CS Instruments LD 510 User manual

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LD 500_SHORT BAL_V2.06 EN Page 1of 32
Short Instruction Manual
Ultracam, LD 510 / LD500
SALES OFFICE SOUTH
Zindelsteiner Straße 15
D-78052 VS-Tannheim
DEUTSCHLAND
Tel.: [phone]
Fax: [phone]
[email protected]
www.cs-instruments.de
SALES OFFICE NORD
Gewerbehof 14
D-24955 Harrislee
Deutschland
Tel.: [phone]
Fax: [phone]

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LD 500_SHORT BAL_V2.06 EN Page 2of 32
1. Safety instructions
About this document
•Read this document carefully and familiarise yourself with the product before
use. Pay particular attention to the safety instructions and warnings to prevent
personal injury and product damage.
•Keep this document close at hand so you can refer to it if necessary.
•Pass the document on to future users of the product.
Ensuring safety
•Only use the product in an appropriate manner and for its intended purpose and
within the parameters specified in the technical data. Do not use force.
•Never use the device to measure on or in the vicinity of live parts!
oMaintain an adequate safety distance when performing leak detection
operations on electrical systems to avoid dangerous electric shocks!
•Avoid any direct contact with hot or rotating parts.
•Always switch on the device first before putting on the headset! At high signal
levels (headset bar chart in the red zone), the volume level may also be similarly
high.
•Never point the integrated laser directly at the eyes! Strictly avoid directly ex-
posing the eyes of humans and animals!
•Laser module: corresponds to DIN EN 60825-1: 2015-07 Class 2 (< 1 mW)
•Observe the prescribed storage and operating temperatures.
•Improper handling or use of force leads to loss of warranty.
•Any form of tampering with the device that does not conform with its desig-
nated use and is not described in the procedures will forfeit any warranty and
exclude liability.
•The device is exclusively designed for the intended use as described here.
Protecting the environment
•Dispose of defective/empty batteries in accordance with the relevant legal provi-
sions.
•At the end of its useful life, dispose of the product at the separate collection
point specified for electrical and electronic equipment (observe local regulations)
or return the manufacturer for disposal.
CS Instruments GmbH & Co. KG offers no guarantee in relation to the suitability for any other purpose
and accepts no liability for any printing errors in this operation manual. The same applies to conse-
quential damage in connection with the delivery, capacity or use of this device.

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The following accumulator is included in this electric device
Battery type
chemical system
accumulator
LiIon 2S1P
Information for safe removal of the battery
•Warning: Make sure that the battery is completely empty.
•Removal of the battery
Removing the battery cover Disconnecting the connerctor Carefully pull out the battery
•Carefully remove the accumulator.
•The accumulator and the device can now be disposed of separately.

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LD 500_SHORT BAL_V2.06 EN Page 4of 32
2. Intended use
The LD 500 is a leak detector for quick and reliable leak detection in/on compressed air systems.
The LD 500 leak detector evaluates the ultrasonic waves generated by the leakage based on distance
and pressure.
It is solely designed and constructed for the intended use described here and may only be used for this
purpose.
The user must verify that the device is suitable for the intended use. The technical data listed in this
datasheet are binding.
Improper handling or operation outside the technical specifications is not permitted. Claims of any
kind for damages arising from improper use are excluded.
Disclaimer:
The parameters that determine the “Estimated Leak Flow” value are pressure, distance, and the ul-
trasound level in dB. Especially the distance is critical and must be parametrized as accurately as pos-
sible. Also, ambient ultrasound in the frequency range of 40 kHz can affect the measurement accu-
racy, including ultrasound of other leaks nearby and leak reflections. Additionally, if the leak’s ultra-
sound is sealed, this influences the measurement and the measuring angle relative to the air stream
of the leak. Thus, it is impossible to guarantee that the measures taken during the assessment period
fully represent your current leakage rate. The “estimated Leak Flow” should help you prioritize com-
pressed air leaks since repairing leaks requires spare parts and labor costs.
3. Technical data LD 500
Dimensions hand-held
housing
263 x 96 x 280 mm (with preamp module and acoustic trum-
pet)
Weight
0.55 kg with preamp module and acoustic trumpet,
complete set in case approx. 3.0 kg
Operating frequency
40 kHz (+/-2 kHz)
Power supply
Internal 7.2 V lithium-ion battery
Operating time
> 9 h (continuous operation) / UltraCam +LD500 >6h
Charging time
max.4 h
Charging
ext. battery charger (included in scope of delivery)
Laser
Wavelength 645 –660 nm, output power < 1 mW
(laser class 2)
Connections
3.5 mm stereo jack for headset,
Power supply socket for connecting an external charger
USB connection
Colour screen
3.5" touch panel TFT transmissive
Interface
USB for data export/import, SW update, etc.
Data logger
8 GB memory card storage (micro SD class 4)
Area of use
Indoor
Operating temperature
-5 °C to +40 °C
Storage temperature
-20 °C to +50 °C

