OPERATING MANUAL ninp69e1-a (1410) Type no. ILS.210.
ninp69e1-a (1410) Content 1 General Information 8 1.1 1.2 1.3 About This Manual Introduction to the ILS500 F Disposal 8 8 9 2 Equipment and Storage 2.1 2.2 2.3 Supplied Equipment Required Equipment Storage 3 ILS500 F Description 3.1 3.2 3.3 3.4 3.5 3.6 Front View Rear View (Electrical) Configuring Ports and Interfaces (Electrical) Rear View (Pneumatical) Configuring Ports and Interfaces (Pneumatical) Labels 4 Setup 4.1 4.2 4.3 4.4 4.
9.2 9.3 Maintenance Functional Verification 63 69 10 Service 70 11 Technical Data 71 11.1 11.2 11.3 11.4 Electrical Specifications Pneumatic Specifications Other Data Interfaces and Connectors 12 Spare Parts and Accessories 84 13 Support from INFICON 85 13.1 13.
General Safety Precautions Definitions of Warning, Caution and Notice Warning Indicates procedures that must be strictly observed to prevent hazards to persons. Caution Indicates procedures that must strictly be observed to prevent damage to or destruction of the instrument. Notice Indicates special requirements the user must comply with.
Warning Pressurizing objects at too high pressures can lead to the object bursting. This in turn can result in serious injury or even death. Never pressurize objects that have not previously been burst-tested or have otherwise been approved for the test pressure you intend to use. Failure to observe the following precautions could result in damage to the equipment: Caution Caution Always switch power off before connecting or disconnecting any cable.
Safety ILS500 F Warning The ILS500 F must never be introduced to pressures higher than that approved for the object to be tested and never beyond the ILS500 F specification. Warning Be sure to have a pressure relief valve in case of accidental tracer gas pressure increase. Warning ninp69e1-a (1410) When dealing with high pressures, a blast protection is needed between the Test Ports and the Test Object.
1 General Information Please read this Operating Manual carefully before putting your Sensistor ILS500 F into service. When reading, please pay particular attention to the WARNINGS, CAUTIONS and NOTICES found throughout the text. 1.1 About This Manual The purpose of this manual is to: • Describe the working principles of the ILS500 F and its different parts • Show examples of different types of test stations • Teach the reader how to set up the ILS500 F for different test purposes 1.1.1 1.
1.2.2 Available Configurations Sensistor ILS500 F Sensistor ILS500 F Standard For common tracer gas leak detection High Pressure (HP) When a higher tracer gas pressure is needed. The actual configuration is shown on the ILS500 F display during start-up and in the menu when clicking Setup >> Info. Disposal According to EU legislation, this product must be recovered for separation of materials and may not be disposed of as unsorted municipal waste.
2 Equipment and Storage 2.1 Supplied Equipment Notice When receiving the equipment, check that it has not been damaged during transport.
2.2 Required Equipment 1 5 3 2 4 6 1 2 3 4 5 6 2.3 Tracer Gas Compressed Air Two-Step Gas Regulator Compressed Air Filter Exhaust Hose Emergency Stop Circuit (recommended) Storage For prolonged storage, factors such as temperature, humidity, saline atmosphere etc., may damage the detector elements. Please contact your local representative for more information.
3 ILS500 F Description ILS500 F is manually controlled using the START and STOP buttons and the menu system of the touch panel. The screen also shows the steps of the test sequence graphically and in plain text. 3.
3.2 Rear View (Electrical) 12 1 11 10 2 9 3 8 4 5 7 Rear View (Electrical) 1 2 3 4 5 6 7 8 9 10 11 12 Leak Detector (for connection of ISH2000 or T-Guard) Safety Interface Fuses Power Switch Power Input Probe Control Port (for connection of ISH2000) Control Output Tooling Interface Status Output Inputs 1 and 2 (optional) Ethernet Printer Port/RS232 For more information, see on page 71.
3.3 Configuring Ports and Interfaces (Electrical) Port/Interface Connect Leak Detector ISH2000 or T-Guard. Safety Interface Emergency Stop Circuit. Power Input Power Cable. Probe Control Port Pin-to-pin cable (for external mounting of ISH2000 Leak Detector). Control Output Optional External Valves. Tooling Interface External sensors for tooling control. Status Output Light Tower etc. Input 1 (optional) Analogue Input (not supported by std software).
