay contacts for auxilliary external use.3 AUX2 - +/-1-5 A* Terminal 2 of safe relay contacts for auxilliary external use.4 ESTATUS OUT 0.5 A Internal emergency circuit stopped. Use for reset lamp or PLC monitoring.5 SAFESPLY** SUPPLY -2.5 A 24VDC supply from EXTERNAL emergency stop circuitry.6 COM GND 1.0 A Common GND

Safety, Tooling and Control Connectors

IMPORTANT: Mount the 5, 6 and8-pin female connectors forSafety, Tooling and Controlaccording to the instructions onprevious page.

2.9 Safety



Purpose: Electrical tooling interface.

Pin Signal Type Max load Comment1 +24VDC SUPPLY 300 mA Tooling switch supply. E.g. proximity switch2 TS1 IN -7 mA Tooling switch 13 TS2 IN -7 mA Tooling switch 24 TS3 IN -7 mA Tooling switch 35 TS4 IN -7 mA Tooling switch 46 MARKER* OUT 0.5 A Marker output. Selectable mark on REJECT or ACCEPT7 COM GND -1.0 A Common GND8 COM GND -1.0 A Common GND

* The MARKER output (Tooling Connector, pin 6) can be used to send a start pulse to marking equipment

such as an engraving machine or a valve controlling a simple pneumatic stamp. Function and length of

pulse is set by the following two parameters:

Marker Output: Length of marker output pulse. Output will go high at end of gas test and stay high for the

given time.

Marker Output High if Leak: Decides function of marker pulse. To mark rejected part set to OFF. To mark

accepted part, set to ON.

ControlConnector: 8 pin male Weidmüller, Omnimate BL3.5. Mating screwterminal included.

Purpose: External start and stop. Control of optional external valves.

Pin Signal Type Load Comment1 +24VDC SUPPLY 2.0 A Start and stop switch and supply.2 EXTSTART IN - 7 mA Start button return (NO contacts) other contact to +24VDC3 EXTSTOP IN - 7 mA Stop button return side (NO contacts) other contact to +24VDC4 EVAC1 OUT 0.5 A Venturi valve output (Exhaust on high vac model)5 EVAC2 OUT 0.5 A Evacuation valve output6 GASFILL OUT 0.5 A Fill valve output.7 OPTOUT OUT 0.5 A High when ILS500-CP is in locating mode.8 COM GND - 1.0A Common GND for outputs.

Connection of proximity switch (sensor)Pin Signal1 +24VDC2 TS13 TS24 TS35 TS46 MARKER7 COM8 COM

+V, BrownOut, Black

0V, Blue

PNP type, NO

2.10 Tooling


2.11 ILS500 Printer/ RS232 Specification

Data Rate: 9600 baud (default), 1200 baud

Data bits: 8

Stop bits: 1

Parity: None

Flow Control: None

Printing of resultsThe printer port prints the result of every test. In hand probe mode the result printed is

“ACCEPT” or “REJECT”. After an active probe test cycle the gas analysis value from the H2000 PLUS is

printed. The printout can be “2.4E+00A”. See the H2000 PLUS manual.

If the test cycle is rejected by any other test this will be printed.

USER FAIL Operator has pressed stop

EVAC FAIL Evacuation failed

VDEC FAIL Vacuum decay test failed

FILL FAIL Tracer gas filling failed

REFI FAIL Tracer gas refill failed

PDEC FAIL Pressure decay test failed

BLOC FAIL Blockage test failed

Hardware error prints “ERROR”.


Statistics Printed data Explanation REC:AP29 - recipe name. Printed if recipes is activated

TOT:00031 - total

ACC:00009 - accepted

REJ:00022 - rejected

EVA:00001 - evacuation

VDE:00000 - vacuum decay

BLO:00006 - blockage test

FIL:00001 - gas filling

PRE:00000 - pressure decay

GAS:00014 - gas detector

CommandM<CR>N<CR>Q<CR>

K<CR>

S<CR>RS<CR>R1<CR>

R2<CR>

R3<CR>

R4<CR>

R5<CR>

R6<CR>

R7<CR>

R8<CR>

ActionStart

Print request

Stop

Calibrate

Statistics

Reset statistics

Recipe 1

Recipe 2

Recipe 3

Recipe 4

Recipe 5

Recipe 6

Recipe 7

Recipe 8

ExplanationSame function as START button. Starts test cycleReturns H2000 Analysis value.Same function as STOP button. Used to stop orterminate test cycle and/or acknowledge a rejectedtest.Starts calibration if the H2000 PLUS has an activeprobe.Prints statistics.Clears the statistics.Activates recipe number 1. Recipe must exist andrecipe function must be on.