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Altitude
Up to 4000m above sea level
Max. Humidity
<95% rH, without condensation
Permissible degree of
contamination
2
Protection class
IP20
Available attachments
UltraCam, Acoustic Trumpet, Straightening Tube,
Gooseneck, Parabolic Mirror
UltraCam
30 Digital Microphones, 5 LED’s, 1 Light sensor
4. The LD 500
5. Preparing the device
The device must be configured before starting the leakage scan. The user can access the menu by
clicking the "Home" button.
Setting the language
Home →Settings →Device Settings →Set Language →
English
Acoustic trumpet
Camera
USB connection
Plug-in connection for
power supply (battery
charger socket)
Save button
Volume (+/-)
On/Off button
Foil keypad (4 buttons)
Unlock button for preamp
module
Preamp module
3.5" TFT colour display
with touch panel

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Checking the current firmware and firmware updates
Regularly check the manufacturer homepage for a new firmware version. We are continuously devel-
oping the product so you can use the device with the most up-to-date software version including all
available functions.
1. Check the firmware status on the homepage and download it from the following URL:
https://www.cs-instruments.com/de/downloads/software/firmware-leckage-suchgeraete
2. Check firmware of the LD500
Path: Home→Settings →About LD500 →Software Version
3. Unpack the ZIP file
4. Copy the DEV0004 folder to a USB stick
The folder structure must be as follows: (D:)\DEV0004\Update
5. Connect the USB stick to the LD 500 and connect the power supply
6. Perform system update with:
Path: Home →Settings →Device Settings →System
Update
7. Click on the "Check USB Stick for new Software updates" box
8. Available update is shown
9. Execute the "Update selections" function to perform the update
10. Restart the device and update the channels
The device is now up-to-date

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Configuration of LD 500
Home →Configuration 
In the configuration settings, the unit system can be se-
lected and the required parameters entered to calculate
the leakage costs per year.
➔Select ISO or US unit system
➔To define the costs, call up the text field "Costs/1000
Nm³"
➔Enter working hours per year (compressed air system
is operated actively)
There are 2 variants available to define the costs:
•Standard mode: Cost per 1,000 volume units. The
costs and the currency can be entered directly. Standard
value: €19 / 1,000 m³ or €0.58 / 1,000 cf.
•Expert mode: The electricity costs/kWh as well as the
specific output of the system can be defined here in de-
tail.
The specific output refers to the efficiency of the com-
pressor system. For example, how much electrical en-
ergy (kWh) is required to produce 1 cubic metre of com-
pressed air (m³). Three predefined system values are
created for this, as well as a user-defined input field for
individual entry.
The cost type can also be set in expert mode. The "Electricity costs [70%]" are calculated by the "con-
sumed electrical energy" of the compressed air system, which typically represents 70% of the total
costs. For "Total costs [100%]", the investment and maintenance costs are taken into account, which
are in addition to the electricity costs over the entire service life of the compressors.

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5.3.1 Setting the LD 500 parameters
Entering the parameters is necessary for the calculation of the leak flow rate.
The following settings must be made.
➔Sensor type
(manual selection only necessary for sensor types with-
out autotool recognition)
Change the sensor type according to the application and
ambient conditions, see chapter 7.4.
If the auto sensor detection is active, the free selection of
the sensor type is blocked. Prerequisite here is an intelli-
gent mainboard of the LD 500 and an intelligent sensor
(e.g. Acoustic trumpet).
Automatic sensor detection, see chapter 7.4.
Home →Configuration →Parameter Pressure and
distance
Values for the pressure and distance can be freely se-
lected in the two fields with the white coloured back-
ground, provided these are within the valid selection
range.
The pressure can be set variably between 1 –10 bar.
Different distances from the LD 500 to the leakage are defined for the different sensor types to calcu-
late valid leakage loss and costs per year. These distances must be adhered to as accurately as possible,
see chapter 6.4.
Note on the distance setting for the quantification function:
The distances to be maintained for quantifying the leakage always refer to the front of the respective
attachment measured to the leakage.