3.4 Rear View (Pneumatical) 9 8 1 7 2 6 4 Rear View (Pneumatical) 1 2 3 4 5 6 7 8 9 Optional Port Test Port 2 Compressed Air Input Tooling Valve Outputs 1-4 Vacuum Gauge Vent Test Port 1 Tracer Gas Input Plugged Port Exhaust Notice 15 ILS500 F Description Do not remove the plug from the plugged port in pos. 8.
3.5 Port/Interface Port Thread Exhaust Barb Fitting: ID 25 mm (1 in.) Tracer Gas Input Test Port 1 Test Port 2 Compressed Air Input BSP 3/8" (NPT 3/8" adaptor included) BSP 3/8" (NPT 3/8" adaptor included) BSP 3/8" (NPT 3/8" adaptor included) BSP 3/8" (NPT 3/8" adaptor included) Tooling Valve Outputs 1-4 Hose Connectors: OD 4 mm (0.16 in.) Labels ninp69e1-a (1410) 3.
ninp69e1-a (1410) Pneumatical Label 17 ILS500 F Description Electrical Label
4 Setup Caution Check that you comply with all relevant legislation and safety standards before putting your ILS500 F into service. Notice Start-up time for the leak detectors can be up to 10 minutes, depending on the condition. ninp69e1-a (1410) 4.1 Placement of the ILS500 F Place the ILS500 F on a flat surface, as close as possible to the test fixture and ventilation system. Some free space must be provided around the ILS500 F to enable maintenance and service access. ≥350 mm (14 in.
Notice The front feet under the ILS500 F can be flipped out to raise the front for a better viewing angle. 4.2 Electrical Connections 4.2.1 Setting Up an Emergency Stop Caution ninp69e1-a (1410) To short-circuit is not recommended and should only be made for preliminary testing before connecting compressed gases or test tooling with moving parts. You have the following two options to prepare the ILS500 F for start: • Connect the ILS500 F through an external emergency stop relay.
4.2.2 Connecting to Mains 1 4.2.3 Plug the Power Cable into the Power Inlet of the ILS500 F and into the nearest socket. Connecting Extra Features ninp69e1-a (1410) When using the ports for Options, Status, Tooling and Control, make sure to mount the connectors as shown below. Top pin is number 1 For more information about the connection ports, see on page 71.
4.3 Pneumatic Connections 4.3.1 Connecting Compressed Air Caution Make sure that compressed air is dry, well filtered and oil free. Recommended filter grade is 5 μm or finer. Inadequate filtering will result in increased maintenance. Caution Make sure to use adequate pressure and flow. For more information, see on page 72. Use the hose to connect the compressor and the ILS500 F. ninp69e1-a (1410) 1 4.3.
ninp69e1-a (1410) 1 Secure gas cylinder safely. 2 Open the cylinder valve briefly to blow out dirt that may have collected in the outlet. 3 Install the two stage gas regulator on cylinder. 4 Turn regulator fully counterclockwise for zero output pressure. 5 Connect a regular welding gas hose or similar between the Tracer Gas Port and the pressure regulator. Check that the hose is certified to withstand the maximum output pressure of the regulator.
4.3.3 Connecting Exhaust to Air Vent Min 2 m (6.5 ft.) Ø ≥100 mm (4 in.) Max 10 m (30 ft.) Ø ≥25 mm (1 in.) 3 2 1 Exhaust Recommendation ILS500 F Exhaust Hose Bleed Air • The exhaust gas must be directed out of the building. It is best placed on the roof of the building, far away from the fresh air intake of the test station. • It is recommend that a dedicated duct is installed. Install an electric duct fan and an optional wind extractor.
4.3.4 Connecting to Test Port 1 and 2 • Use both Test Ports if applicable. • Hose ID ≥8 mm (0.31 in.). • The hoses should be as short as possible. If the test object has 2 or more ports, connect to ports on opposite sides of object. Notice ninp69e1-a (1410) 4.3.5 The larger the test object, the more important to follow the recommendations above. Connecting Tooling Warning Be aware that the faster the connection is made, the higher the risk for injury.