Activates recipe number 2. Recipe must exist andrecipes must be on.







ResponsMSEx. 0.0E+00A

See below.

R1 when download starts.OK when download finished or ifR1 is already active.NO if R1 doesn’t exists.R2 when download starts.OK when download finished or ifR2 is already active.NO if R2 doesn’t exists.R3 when download starts.OK when download finished or ifR3 is already active.NO if R3 doesn’t exists.R4 when download starts.OK when download finished or ifR4 is already active.NO if R4 doesn’t exists.R5 when download starts.OK when download finished or ifR5 is already active.NO if R5 doesn’t exists.R6 when download starts.OK when download finished or ifR6 is already active.NO if R6 doesn’t exists.R7 when download starts.OK when download finished or ifR7 is already active.NO if R7 doesn’t exists.R8 when download starts.OK when download finished or ifR8 is already active.NO if R8 doesn’t exists.

CommandsThe printer port can also be used to control the ILS500.

The most commonly used functions can be started/configured over the RS232 interface.


3. Service Menu

The Service Menu contains functions for trouble

shooting and testing of the system.

The software versions are displayed in the lower right

corner. This might be requested when communicating

with the supplier or his appointed service partner.

3.1 OutputsThe PLC OUTPUTS menu shows the current status of

each system output.

A black box means output is ON.

You can manually override the status of all outputs that

are in off state. Simply press on the respective box. N.B.

You can not turn off an output set to high by the system.

3.2 InputsThe PLC INPUTS menu shows the current status of

each system input.

A black circle means input is ON.

This is a display only. You can not affect the state of the

inputs from this display.


3.3 Analogue Inputs ConfigurationThis menu is primarily used for analysing the signal

and noise of the vacuum and pressure sensor signals.

Channel 1: OptIn 1. Analog / digital input. Not

supported by std software.

Channel 2: OptIn 2. Original Adixen Sensistor

accessories, for example. Active Holder for

Hand Probe.

Channel 3: Vacuum sensor

Channel 4: Pressure sensor.

The k and m of the linear correction for the vacuum and

pressure sensors are set to give readings in “bar”. Do

not change k and m for another unit. System base unit

must be “bar”.

The only reason to change the k and m is to fine tune

the calibration of the respective sensor.

Do not make bigger adjustments than 5% for “k” and

20% for “m”.

If bigger adjustment is needed you should instead replace

the sensor.

N.B. The system readjusts the zero point during the start

up procedure. Try to restart the system before adjusting

the m parameter.

Important! Do not change the input mode setting as

this will result in malfunction of the sensor scaling.


3.4 System ResetA system reset will set all current parameters to factory

default as given in the Parameter Index in the User Ma-

nual.

Recipes and passwords will not be reset.

Press and hold STOP button more than

3 seconds to display this choice. Tick

box while pressing STOP button to reset

recipes, passwords and A/D con-

figuration.

3.5 H2000 SettingsThis menu gives easy access to all H2000 parameters

that are controlled from the ILS500.

A: Leak Alarm Level

B: Calibration Coefficient

C: Leak Rate Unit (A, B and H must all

be expressed in this unit)

D: APC Timer A

E: APC Timer B

F: APC Timer C

G: APC Timer D

H: Purge Level

Open the “APC Settings” in the H2000 PLUS for

specific description of APC Timers A through D.

The X marks behind the parameters controls whether

the respective parameter is downloaded to the H2000

PLUS upon recipe changes.

Downloading all parameters takes roughly 10 seconds.

By restricting the download to only those parameters

that differs between the different recipes, you can reduce

this time, making recipe selection quicker.


3.6 RS232This menu is used mainly for testing and setting up the

serial communication in the ILS500.

The left part of the display handles the RS232

communication between the PLC controller and the

H2000 PLUS detector.

By pressing any of the buttons you can send commands

to the detector.

