Inficon Sensistor ILS500 User manual

Sensistor ILS500
O P E R A T I N G M A N U A L
ninb63en1-05 (1904)
Hydrogen Leak Detection System
Type no. ILS500.210.306

Content 3
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Content
1General Information 9
1.1 About This Manual 9
1.2 Related Manuals 9
1.3 Introduction to the ILS500 9
1.4 Disposal 10
2Equipment and Storage 11
2.1 Supplied Equipment 11
2.2 Required Equipment 12
2.3 Storage 12
3ILS500 Description 13
3.1 Front View 13
3.2 Rear View (Electrical) 14
3.3 Configuring Ports and Interfaces (Electrical) 15
3.4 Rear View (Pneumatical) 16
3.5 Configuring Ports and Interfaces (Pneumatical) 17
3.6 Labels 17
4Hand Probe P50 19
4.1 General Information 19
4.2 Description 19
4.3 Calibration 19
5System Examples 20
5.1 Simple Hand Probe System 20
5.2 Automatic Chamber Test 21
5.3 Chamber Test with Leak Locating Option 22
6Setup 23
6.1 Placement of the ILS500 23
6.2 Electrical Connections 24
6.3 Pneumatic Connections 27
6.4 Set Up Test Area 31
7Menu System 32
7.1 ILS500 Display 32
7.2 Passwords 34
7.3 Menu Overview 35
8Using the ILS500 40
8.1 Test Sequence 40
8.2 Run a Test 41

Content 4
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9 Recipes 44
9.1 Recipe Overview 44
9.2 Create a Recipe 45
9.3 Test Settings 46
9.4 Optimizing the Test Cycle 53
10 Calibration 58
10.1 About Calibration 58
10.2 Calibration Overview 58
10.3 How to Calibrate 60
11 Troubleshooting 62
11.1 Fault Symptoms 62
11.2 Perform Hardware Test 62
12 Maintenance Instructions 75
12.1 Software Update 75
12.2 Maintenance Plan 76
12.3 Maintenance 77
12.4 Functional Verification 83
13 Service 84
14 Technical Data 85
14.1 Electrical Specifications 85
14.2 Pneumatic Specifications 86
14.3 Other Data 87
14.4 Interfaces and Connectors 88
15 Spare Parts and Accessories 99
16 Support from INFICON 101
16.1 How to Contact INFICON 101
16.2 Returning Components to INFICON 101
17 Declaration of Conformity 102
18 Declaration by the Manufacturer 103
Appendix
A: Parameter Index 104

5
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General Safety Precautions
Definitions of Warning, Caution and Notice
General Safety
Failure to observe the following precautions could result in serious personal
injury:
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
Pure Hydrogen is a flammable gas. Use only ready-made Hydrogen Tracer Gas
comprising 5% Hydrogen in Nitrogen. This is a standard industrial gas mixture used
in a variety of industrial applications.
Warning
Since the tracer gas mix contains no oxygen, releasing large amounts of the gas in a
confined space may lead to asphyxiation.
Warning
Compressed gases contain a great deal of stored energy. Always carefully secure
gas bottles before connecting a pressure regulator. Never transport gas bottles with
a pressure regulator fitted.

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Failure to observe the following precautions could result in damage to the
equipment:
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.
Caution
Do not open the detector! Service of this equipment may only be carried out by
service organizations authorized for this purpose by INFICON.
Caution
If the detector suffers external damage, it must be checked and repaired by a service
organization authorized by INFICON.
Caution
Do not expose the probe to a hydrogen concentration greater than 0.1% when the
instrument is not operating, as this could damage or destroy the probe sensor.
Caution
When the instrument is operating, the sensor can withstand temporary exposure to
hydrogen concentrations up to 100%. Avoid long exposures to high concentrations.
Caution
Always switch power off before connecting or disconnecting any cable.

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Notice Whenever the word 'hydrogen' is used in this manual, it implies that the
hydrogen gas is safely mixed with nitrogen in the proportions 
95% Nitrogen / 5% Hydrogen.
Before connecting the tracer gas, confirm that the connectors or test
object is designed for operating at the test pressure to be used.

8
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Safety ILS500
INFICON can not take any responsibility for the consequences arising from
inappropriate use of certain test pressures.
Warning
The ILS500 must never be introduced to pressures higher than that approved for the
object to be tested and never beyond the ILS500 specification.
Warning
Be sure to have a pressure relief valve in case of accidental tracer gas pressure
increase.
Warning
When dealing with high pressures, a blast protection is needed between the Test
Port and the Test Object.
Warning
When dealing with test objects that cannot stand high pressure increase, make sure
to mount a flow control valve on the Test Ports.
Warning
Make sure not to confound Compressed Air and Tracer Gas.
Notice The ILS500 has no internal emergency stop circuit. ILS500 is prepared for
integration into an external emergency stop circuit.
Check that all relevant legislation and safety standards are complied with
before putting the ILS500 into service. See further information under
Installation.