4.4 Connect External Leak Detector Notice When external leak detector is connected, some settings must be updated. These settings are made in the Hardware Setup menu. Start-up time for the leak detectors can be up to 10 minutes, depending on the condition. Connect External ISH2000 External ISH2000 is connected to the Probe Control port and Leak Detector port. For more information about the connections and cables, see on page 81. Connect External T-Guard 4.
1 4 2 3 Fresh Air Curtain Recommendation ninp69e1-a (1410) 1 2 3 4 Fan Local Air Jet Test Object Filter • Try to create a laminar flow over the test area. • Curtain should cover the entire test area (test hood or sample point) and extend at least 0.5 m outside the area. • Air speed in curtain should be rather low, typically 0.1 m/s. • Additional small fan(s) can be set up within the curtain for directional purging of test chamber etc.
5 Menu System 5.1 ILS500 F Display 1 -0+ -0,70 5,00 bar 2 Ready for Start ninp69e1-a (1410) 3 1 2 3 5.1.1 Status Bar Main Display Navigation Button Bar (varies depending on menu) Menu Buttons Use the menu buttons for quick navigation.
5.1.2 Navigation and Other Buttons Go Back 5.1.3 Escape (changes will not be saved) ESC Previous Page (changes will be saved) Next Page Activated Unactivated Selected Deselected Save (only shown if usb is connected) Load Open switch Closed switch Entering Numbers and Text 1 Click on the value. A numeric or alphanumeric on-screen keyboard will open. 2 Enter the desired digits or characters. 3 Click on the enter symbol to store the new value.
5.2 Passwords To access the menus, use default password "1234" for "Service". The password can be changed under Settings / Advance Settings / Passwords. Passwords Calibrate Log In Select Recipe Log Out Setup excl. Tooling Adv. Setup excl. Service Setup User ninp69e1-a (1410) Notice 5.2.1 Service Menu Remember to change the passwords of all menus you want to protect. Anyone using this manual can access the system if you keep the default password.
5.3 Menu Overview For information about parameter factory default settings, see on page 88. Notice If the instrument is equipped with a Leak Detector ISH2000, some settings are blocked. These settings are made via the ILS500 F operator panel.
Settings ninp69e1-a (1410) Hardware Setup Hardware setup. Test Settings For more information see chapter 7on page 38.
Advanced Settings Advanced Settings Timers Service Menu Pressures Passwords Options IP-settings ISH2000 Advanced settings to fine tune the fill cycles and settings for service staff. For more information, see chapter 10, “Service” Recipes For more information, see chapter 9, “Maintenance Instructions”.
Statistics Statistics Total: Accepted: Rejected: Evacuation: Vacuum Decay: Blockage: Gas Fill: Pressure Decay: Gas Test: 0 0 0 0 0 0 0 0 0 Print Reset Press 3 sec Information about test statistics and number cycles events during a test period. For more information see on page 35. ninp69e1-a (1410) Region Regions settings. Language Language English Swedish Japanese Italian German Language settings.
Info Info Type: ILS500 F Serial number: 0 CPU software v 3.00.08 Display version: 3.00.09 Backup Battery Level (3,0 V) Brightness display ninp69e1-a (1410) Instrument information, software versions, battery status and display light settings.
6 Using the ILS500 F Warning Ensure that the tracer gas supply pressure (feeding the ILS500 F tracer gas inlet) is set up properly. Caution To abort a test sequence and reset to standby, press STOP for 3 s. ninp69e1-a (1410) Notice 6.1 The following description is an example for illustration only. The design of the text fixture, the use of probe(s) and tooling functions etc. should be adapted to suit your particular application.
Step Comment 5 Tracer Gas Filling Tracer gas filling before gas test. 6 Blockage Test • Reveals internal blockages in tested object. • Ensures that connection lines and test fixture are correctly connected. The test object is filled through Test Port 1 while the pressure is recorded in Test Port 2. Practical for testing e.g. capillaries etc. 7 Gross Leak Test 3-Gas Pressure Decay Test Performed in parallel with tracer gas test.
6.2.2 6.2.3 Place the Test Object 1 Place the test object in the Test Chamber or connect it to one, two or more connection ports. 2 Connect any extra equipment needed. Perform Tracer Gas Filling Caution If ISH2000 is put into operation with ILS500 F the sensor withstands temporary exposure to hydrogen concentration up to 100%. Avoid long exposures to high concentrations. Tracer Gas Filling Press Start on the ILS500 F. 2 Perform a tracer gas leak test.