Measure Mode: Sets the H2000 PLUS in

“Analysis Mode”.

Detection Mode: Sets the H2000 PLUS

in “Detection Mode”.

Hand Probe: Sets Probe Type to

“Hand Probe”.

Active Probe: Sets Probe Type to loaded

driver, for example AP29.

Printer: Activates printer type

“Analysis Data Output”.

Measure: Starts an active hydrogen

measurement / sampling.

Calibrate: Starts the H2000 PLUS

calibration routine.

Stop: Terminates a running

measurement.

Data sent from the H2000 PLUS is shown in the

“Received Data” window.

The right side of the display handles the Printer / RS232

output of the ILS500.

The communication speed can be set to either 1200 or

9600 baud. Baud rate change will take effect after res-

tarting the ILS500.

Data received on the Printer / RS232 port is shown in

the input windows.


3.7 Service RunThis menu is intended for remote trouble shooting per-

formed by an authorised service centre.

3.8 Hardware TestThe hardware test is a diagnostic tool helping you in

preventive maintenance as well as service and repair.

The test takes you through a number of steps testing all

units that are subject to wear and should thereby help

you to find almost any problem in the ILS500 system.

Keep this manual at hand when performing the test.

You will need the reference table at

the end of this section to help you interpret the test results

correctly.

Remember also that you will need to run through the

whole sequence to interpret the results correctly.

You can choose to test according to the limits of your

specific application.

Setup all parameters for your test object (or load desired

recipe) and connect a leak free sample.

Set test selection switch to ”ILS500 + Object” for

application specific hardware test.

You can also test the ILS500 against factory

specification.

In this case you should plug both test ports using the

plugs delivered with the units.

(Remove ISO to NPT converters if installed.)

Set test selection switch to ”ILS500 plugged” for factory

specified hardware test.


The two lines of text display the current action and

results of the respective test step.

Only on screen per test step is shown here. The diffe-

rent texts showing the possible result of the tests are

shown next to the respective screen.

Pres OUTPUTS for testing the outputs of the ILS500.

Step through the different outputs by pressing the < or

> buttons.

The function and location of each output is described

in the table below.

Before proceeding you should carefully check that your

tracer gas and compressed air feed pressures are correct.

Wrongly set pressure can cause erroneous test results.

The ”Continue” button will be displayed at the end of

each test step. Press ”Continue” for next test step

3.8.1 Pressure and Vacuum SensorsZero points of pressure and vacuum sensors are tested.

Possible results:

Zero Points are OK

Vacuum Zero Point not OK

Offset zero point can result in:

• Incorrect gas filling

• Erroneous vacuum or pressure decay results


3.8.2 Evacuation ValveEvacuation valve is checked for internal leakage.

Possible results:

No Internal Leakage

Internal Leakage

Internal leakage can result in:

• False vacuum decay rejects

• Increased tracer gas consumption

3.8.3 Venturi PumpChecking max vacuum of Venturi pump.

Possible results:

Max Vacuum OK

Poor Max Vacuum

Poor max vacuum‘can result in:

• Failed pre-evacuation

• Slower evacuation

3.8.4 Manifold Tightness (gross)The overall tightness of the manifold is tested using

the vacuum raise method.

Possible results:

No Leakage from Outside

Leakage from Outside

Leaks in the manifold can result in:


• Increased gas consumption

Minor external leakage will be found later during the

gas test step.


3.8.5 Vacuum Sensor ValveThis checks that the valve shuts to protect vacuum sen-

sor before filling.

Possible results:

Valve works

Faulty!

Malfunction can result in:

• Damage to vacuum sensor

• Failed pre-evacuation

3.8.6 Tracer Gas Fill ValveThe step tests the gas fill valve for internal leakage by

registering pressure rise behind the valve.

Possible results:

No Internal Leakage

Internal Leakage


• Erroneous pressure decay results


Increased gas consumption

3.8.7 Test Port 2 ValveN.B. This test will fail if both test ports are connected to

a test object. Proceed and then repeat the entire hardware

test sequence with both ports plugged to perform this

test step.

This step tests Test Port 2 valve for internal leakage by

registering pressure rise behind the valve.