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5.3.2 Setting the LD 500 measurement place
Home →Configuration →Measurement place
The measurement place is stored for each leakage in its
journal data (xml file). This information can be viewed
later in the software leakage report.
The company and building can be recorded upon entering
the building, the place identifies the exact position of the
leakage so it can be easily found again when doing repairs.
➔LeakTag: will automatically increase by one (1) after
storing a measurement.
5.3.3 Importing data from the Leak Reporter software
With the CS Leak Reporter or another LD 500 you can export the database. This can contain the follo-
wing information:
Measuring point:
•Companies
•Buildings
•Places
Error description
•Leckage element
•Action
•Spare part
Before importing into LD 500, you can choose which areas of the database you want to update in LD
500.
Please note that the database (XML file) must be saved in the following directory.
„(D:)\DEV0004\Database\Customers > (XML Database)”
After importing the XML database, you can select which areas of the database will be overwritten or
deleted.
-Companies
-Leckage element
-Spare part
-Action
If you select "Delete unselected elements", the objects of the unselected areas will be deleted.

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LD 500_SHORT BAL_V2.06 EN Page 10 of 32
6. Leakage detection
This chapter describes the best use of the device in practice.
Leakage detection procedure
The following procedure should be performed in the company on a periodic basis to consistently keep
the leakage rate to a minimum. The aim should be a sustainable leakage rate of 5 to 10 % as one-time
detection and elimination does not permanently reduce the leakage rate and new leakages will occur
again afterwards.
Tip:
To determine the ideal time, the use of a volume flow sensor in the main pipe behind the tank is rec-
ommended. At least one week (Monday to Sunday) is recommended as the measurement period. If
an LD510 has been purchased, the flow sensor can be connected to it. During production stops, the
volume flow profile shows the leakage rate. If the threshold value is exceeded, leak detection can be
contracted.
The volume flow measurement can also be used to validate the result of the leak detection and elimi-
nation, as this must reduce the volume flow during stoppages.
Possible causes of leakage:
Generally, leakages can be found at the connection elements in the compressed air system.
•Leaking couplings and hose clamps
•Leaking screw and flange compressors
•Porous/defective hoses
•Porous/defective seals of tools and machines
•Faulty steam traps
•Leaking or incorrectly installed dryer, filter and maintenance units
•etc.
5. Leakage remedial action
2. Leakage quantification
3. Leakage documentation
4. Leakage report creation
1. Leakage detection

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Surface leakage detection with the LD 500
After start-up, the device shows the leakage detection view. The following figure lists the various
functions and displays.
Selection of accessories
To simplify leakage detection for the user, several attachments are available for different measuring
conditions.
6.4.1 UltraCam
Note on use:
•The openings of the digital microphones
must not be cleaned with a compressed air
gun.
•The openings of the digital microphones
must not be cleaned with liquids.
•The UltraCam must generally be protec-
ted from dust and liquids.
•The UltraCam should be transported and
stored in its clean case if possible.
Display block for:
Signal level in dB | Leakage
size | Costs /year
Laser "On"/"Off"
Bar graph display of signal
level
Laser "On" icon
Date/time and
battery level indicator
(change indicator)
Settings
High sensitivity
Home menu
Storing the measurement
Leak-Tag number
Sensitivity level button
Camera image

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The new UltraCam has a digital data interface to the LD 500 LD 510. That the LD 500 / LD 510
can communicate with the UltraCam, the following prerequisites must be met:
- The main board must be "HW-Stand 2.0" to enable communication between the main body
of the LD 500 and the tool. This main board has been installed since approx. August 2020.
- The firmware of the LD 500 / 510 must be at least V5.0, that the interface of the UltraCam
is called correctly and that the ultrasonic cards are received.
Under Settings > About LD 500 / LD 510 the device shows the data.
In the example the hardware version is 1.00 and therefore not intelligent. →In this case,
CS-Instruments can replace the mainboard.
If both requirements are met, the LD 500 automatically recognizes that a tool with automa-
tic distance measurement is connected.
Functionality
The LD 500 / 510 leak detector measures ultrasound generated by compressed air, steam,
gas and vacuum leaks, as well as partial discharge on insulators, transformers, switchgear,
high-voltage lines (corona effect).
Acoustic leak detection:
The ultrasound, which is inaudible to the human ear, is measured by the UltraCam and
mixed into the audible sound frequency range in the LD 500/ 510, allowing you to precisely
locate the ultrasonic source (the compressed air leak) via the acoustic signal on the headset
5.00