7 Recipes A recipe is a collection of settings suited for a particular test setup. This is used to have different settings for different test objects. 7.1 Recipe Overview Click Settings >> Recipes to enter the three Recipe Setup menus.
Connect with Recipe Use from list Keep Tooling in Test Step Keep Pressure in Test Step Import from USB Export to USB 7.2 Create a Recipe 7.2.1 New Recipe 7.2.2 39 Deletes the chosen recipe. A new window will open. Connects two recipes to form one test cycle. Write the name of the recipe to be included, or choose one from the list in Use from list. Shows all saved recipes. By clicking the blue button the recipe displayed is added to Connect with recipe.
7.3 Test Settings 1 Click Settings >> Test Settings to enter the two Test Settings menus. Test Settings ON Setup ON Setup Tooling Connection Pre Evacuation Gross Leak Test Tracer Gas Filling Test Settings Blockage Test Tracer Gas Test Gas Evacuation ninp69e1-a (1410) Tooling Disconnection 2 Set which steps to include in the test sequence by selecting the ON boxes. 3 Click Setup to the right of each selected step to enter the Setup menus. Notice 7.3.
Stand-By STAND-BY Tooling Outputs ON 1 Go to next step with 2 3 4 Start Button and Tooling Inputs Delay 0.0 1 Click on the Tooling Outputs to be activated in stand-by (between tests). 2 Choose how to move on to the next step. - Set action in list. - Select Tooling Inputs. 3 Set desired delay time. Connection Step 1 Tooling Outputs ON ON 1 2 3 4 Go to next step with Auto and Tooling Inputs Info 41 Recipes Delay 0.0 1 Select the ON check box to activate the step.
Test Step Test Step Tooling Outputs ON Condition for starting test 1 2 3 4 and Tooling Inputs Info 1 7.3.2 Delay 0.0 See Connection Step 1 - 3 above and follow the instructions. Pre Evacuation ninp69e1-a (1410) Pre Evacuation Pre Evacuation Setpoint -0.70 bar Extended Pre Evacuation 0,0 s Pre Evacuation Setpoint Extended Pre Evacuation A value of -0.70 bar (-0.07 MPa, -10 psi) is adequate for most applications. This creates 70% vacuum. To ensure a complete filling.
7.3.3 Gross Leak Tests Gross Leak Test Evacuation Timeout 10.0 s Vacuum Decay Test - before gas test Evacuation Timeout Vacuum Decay Test Pressure Decay Test Object will be rejected if Pre Evacuation Setpoint is not attained within time set. If to be included in the test sequence, select the box and click the blue button to enter Pressure Decay Test setup menu (see below).
Pressure Decay Test Gas Pressure Decay Test Pressure Stabilisation Time 5.0 s Pressure Decay Test Time 5.0 s Pressure Decay Limit Pressure Stabilisation Time Pressure Decay Test Time Pressure Decay Limit ninp69e1-a (1410) 7.3.4 0.10 bar Delay time before Pressure Decay test begins. Time during which pressure drop is recorded. Allowed pressure drop during test time.
External Fill Regulation Pressure Unit 7.3.5 If selected, this is the setpoint of fill pressure alarm. Internal pressure regulation is disengaged and pressure will be that of the gas supply line. ILS500 F checks that fill pressure is above Pressure Setpoint before proceeding to gas test step. Select desired unit. Blockage Test Notice This test can only be performed if both test ports are used and connected on either side of the possible blockage.
7.3.6 Gas Evacuation Gas Evacuation Gas Evacuation Setpoint -0,30 bar Extended Gas Evacuation 0,0 s Gas Evacuation Setpoint Extended Gas Evacuation Tooling Disconnection ninp69e1-a (1410) 7.3.7 Set desired level of Gas Evacuation. -30 kPa (-0.3 bar, -4.4 psi) creates 30% vacuum, which is adequate for most applications. Extends time for gas evacuation, after Gas Evacuation Setpoint has been reached.