Possible results:

No Internal Leakage

Internal Leakage


• False blockage test accepts


3.8.8 Tracer Gas Fill ValveThis step tests that tracer gas fill valve opens to fill gas.

Test will fail if tracer gas feed pressure is too low. If

this is the case, adjust pressure and restart hardware

test from beginning.

Possible results:

• Valve works

• Faulty!

Malfunction will result in:

Failed gas filling.

3.8.9 External gas leaksThe ILS500 is now prepared for a manual test for

external leakage.

Use the hand probe to check for leakage

Start by checking all connections between the ILS500

and your test object. Follow each test line carefully and

check every joint.

Proceed to check around the gas valves and manifold

inside the ILS500.

3.8.10 Manifold Tightness (gross)The overall tightness of the manifold is tested using the

pressure decay method.

This is a complement to the gas test, revealing leakage

out, through the exhaust etc.

Possible results:

No Internal Leakage

Internal Leakage

Internal leakage

can result in:

• False pressure and vacuum decay rejects

• Increased tracer gas consumption


3.8.11 Evacuation ValveThis step tests that evacuation valve opens to release

tracer gas to exhaust. Same test as previously but un-

der pressure instead of vacuum.

Possible results:

• Valve works

• Faulty!

Malfunction will result in:

Failure to terminate test cycle

3.8.12 Indicator LampsThis is a “manual” test. The ILS500 lights up one lamp

at the time. Simply check that the right lamp comes

on.

Check function of each lamp by pressing “Continue”.

Remember to check lamps on both touch panel and

external control panel (if installed).

3.8.13 Tooling Outputs 1 - 4This test that tooling outputs opens to deliver

compressed air to tooling cylinders etc.

WARNING! Use eye and ear protection if you leave

tooling outputs open during this test. The high noise

and powerful air jets are harmful.

Check function of each output by pressing “Continue”.

3.8.14 START and STOP buttonsThis is a “manual” test. The test continues when the

correct button is pressed.

The test checks the activated START and STOP buttons

only. Use INPUT menu under Service menu to check

buttons that are turned off.


3.9 Interpretation of hardware test results.

Use the table below, to correct errors detected by the hard ware test routine.

Tested Unit

Vacuum and Pressure

Sensors.

Evacuation Valve.

Venturi Pump.

Gas Valve Manifold.

Vacuum Sensor

Protection Valve.

Tracer Gas Fill Valve.

Test Port 2 Valve.

Tested Feature

Zero point.

Internal leaks.

Maximum vacuum.

Leaks from outside.

Function.

Internal leaks.

Function.

Reason for error

Broken / Disconnected cable.

Wrongly set A/D parameters.

Broken vacuum or pressure

sensor.

Dirty or worn valve seals.

Compressed air pressure too

low or too high. See section

5.2.

Dirt inside Venturi.

No signal to Venturi pilot

valve.

No signal to Evacuation pilot

valve.

Dirty or broken Venturi pilot

valves.

Dirty or broken Evacuation

pilot valves.

Leaks to outside?

If no gas leaks.

If no internal leaks in tracer

gas valve.

No signal to pilot valve.

Dirty or broken pilot valve.

Vacuum sensor protection

valve broken.

Dirty or worn valve seals.

Leaking pilot valve.



Test port 2 valve broken.

ActionCheck cable of sensors.

Check and adjust Analog Input settings.

Replace sensor if “m” value needs more

than 20% change.

Replace sensor.

Replace or clean evacuation valve.

Adjust compressed air pressure.

Remove and clean Venturi.

Check ”Venturi Pump” output.

Send in for repair.

Check ”Evac Valve” output.

Send in for repair.

Replace two upper valves in pilot ramp.

Replace fourth valve from bottom in pilot

valve ramp.

Check for leaks with Hand Probe (later in

hardware test sequence).

Check internal leaks in tracer gas fill valve.

Replace/clean vacuum sensor protection

valve.

Check ”Sensor Protect” output.

Send in for repair.

Replace valve third valve from bottom in

pilot ramp.

Replace valve.

Replace or clean tracer gas fill valve.

Replace fourth valve from bottom in pilot

valve ramp.

Check ”Test Port 2” output.

Send in for repair.

Replace third valve from bottom in pilot

ramp.

Replace valve.


Tested Unit

Tracer Gas Fill Valve.

Gas Valve Manifold.

Evacuation Valve.

Lamp.