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LD 500_SHORT BAL_V2.06 EN Page 13 of 32
and the camera image, even in noisy environments.
Optical leak detection:
The UltraCam uses 30 digital mems, a camera, an FPGA and a processor to calculate the ult-
rasound map. The algorithm used is called beamforming and is based on the delay and sum
function. Each pixel of the ultrasound map is quickly calculated and transmitted to the
LD500.
The threshold (slider on the right edge) defines the limit from which the pi-xels in the image
shown on the screen are colored, based on the measured level in the ultrasound map.
The selected color tone of the coloring depends directly on the intensity of the ultrasound
for the corresponding pixel and is controlled by the LD 500 accordingly.
•No coloring = maximum level <= Threshold
•Blue = little ultrasound
•Green →Yellow →Orange →Red
•White = maximum ultrasound
Threshold
Environment
Meaning
0 %
Find smallest leaks in
environments without
strong ultrasonic sources
If there is no domi-
nant source, a ne-
bula will be shown
on the screen.

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LD 500_SHORT BAL_V2.06 EN Page 14 of 32
10 %
Recommended value!
If there is no ult-
rasound source, the
screen will not be
colored
30 –70%
If strong ultrasonic
sources are present –
so the sensitivity can
be reduced that the
colored area beco-
mes none.
If the threshold has been set very high and is significantly above the existing level in the ult-
rasound card, so that the image is not colored on the screen, the slider for setting the
threshold flashes red and a reduction is recommended.
How to find leaks?
1. Start from a distance and point the device in a direction where pressurized air lines
are located.
2. Find a hotspot (headphones & screen).
3. Come closer when you hear something! This is because the sensitivity of hearing is
higher than imaging.
4. Once the measured ultrasound of the 30 digital mems is sufficiently high, the LD 500
/ 510 will display the source on the screen
5. Save the leakage and document how to fix the leakage and where it is located.

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Recommended distance for ultrasound imaging
•0.3 - 5 meters (low ultrasound level environments)
•0.3 - 2 meters (challenging environments)
•0.1 meter for small leaks
Loss and cost - first indicated
•Leak is in the center of the circle of leak detection
•Click on the left side of the screen
5 LED's and an ambient light sensor
To improve the quality of the captured image, an ambient light sensor measures the amount
of light. If there is too little light, the LEDs provide better illumination.
Intelligent illumination off:
Intelligent illumination: automatic

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LD 500_SHORT BAL_V2.06 EN Page 16 of 32
Intelligent illumination: manual
6.4.2 Automatic Distance measurement
The integrated distance measurement module is available with the UltraCam and optional with the
Acoustic Trumpet.
The following requirements must be met to use the functionalities:
•The Main Board must be "intelligent" to enable the communication between the main body
of the LD 500 and the tool.
•The Firmware of the LD 500 must be at least V3.02
If these requirements are met, the LD 500 will automatically recognize that a tool with automatic dis-
tance measurement is connected.
Description of Functionality:
1. The laser needs to be started to activate the distance measurement as it is done with all
other tools.
2. The LD 500 will then show the measured distance on the display. In this case, it is 3.14 me-
ters or 124".
3. To use the measured distance for the cost quantification, "Distance by Laser" must be acti-
vated under "Parameters.
Note: Before "Distance by Laser" can be activated, the laser must be turned on. Otherwise, the icon
will blink in yellow and red.

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Note: For the trumpet, the valid distance range is 1 –6 meters or 40" –236".
4. The LD 500 will actualize the distance automatically now. The actual measured distance is
shown in the grey bar “Dist:”. The used distance for the cost quantification is shown in the
small bar below next to the pressure's left side.
State
Actual distance
measurement
Used distance pa-
rameter internally:
The certainty that
distance is measured
correctly
Best case
White
Green
High
Check plausibility of
measurement
Yellow
Yellow
Medium
Move into the valid dis-
tance range
White
Yellow & showing 1
m or 6 meters
High, but:
Out of range:
Distance < 1 m
Distance > 6 m
Target on another close
surface to the leak until
"best case" is reached
and the measurement is
robust
Red
Empty
Low:
measuring on a black
surface?
Attention: On black surfaces or in very bright environments measuring the distance can be problem-
atic. Thus, it is still possible to enter manual distances. “Distance by Laser” must be disabled, and
then manual distances can be entered.