This section is a guide for optimizing step 2, 3 and 5. 7.5 Optimizing the Pre Evacuation Step Notice The fastest way to fill a pipe like object is to use push-through filling. That does not require pre evacuation. Begin to determine how deep the pre evacuation needs to be, or if it can be skipped altogether. To do this it is important to fully understand the role of pre evacuation. When the test object is connected it holds one atmosphere of ambient air.
A = Fill Pressure B = 1 atm C = Tracer Gas Fill Factor D = Evacuation Pressure A +--D ----- = C A+B 0.05 -------+---0.07 ---- = 0.8 0.05 + 0.1 The average tracer gas concentration in this example will be 0.8 (80%). When using a tracer gas mix of 5% the result will be: 0.8 x 5% = 4% This is almost twice of that achieved with no pre evacuation. ninp69e1-a (1410) 7.5.2 Example - Calculate Tracer Gas Filling The air left in the object can not always be expected to mix evenly with the injected tracer gas.
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: ---B ---- = E A+B ----0.03 --------- = 0.056 0.5 + 0.03 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. 7.
Troubleshooting 8.1 Fault Symptoms ninp69e1-a (1410) 8 8.2 Fault Symptom Fault Measures Evacuation Failed Failed to reach vacuum within the specified time. Large leak on Test Object or connections. Check the compressed air supply. Gas Fill Failed Failed to fill to the right pressure within the specified time. Large leak on Test Object or connections. Check the incoming gas pressure. Gas Refill Failed Failed to refill the object. Large leak on Test Object or connections.
The 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 F system. Notice Run through the whole sequence to interpret the results correctly. You will need the reference table at the end of this section to help you interpret the test results correctly. Keep this manual at hand when performing the test.
Evacuation Valve Hardware Test Evacuation Valve No Internal Leakage CONTINUE Vacuum: -0.03 bar Pressure: 0.00 bar STOP Evacuation valve is checked for internal leakage. Possible results: • No Internal Leakage • Internal Leakage Internal leakage can result in: ninp69e1-a (1410) • False vacuum decay rejects • Increased tracer gas consumption Venturi Pump Hardware Test Venturi Pump Max Vacuum OK Vacuum: -0.88 bar Pressure: 0.00 bar CONTINUE STOP Checking max vacuum of Venturi pump.
Manifold Tightness (gross) Hardware Test Manifold Tightness No Leakage from Outside Vacuum: -0.82 bar Pressure: 0.00 bar CONTINUE STOP 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: Minor external leakage will be found later during the gas test step. Vacuum Sensor Valve Hardware Test Vacuum Sensor Valve Valve works! CONTINUE Vacuum: 0.00 bar Pressure: 0.
Tracer Gas Fill Valve Hardware Test Tracer Gas Fill Valve No Internal Leakage CONTINUE Vacuum: 0.00 bar Pressure: 0.00 bar STOP The step tests the gas fill valve for internal leakage by registering pressure rise behind the valve.
Tracer Gas Fill Valve Hardware Test Tracer Gas Fill Valve Valve works! CONTINUE Vacuum: 0.00 bar Pressure: 0.50 bar STOP This 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: External Gas Leaks Hardware Test Check for Leaks with Hand Probe CONTINUE Vacuum: 0.00 bar Pressure: 0.
Manifold Tightness (gross) Hardware Test Manifold Tightness Internal Leakage Vacuum: 0.00 bar Pressure: 0.46 bar CONTINUE STOP 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.
Indicator Lamps Hardware Test Lamp in Start Button OK? CONTINUE Vacuum: 0.00 bar Pressure: 0.00 bar STOP Hardware Test Green Lamp (Top Left) OK? 0.00 bar Pressure: 0.00 bar STOP Hardware Test Red Lamp (Bottom Left) OK? CONTINUE Vacuum: 0.00 bar Pressure: 0.00 bar STOP This is a “manual” test. The ILS500 F lights up one lamp at the time. Simply check that the right lamp comes on. 1 57 Troubleshooting Check function of each lamp by pressing “Continue”.
START and STOP buttons Hardware Test Press Start Button (Top Right) OK? Vacuum: 0.00 bar Pressure: 0.00 bar STOP Hardware Test Press Stop Button (Bottom Right) OK? Vacuum: 0.00 bar Pressure: 0.00 bar ninp69e1-a (1410) STOP This 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.