Tooling Valves.

Buttons.

Tested feature

Function.

Leaks to outside.

Function.

Function.

Function.

Function.

Action

Check ”Fill Valve” output. Send in for repair.

Replace valve fourth valve from bottom in pilot

ramp.

Replace valve.

Remove leaking valve. Clean and grease valve

seal before installing again. See instructions

Remove leaking unit. Clean and grease o-ring

before installing again. Units lacking o-ring seal

should be sealed with Loctite 577 or similar.

Check ”Evac Valve” output. Send in for repair.

Replace fourth valve from bottom in pilot valve

ramp.

Check cable to HMI and External Control Panel

Replace lamp.

Check PLC output. Send in for repair.

Replace valve first or second valve from bottom

in pilot ramp.

Check PLC output. Send in for repair.

Check cable to HMI and External Control Panel.

Send in for repair.

Reason for error



Tracer gas fill valve broken.

Wrongly assembled gas

valve.

Wrongly installed

connectors / plugs.

No signal to Evacuation

pilot valve.

Dirty or broken Evacuation

pilot valves.

Disconnected cable.

Broken Lamp.

No signal from PLC.


No signal from PLC.

Disconnected cable.

Broken switch.


MessageDetector Power Off

Detector Error **:

“Check Cable and Sensor”

“Probe Error”

Hardware Error

Vacuum Sensor Error

Hardware Error

Pressure Sensor Error

FX2NC-4AD Power Off

Emergency Stop Activated

H2000 Comm. Error

Reason for errorNo power to H2000PLUS

Detector.

Probe cable disconnected.

Gas sensor damaged.

Active Probe error.

No power to vacuum sensor.

Sensor not connected to AD.

Damaged vacuum sensor.

No power to pressure sensor.

Sensor not connected to AD.

Damaged pressure sensor.

No power to AD module.

Emergency Stop not Reset.

H2000 printer mode turned

off manually.

H2000 serial cable

disconnected.

Action *Check power cable to

detector (internal or external).

Connect cable.

Replace probe or sensor.

Consult Active Probe Manual.

Check cable to sensor.

Check connection to AD.

Replace sensor.

Check cable to sensor.

Check connection to AD.

Replace sensor.

Check power cable on left

side of AD module.

Pull out emergency stop button

to reset.

Restart system.

Connect cable (internal

or external).

* Contact your supplier if the suggested action does not clear the error.

** Check error message on H2000 PLUS display.

3.10 Hardware error messages


Venturi Pump

Evacuation Valve

Tracer Gas Fill Valve

Test Port Valve 2

Vacuum SensorControl Valve

Vacuum Sensor

Pilot Valve 1Pilot Valve 6

Pressure Sensor HP model Pressure Sensor fitted here

3.11 Pneumatic Components Overview

A

B

A

B

A

B

A

B

A

B

A

B

2

1

4

3

6

5

3.12 Pilote Valv Ramp Overview

B r

ow

(to

p)

A r

ow

(b

ott

om

)

Valv

e n

um

ber

LE

Ds

Side view of ports

Valve positions:

5A+6 AMain Air Valve5B+6B Venturi Pump supply4A Evacuation Valve4B Tracer Gas Fill Valve3A Test Port 2 Valve3B Sensor Protection Valve2A Tooling Valve 12B Tooling Valve 21A Tooling Valve 31B Tooling Valve 4


4. MaintenanceILS500 has been designed for a minimum of

maintenance. Regular maintenance is done easily and

quickly using simple and commonly available tools.

There are only three different parts that need regular

maintenance:

• Venturi pump (1 off). The pump will need regular

cleaning.

• Gas Valves (4 off). The gas valves will need regular

cleaning. The gas valves will eventually wear out and

need to be replaced.

• Pilot valves (6 off). Maintenance free, provided that

incoming compressed air is dry and filtered to 5 µm.

The Venturi pump and all gas valves can be tested

automatically by the Hardware Test. See Section 3.8.

Changing Venturi pump and all gas valves takes less

than 15 minutes.

4.1 ToolkitBelow is a list of the tools needed for regular

maintenance.

• Allen Keys (hexagonal): 3 and 4 mm.

• Torx Key: T25

• Screwdriver: Philips 1 or Pozidrive 1.