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States:
Best –case: Used distance parameter internally:
“Dist:” is green, the distance module's measurement is robust, and the used distance is within the
valid range.
Move into the valid distance range: Used distance parameter internally:
Distance measurement = robust but out range!

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6.4.3 Acoustic trumpet (standard attachment)
The acoustic trumpet bundles incident ultrasonic waves,
thereby extending the range of the device. This behaviour
makes it ideal for medium distances.
The leakage can be heard from large distances, for precise de-
tection, the user must approach the leakage and consistently
follow the "loudest" point. Individual compressed air compo-
nents are then checked for precise detection.
Quantification distance (distance) →1 –6 m
Use of acoustic trumpet:
•Average distance to pipe/component 0.2 –6 m
•Low interfering noise
•Leakage freely accessible
•Use at distances of up to 6 metres if no parabolic mirror available
In the case of the intelligent version of the Acoustic trumpet, you do not need to select the type of
sensor.
6.4.4 Straightening tube
The straightening tube permits only very few ultrasonic waves
to pass in the direction of the ultrasonic transducer, allowing
leakages to be located very precisely.
For this reason, the use of the straightening tube is
recommended for small distances, for the precise detection of
the corresponding leakage.
Quantification distance: (Distance) →0.2 m
Use of straightening tube:
•Short distance to pipe/component 0.05 m
•Pipe/component freely accessible
•Pipes and components to be inspected are very close together
•Medium to high noise
•Use when no gooseneck available
6.4.5 Gooseneck
The gooseneck 2.0 is automatically recognized by an intelli-
gent LD 500 - here you do not have to perform the import.
Before the gooseneck 1.0 can be used, its data –located on
the USB stick shipped with the attachment –must first be im-
ported into the LD 500, if it was reordered and cannot yet be
selected
Import:
Home →Export/Import →Import →New tool →Goose-
neck_xxxxxxxx
The gooseneck should be used if the pipes and components to be inspected are physically very close.
In addition, the shape of the gooseneck can be flexibly adapted to easily inspect hard-to-reach pipes
and components.

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LD 500_SHORT BAL_V2.06 EN Page 20 of 32
The sensitivity of the gooseneck has been reduced to dampen noise. This makes it ideal for targeted,
local testing of compressed air components at high noise levels, for example in systems using pneu-
matic cylinders and in compressed air distribution cabinets.
Quantification distance (distance) →0.05 m
Use of gooseneck:
•Short distance to pipe/component 0.05 m
•Leakage not freely accessible
•Medium to high ultrasonic noise
•Pipes and components to be inspected are very close together
6.4.6 Parabolic mirror
The Parabolic mirror 2.0 is automatically recognized by an intelli-
gent LD 500 - here you do not have to perform the import.
Before the parabolic mirror 1.0 can be used, its data –located on
the supplied USB stick –must be imported into the LD 500, if it was
reordered and cannot yet be selected.
Import:
Export/Import →New tool →Parabol_xxxxxxxx
The parabolic mirror bundles horizontally incident ultrasound in its
focal point where the ultrasonic transducer is located. On the one
hand, this leads to a considerable amplification of the measured ul-
trasound (high range) and, on the other hand, to a very precise directional behaviour, since ultrasound
that does not incident horizontally is reflected by the reflector.
The combination of these two characteristics enables the parabolic mirror to precisely locate leaks at
large distances.
Quantification distance (distance) →3 –12 m
Use of parabolic mirror:
•Large distance to pipe/components 3 –15 m
•Interfering noise
•Leakage not freely accessible (behind a fence)
•Near leaks (superimposition)
Selecting the sensitivity levels of the acoustics
Ultrasound levels can be understood as a "loudness" of the leakage.
With the “Sensitivity" button, the sensitivity of the LD 500 can be adjusted to the environment, which
strongly influences the acoustic behaviour of the device and increases or decreases the valid value
range. A reduction in sensitivity reduces the range of the leakage reading but the "responding area",
indicated by the circle in the display, also gets smaller, which considerably simplifies detection.