8.2.1 Hardware Error Messages Error Message Reason for Error Corrective Action* Hardware Error Vacuum Sensor Error No power to vacuum sensor. Check cable to sensor. Sensor not connected to AD. Check connection to AD. Damaged vacuum sensor. Send in for repair. Hardware Error Pressure Sensor Error No power to pressure sensor. Check cable to sensor. Sensor not connected to AD. Check connection to AD. Damaged pressure sensor. Replace sensor.
8.2.2 Interpretation of Hardware Test Results Use the table below, to correct errors detected by the hardware test routine. Tested Unit Tested Feature Reason for Error Action Evacuation Valve Internal leaks Dirty or worn valve seals. Replace clean evacuation valve. Venturi Pump Maximum vacuum Compressed air pressure too low or too high. Adjust compressed air pressure. Dirt inside Venturi. Remove and clean Venturi. Dirty or broken Venturi pilot valves. Replace two upper valves in pilot ramp.
Tested Unit Tested Feature Reason for Error Action Tracer Gas Fill Valve Internal leaks Dirty or worn valve seals. Replace or clean tracer gas fill valve. Leaking pilot valve. Replace fourth valve from bottom in pilot valve ramp. Function Dirty or broken pilot valve. Replace third valve from bottom in pilot ramp. Test port 2 valve broken. Tracer Gas Fill Valve Gas Valve Manifold Function Leaks to outside Replace valve. Dirty or broken pilot valve.
9 Maintenance Instructions There are three different parts that needs regular maintenance: • Venturi Pump Needs regular cleaning. • Gas Valves Needs regular cleaning and wears out. • Pilot Valves Maintenance free if incoming compressed air is dry and filtered to 5 μm. Changing Venturi Pump and all Gas Valves takes less than 15 minutes. 9.1 Maintenance Plan Part Interval Action Venturi Pump 3 months Perform a Hardware Test. Check Ultimate Vacuum. Clean venturi nozzles when necessary.
9.2 Maintenance 9.2.1 Tools and Safety Equipment When performing regular maintenance of the ILS500 F the following equipment is needed. Description Note Allen Keys (Hexagonal 3 and 4 mm) Torx Key (T25) Screwdriver (Philip 1 or Pozidrive 1 When performing tooling output test. Protective Ear Plugs When performing tooling output test. Interior View 1 2 ninp69e1-a (1410) 9.2.
5 6 7 8 9 10 Tracer Gas Fill Valve Test Port Valve 2 Vacuum Sensor Control Valve Pressure Sensor (HP model only) Vacuum Sensor Pressure Sensor ninp69e1-a (1410) Pilot Valve Ramp 9.2.
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 4 mm Allen key to remove the four screws holding the Venturi pump. 4 Remove the o-ring under the Venturi. Remove the hose from Venturi inlet. Push hose into connector and press orange ring down to release hose, then pull hose out. 5 65 Remove the hose fitting from the Venturi. Maintenance Instructions ninp69e1-a (1410) 9.2.
Install new Venturi or use compressed air jet and a cotton bud, pipe cleaner or small brush to clean the nozzles inside the Venturi. 7 Replace hose fitting on Venturi inlet. 8 Reconnect inlet hose. 9 Clean o-ring and install in groove on valve manifold. ninp69e1-a (1410) 6 10 Reinstall and tighten the four screws. 11 Put plastic washer inside Venturi outlet and reinstall barbed fitting. Tighten with spanner. 12 Reconnect the exhaust hose.
Replacing Gas Valves 1 Use a 3 mm Allen key to remove the four screws holding the valve to be changed. 2 Lift the old valve out and put the new valve in. Notice the correct orientation in the picture below. 3 Tighten the screws 2-3 mm (0.08-0.12 in.) at a time moving the key from screw to screw so that the valve doesn’t tilt much. 4 Tighten the screws and replace the cover. 5 Run through the hardware test again to test that the changed/removed valve(s) perform as required.
Replacing Pilot Valves 1 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. 2 Push down on the LEDs while pressing the screw down until you feel the locking mechanism “snap”. 3 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. 4 Push the screw in while inserting the new valve.