4.2 Maintenance planThe inspection intervals given below are for a “typical”

application. The correct interval depends on the amount

of dust and dirt pumped through the venturi. You will

have to make up your own maintenance schedule based

upon your own experience.

Details of each maintenance point are described under

the respective headline below.

* Inspection interval for the Evacuation, Fill and Test Port 2 valves depends greatly on the amount of particulates

in the objects tested. Metal burrs and other sharp particles will wear the valves down, requiring shorter maintenance

intervals.

Part

Venturi pump

Evacuation, Fill and

Test Port 2 Valves

Vacuum Sensor

Valve

Pilot Valves

Gas sensor

Interval

3 months

3-6 months*

12 months

12 months

3 months**

Action

Use the Hardware Test function to check ultimate vacuum.

Clean venturi nozzles when necessary.

Use the Hardware Test function to check condition of valves.

Replace or clean valves when necessary.

Use the Hardware Test function to check condition of valve.

Replace or clean valve when necessary.

Set PLC in STOP position, remove output hose from load

side and block with finger. Change valve if pressure builds.

Check sensitivity and response time. See manual for H2000

PLUS and/or active probe used.


You can install a particle filter between the Test Port

and the object to prolong maintenance intervals. Be

aware though that this will result in prolonged cycle

times and higher tracer gas consumption.

** N.B. The gas sensor check in the maintenance plan

can not replace the regular sensor calibration. Sensor

calibration should be carried out typically every day as

part of the total test system self check.

4.3 Venturi PumpThe Venturi pump is a simple single stage device without

valves or other moving parts. It will not normally wear

down and will therefore not need to be replaced.

It can, however, collect dirt and dust and gradually lose

capacity.

If this occurs it must be removed and cleaned.

4.3.1 Cleaning/replacing the Venturi Pump

1) Remove the Exhaust hose from the barbed hose fitting.

2) Unscrew and remove the barbed hose fitting and the

plastic washer.

3) Use a T25 key to remove the two screws holding the

side cover (next to gas ports).

4) Slide the cover back and lift it off. Rock the rear end

of the cover up and down a few times to loosen.


5) Use a 4 mm Allen key to remove the four screws

holding the Venturi pump.

6) Remove the o-ring under the Venturi. Re-move the

hose from the Venturi inlet.

Push hose into connector and press orange ring down

to release hose, then pull hose out.

7) Remove the hose fitting from the Venturi.

8) Install new Venturi or use compressed air jet and a

cotton bud, pipe cleaner or small brush to clean the

nozzles inside the Venturi.

9) Replace hose fitting on Venturi inlet.

10) Reconnect inlet hose.

11) Clean o-ring and install in groove on valve manifold.

12) Reinstall and tighten the four screws.

13) Put plastic washer inside Venturi outlet and reinstall

barbed fitting. Tighten with spanner.

14) Reconnect the exhaust hose.

15) Run through the hardware test again to test that the

Venturi delivers adequate max vacuum.


4.4 Gas Valves


right hand cover (next to gas ports)..


of the cover up and down a few times to loosen. See

above.

3) Use a 3 mm Allen key to remove the four screws

holding the valve to be changed.

4) Lift the old valve out.

5) Put the new valve in. Notice the correct orientation in

the picture above.

6) Tighten the screws 2-3 mm at a time moving the key

from screw to screw so that the valve doesn’t tilt much.

7) Tighten the screws and replace the cover.

8) Run through the hardware test again to test that the

changed/renoved valve(s) perform as required.

9) Use hand probe to check that there is no external

leakage (this part of Hardware Test is routine).


4.5 Pilot Valves


right hand cover (next to gas ports).


of the cover up and down a few times to loosen. See

above.

3) Use small screw driver to loosen the screw holding

the valve. You must back the screw all the way out until

you feel it “jumping” in the thread entrance.

4) Push down on the LEDs while pressing the screw

down until you feel the locking mechanism

“snap”.

5) Lift the old valve out from the coil side. If the valve

does not come off, repeat steps 3 and 4 making sure the

screw is completely backed out.

6) Push the screw in while inserting the new valve. Insert

the end facing the screw first and then push the coil side

down.

7) Tighten the screw.

8) Replace the cover.