9.2.7 Replacing Sensors Caution Service of the sensors may only be carried out by service organizations authorized for this purpose by INFICON. 9.3 Functional Verification ninp69e1-a (1410) See Perform Hardware Test on page 50.
10 Service Caution In case of a dysfunctional Sensistor ILS500 F, please send the product for service at ninp69e1-a (1410) your most convenient service facility. Please visit www.inficon.com for addresses.
Technical Data 294 mm (11.6 in.) 11 275 mm (10.8 in.) 11.1 364 mm (14.3 in.) Electrical Specifications ninp69e1-a (1410) Electrical Supply Mains Voltage Single Phase 110-240VAC 50/60 Hz Current 1.0 A at 100 VAC 0.45 A at 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, 0.2 x 1.3 in.
Communication Ports 11.2 Data rate 1200-115200 baud Data bits 8 Stop bits 1 Parity None Flow control None Pneumatic Specifications Compressed Air Supply Pressure Std Model 0.35–0.7 MPa (3.4–6.9 bar) (50–100 psi) HP model 0.5–0.7 MPa (4.8–6.9 bar) (70–100 psi) Peak Consumption at 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 Supply Composition Pressure Inert non-condensing gas Std Model 0.005–1.0 MPa (0.05–10.0 bar) (0.
Pneumatic Valve bore* 7 mm (0.28 in.) *Capacity is given for 500 mm (20 in.) of ID 10 mm (0.4 in.) hose between ILS500 F and test volume. 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 0.6 MPa (87 psi) ninp69e1-a (1410) Tooling Output Valves Valve type Normally closed, 3/2 valve Qn 160 std l/min Cv 0.16 USGPM/psi Gas and Air Connection 11.
11.4 Interfaces and Connectors All interfaces signals except the serial. Communication interfaces are discrete 24 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 instrument specification. Caution Outputs are not relay types. Do not connect external drive source such as 24 V or 100/ 230 VAC. Printer Port/RS232 ninp69e1-a (1410) 11.4.
Printing of results The printer port prints the result of every test. In hand probe mode the result printed is “ACCEPT” or “REJECT” followed by date & time and recipe name (if used) and end Char New Line (0A, LF).<09> (Char Tab, 09) is used as a separator. For Example: "TEST_ACCE<09>2013-09-04 13:23:03<09>Factory Default<0A>" After an active probe test cycle the gas analysis value from the ISH2000 is printed. The printout can be “2.4E+00A<09>2013-09-04 13:23:03<09>Factory Default<0A>".
Commands 11.4.2 76 Command Action K<0A> Starts a calibration. If the function is busy, the ILS500 prints the time remaining for the ongoing calibration in seconds. For example, if two seconds remains the printout is as follows: WAIT 2 <0A> S<0A> Statistics (see table below) RS<0A> Reset statistics R<09> Factory Default <0A> loads a recipe. For example “R<09>Factory Default” loads the recipe Factory Default. When the recipe is loaded the recipe name is echoed back.
ninp69e1-a (1410) 11.4.3 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 Comment 1 +24 VDC SUPPLY 250 mA Option supply. 2 VIN1 IN -60 mA Voltage input:Digital 24 VDC or analogue 0-10 VDC. 3 IIN1 IN +/-30 mA Current input: 0-20 mA. 4 COM1 IN -250 mA Signal common (GND). 5 COM/SHLD GND +/-30 mA Shield.
Status Output Connector: 6 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal included. Purpose: Test Status Outputs. Sourcing 24 VDC transistor outputs. Pin Signal Type Load Comment 1 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. Notice 11.4.
Pin Signal Type Load Comment 1 +24 VDC SUPPLY 300 mA Tooling switch supply (e.g. proximity switch). 2 TS1 IN -7 mA Tooling switch 1. 3 TS2 IN -7 mA Tooling switch 2. 4 TS3 IN -7 mA Tooling switch 3. 5 TS4 IN -7 mA Tooling switch 4. 6 MARKER* OUT 0.5 A Marker output. Selectable mark on REJECT or ACCEPT. 7 COM GND -1.0 A Common GND. 8 COM GND -1.0 A Common GND. ninp69e1-a (1410) * 11.4.