1

2

1

2

3


5. Technical specification5.1 Electrical Specifications

Electrical supplyMains Voltage: Single Phase, 85 - 260 VAC / 47 - 63 Hz

Current: 1.0 A @ 100VAC / 0.45 A @ 230 VAC

Power Rating: 120 W max / 33 W typical average

Inrush Current: max 40 A

Mains Connector: IEC/EN 60320-1/C14

Recommended Fuse Rating: 2 A slow / 6.3 x 32 mm (2 needed)

I/O Port ConnectorsExternal Control Panel: male, 25 pin, D-sub

APC (Active Probe Control): female, 25 pin, D-sub

OptIn1 and OptIn 2: 5 pin BL 3.5/5*

Status and Safety: 6 pin BL 3.5/6*

Tooling and Control: 8 pin BL 3.5/8*

*Weidmüller Omnimate, detachable screw terminal

I/O Port SignalsSignal specification: 24 VDC logic

Output Voltage: 23 ±1 VDC

Output Capacity: Max 0.5 A / output (max 2.5 A total)

Input Voltage HI Min 16 VDC

Input Voltage LO Max 4 VDC

Input Current HI/LO Max 7 mA

Communication PortsEthernet: RJ45, 10/100 Mbit/s, TCP/IP

RS232: male, 9 pin, D-sub

Data rate: 9600 baud

Data bits: 8

Stop bits: 1

Parity: none

Flow control: none


HMI Panel(if externally mounted)

PrinterIlogger(RS232)

Ethernet

Options Inputs1 and 2

Status Outputs

Safety interface

Tooling Interface

Control Outputs

APC Ports

External ControlPanel

H2000 Serial(if externallymounted H2000)Also used for APCdriver download

Hydrogen Probe

Fuses

Power Switch

Power Inlet


5.2 Pneumatic Specifications

Compressed air supplyPressure Std model: 0.35 – 0.7 MPa (50 – 100 psi)

Reduced vacuum capacity

below 0.5 MPa (70 psi)

HP model: 0.5 – 0.7 MPa (70 – 100 psi)

Peak Consumption @ 6 bar (87 psi) 240 l/min (508 SCFH)

Quality: Oil free and filtered to 5 µm

Dew point: Max 10°C (50°F)

Tracer gas supplyRecommended Composition: 5% H

2 / 95% N

2

Pressure Std model: 0.005 – 1.0 MPa (0.72 – 145 psi)

HP model: 0.02 – 4.5 MPa (3 – 652 psi)

Quality: Industrial grade purity (>95% purity)

ExhaustCapacity in Exhaust Duct: Min 30 m3/h (1000 SCFH)

Dimension of Hose Leading to Duct: 25 mm ID (1”)

PneumaticCapacity is given for 500 mm of 10 mm ID hose between ILS500 and test volume.

Valve bore: 7 mm (0.28”)

Evacuation:Max Vacuum: –85 kPa (–12.3 psi)

Capacity: 0.4 s/l to –50 kPa (–7.2 psi)

1.5 s/l to –80 kPa (–11.6 psi)

Filling:Capacity at 1 MPa supply: 0.1 s/l to 0.1 MPa (14.5 psi)

0.5 s/l to 0.6 MPa (87 psi)

Tooling Output Valves:Valve type: Normally closed, 3/2 valve

Qn: 160 std l/min.

Cv: 0.16 USGPM/psi

Gas and Air Connection:Ports: Female ISO3/8” (ISO to NPT 3/8”

adapters included)

Hose connectors: 4 of OD 10 mm connectors included


ExhaustID 25 / 1” hose

Tracer gasISO 3/8” female

Test Port 1ISO 3/8” female

Vacuum Gauge Vent(Emits small amountof Tracer gas)

External Vacuum Pump(Vac. model only)

Optional Port

Test port 2ISO 3/8” female

Compressed AirISO 3/8” female

Tooling Valve Outputs 1 – 4.OD 4 mm hose connectors.


Fill capacity was tested with the following set-up:

Tracer gas supply pressure: 1.0 MPa (145 psi)

Connection hose size: ID10 mm

Hose length: 500 mm

End vacuum was tested with both test ports plugged.

5.3 Evacuation and Filling Capacity

Evacution capacity was tested with the following set-up:

Compressed air pressure: As shown in graph

Connection hose size: ID10 mm

Hose length: 500 mm

Fill speed at 1.0 MPa gas supply

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

0,90

1,00

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1

Fill pressure (MPa)

Evacuation speed at different compressed air pressures

0,00

0,50

1,00

1,50

2,00

2,50

3,00

-900 -800 -700 -600 -500 -400 -300

Vacuum level (mbar)

0,35 MPa

0,4 MPa

0,55 MPa

0,6 MPa

End vacuum vs Compressed Air Pressure

-1000

-900

-800

-700

-600

-500

0,35 0,40 0,45 0,50 0,55 0,60 0,65 0,70

Compressed Air Supply Pressure (MPa)


5.4 General

Environment:Temperature: 10 – 40°C (50 – 100°F)

Humidity: 85% RH (non condensing)

Dimension/Weight:H x W x D 295 x 275 x 330 mm (12 x 11 x 13”)

Weight: 17.6 Kg (38.8 lb)

Disposal of product when taken out ofserviceAccording to EU legislation, this product must be recovered for separation

of materials and may not be disposed of as unsorted municipal waste.

If you wish you can return this Adixen Sensistor product to the manufacturer

for recovery.

The manufacturer has the right to refuse taking back products that are

inadequately packaged and thereby presents safety and/or health risks to

the staff.

The manufacturer will not reimburse you for the shipping cost.

Shipping address:

Adixen Sensistor AB

Westmansgatan 49

582 16 Linköping

Sweden

DS-

kons

ult

SWEDENAdixen Sensistor ABBox 76SE-581 02 LinköpingSwedenTel. 46 (0)13 35 59 00Fax. 46 (0)13 35 59 01

TAIWANAlcatel Vacuum Technology TaïwanNo. 169-3, Sec.1, Kang-Leh RdSong-Lin Village, Hsin-Feng 304Hsin-Chu CountyTaïwan - R.O.C.Tel. (886) 3 559 9230Fax.(886) 3559 9231

UNITED KINGDOMAlcatel Vacuum Technology UK Ltd8 Bain Square - Kirkton CampusLivingston - West LothianEH54 7DQ - ScotlandUnited KingdomTel. (44) 1 506 418 000Fax. (44) 1 506 418 002

USAAlcatel Vacuum Products67, Sharp StreetHingham - MA 02043USATel. (1) 781 331 4200Fax. (1) 781 331 4230

CHINAAlcatel Vacuum Technology, ShanghaiN°82 Lane 887 Zuchongzhi RoadZhangjiang High-Tech Park,Shanghai 201203ChinaTel. (86) 21 5027 0628Fax. (86) 21 3895 3815

FRANCE (Head office)Alcatel Vacuum Technology France98, avenue de Brogny - BP 206974009 Annecy cedexFranceTel. (33) 4 50 65 77 77Fax. (33) 4 50 65 77 89

GERMANYAlcatel Hochvakuumtechnik GmbHAm Kreuzeck 10 - Postfach 115197877 WertheimGermanyTel. (49) 9342 9610 0Fax. (49) 9342 9610 30

ITALYAlcatel Vacuum SystemsVia Trento, 3020059 Vimercate (Mi)ItalyTel. (39) 0396 86 38 55Fax. (39) 039 66 71 25

JAPANAlcatel-Lucent Japan Ltd.1-9-4 Kita Shin-YokohamaKohoku-kuYokohama, Kanagawa 223-0059JapanTel. (81) 3 6431 7130Fax. (81) 45 544 0049

KOREAAlcatel Vacuum Technology Korea447 Banwol-dong, Hawsung-si,445-330 Kyungki-do,South KoreaTel. (82) 031-206-6277Fax. (82) 031-204-6279

NETHERLANDSAlcatel Vacuum Technology BeneluxLandzichtweg 60NL 4105 DP CulemborgThe NetherlandsTel. (31) 345 478 400Fax. (31) 345 531 076

SINGAPOREAlcatel-Lucent Singapore49 Jalan Pemimpin#01-02 APS Industrial Building577203SingaporeTel. (65) 6254 0828Fax. (65) 6254 7018

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ILS500-Appendix - INFICONsensistor.com/wp-content/uploads/2015/05/TM-ILS500-200810.pdf · • Set the Pre-evacution Setpoint to half of the previous and repeat the test from step