11.4.8 Signal Type Load Comment 4 EVAC1 OUT 0.5 A Venturi valve output. 5 EVAC2 OUT 0.5 A Evacuation valve output. 6 GASFILL OUT 0.5 A Fill valve output. 7 OPTOUT OUT 0.5 A 8 COM GND -1.0 A Common GND for outputs. Probe Control Port Connector: 25 pin female D-sub Purpose: For external connection of ISH2000. ninp69e1-a (1410) 11.4.7 Pin Power Input Specification 11.4.9 AC mains voltage 110-240 V 50/60Hz. AC mains current Typically 1 A (2 A pulse at power on).
Purpose: Emergency stop interface. Pin Signal Type Load 1 +24 VDC SUPPLY 2.5 A 2 AUX1 - +/-1-5 A* Terminal 1 of safe relay contacts for auxiliary external use. 3 AUX2 - +/-1-5 A* Terminal 2 of safe relay contacts for auxiliary 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 24 VDC supply from EXTERNAL emergency stop circuitry. 6 COM GND 1.0 A Common GND.
Pin Signal 4 Not Used 5 GND 6 Not Used 7 Not Used 8 Not Used 9 Not Used Connector: USB Purpose: Used for import and export of recipes. To access the USB port, remove the cover. See Removing the Cover on page 64. USB is connected USB Memory connected Import from USB Export to USB An icon for USB is shown when installing the USB flash drive. 82 Technical Data ninp69e1-a (1410) 11.4.
Import Recipe from USB Importing database table Recipe1 from csv-file... USB Memory connected Import from USB Export to USB When importing recipes all recipes are imported from a file named Recipe1.csv. Export Recipe from USB Exporting database table Recipe1 to csv-file... USB Memory connected ninp69e1-a (1410) Import from USB Export to USB When exporting recipes all recipes are exported to a file named Recipe1.csv.
12 Spare Parts and Accessories 1 Pos. 1 ninp69e1-a (1410) 2 2 Part Type Power Cables EU 591-146 UK 591-147 US 591-853 Standard Model 590-680 HP Model 590-685 No-Stop Maintenance Kit Description Part no. Venturi 1 pcs Fill valve 4pcs Pilot valve 1 pcs Fuse 2 pcs Necessary tools For a complete list of all spare parts and accessories, please contact: support.sweden@inficon.
13 Support from INFICON 13.1 How to Contact INFICON For Sales and Customer Service, contact your nearest INFICON Service Center. The address can be found on the website: www.inficon.
14 Declaration of Conformity Declaration of CE Conformity Manufacturer INFICON AB Westmansgatan 49 SE-582 16 Linköping Sweden Object of the declaration (marketing identification): Sensistor ILS500, Leak Detection System, … Sensistor ILS500 HP, Leak Detection System, high pressure model… Sensistor ILS500 F, Leak Detection Filler, … Sensistor ILS500 FHP, Leak Detection Filler, high pressure model… Type no for construction identification: ILS.210.
15 Declaration by the Manufacturer DECLARATION BY THE MANUFACTURER (Directive 2006/42/EC, Art. 4.
Appendix A: Parameter Index ninp69e1-a (1410) Parameter Range Factory Default Block Test Pressure 0.3 bar Blockage Test Time 2s Blockage Test OFF Choose at startup OFF Demo Mode OFF End of Test Signal 1s Evacuation Timeout 10.0 s Extended Gas Evacuation 0s Extended Gas Fill 0s Extended Pre Evacuation 0s External Acknowledge OFF External Gas Regulation OFF External Start/Stop OFF Fill Pulse Open 20 ms Fill Pulse Closed 200 ms Fill Setpoint 0.3 bar Fill Signal Filter 0.
Parameter Range Factory Default 0s Refill Hysteresis 0.2 bar Refill Timeout 5s Status - pin 5 End of Test Test Timeout 10 min Tooling Connection OFF Tooling Disconnection OFF Two-Hand Control OFF Use Recipes OFF Vac. Stabilisation Time 5s Vacuum Decay Limit 0.
INFICON AB Westmansgatan 49, S-58216 Linköping, Sweden UNITED STATES TAIWAN JAPAN KOREA SINGAPORE GERMANY FRANCE Vi sit o ur web site fo r con ta ct info rma tion an d sa le s o f fi ces wo rld wid e. Document: ninp69e1-a (1410) UNITED KINGDOM w w w. i n fi c o n .