General Information 9
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1 General Information
Please read this Operating Manual carefully before putting your Sensistor ILS500 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 and its different parts
•Show examples of different types of test stations
•Teach the reader how to set up the ILS500 for different test purposes
1.1.1 Document History
1.2 Related Manuals
Extensive information about the Leak Detector can be found in the manuals for the
Sensistor ISH2000:
•Operating Manual Sensistor ISH2000
•Technical Reference Manual Sensistor ISH2000
1.3 Introduction to the ILS500
The Sensistor ILS500 is an all-in-one Tracer Gas Leak Detection System.The purpose
of the ILS500 is to make it possible to set up a fully automatic leak test system quickly,
to a low cost.
1.3.1 Intended Use
ILS500 is designed for indoor use only.
All functions are accessible and programmable using a touch panel, a PC or via the
Internet. The test sequence is controlled by an integrated controller.
Different sets of parameters can be saved. Each set forming a specific recipe for a
specific test object.
Revision Date Remark
e11-2013 New Tracer Gas Filler with New Hydrogen Leak Detector
f10-2014 Updated version

10 General Information
ninb63en1-05 (1904)
1.3.2 Available Configurations
Sensistor ILS500
The actual configuration is shown on the ILS500 display during start-up and in the
menu when clicking Setup >> Info.
1.4 Disposal
Sensistor ILS500
Standard For common tracer gas leak detection.
High Pressure (HP) When a higher tracer gas pressure is needed.
Notice Start-up time for the leak detectors can be up to 10 minutes, depending
on the condition.
According 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 INFICON product to the manufacturer
for recovery.
The manufacturer has the right to refuse taking back products that
are inadequately packed and thereby presents safety and/or health
risks to the staff.
The manufacturer will not reimburse you for the shipping cost.
Shipping address:
INFICON AB
Westmansgatan 49
582 16 Linköping
Sweden

Equipment and Storage 11
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2 Equipment and Storage
2.1 Supplied Equipment
Supplied Equipment
Accessories to the ILS500 can be found on page 99.
Notice When receiving the equipment, check that it has not been damaged
during transport.
1ILS500
2Hand Probe P50
3Probe Cable (3 m)
4Power Cables (EU, UK, US)
5Screw Terminal Connectors for External I/O Signals
6Thread Converter Set (ISO to NPT Conversion)
7Hose Connection Kit
8Safety Override Loopback
9USB flash drive with other relevant manuals
10 Operating Manual Sensistor ILS500 (this manual)
11 Operating Manual ISH2000
12 Warning Paper about use of Hand Probe
2
3
7
8
9
10
11
1
12
4
5
6
Notice All pneumatic ports are plugged upon delivery. Store the removed plugs.
They are used for future hardware testing.

12 Equipment and Storage
ninb63en1-05 (1904)
2.2 Required Equipment
Required Equipment
For more information, see on page 99.
2.3 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.
1Tracer Gas
2Compressed Air
3Two-Step Gas Regulator
4Calibration Leak with Certificate (small or large) or
5Calibration Gas with Certificate
6Compressed Air Filter
7Oil Separator (recommended)
8Exhaust Hose
9Emergency Stop Circuit (recommended)
13
6
2
7 8
4
5 9

ILS500 Description 13
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3 ILS500 Description
ILS500 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.
3.1 Front View
ILS500 Front View
1Red lamp
2Green lamp
3ILS500 Touch panel
4START button
5STOP button
6ISH2000
1
2
3
4
5
6

14 ILS500 Description
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3.2 Rear View (Electrical)
Rear View (Electrical)
For more information, see on page 85.
1Leak Detector
2Connection Port
3Safety Interface
4Fuses
5Power Switch
6Power Input
7Probe Control Port
8Control Output
9Tooling Interface
10 Status Output
11 Inputs 1 and 2 (optional)
12 Ethernet
13 Printer Port/RS232
2
13 1
12
8
9
10
11
6
3
4
5
7

ILS500 Description 15
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3.3 Configuring Ports and Interfaces (Electrical)
Port/Interface Connect
Leak Detector File Transfer Cable 
(for downloading custom APC drivers)
Pin-to-Pin Cable 
(for external mounting of ISH2000)
Connection Port Probe
Safety Interface Emergency Stop Circuit
Power Input Power Cable
Probe Control Port APC Units
Control Output Optional External Valves
Tooling Interface External Tools
Status Output Light Tower etc.
Input 1 (optional) Analogue Input
(not supported by std software)
Digital Input
(not supported by std software)
Input 2 (optional) Active Holder for Hand Probe
Ethernet Ethernet 
(remote view and control of touch panel)
Printer Port/RS232 Serial Printer
Logging Device 
(e.g. PC)
Remote Control 
(START, STOP etc.)

16 ILS500 Description
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3.4 Rear View (Pneumatical)
Rear View (Pneumatical)
1Optional Port
2Test Port 2
3Compressed Air Input
4Tooling Valve Outputs 1-4
5Vacuum Gauge Vent
6Test Port 1
7Tracer Gas Input
8Plugged Port
9Exhaust
1
5
6
9
8
7
4
3
2
Notice Do not remove the plug from the plugged port in pos. 8.

ILS500 Description 17
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3.5 Configuring Ports and Interfaces (Pneumatical)
3.6 Labels
Machine Plate
Tooling Plate
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.)

18 ILS500 Description
ninb63en1-05 (1904)
Pneumatical Plate Electrical Plate

Hand Probe P50 19
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4 Hand Probe P50
4.1 General Information
4.2 Description
Hand Probe P50 (Rigid Neck)
The Hand Probe P50 is a non-sniffing probe. Gas analysis takes place in the
replaceable sensor located in the tip of the probe.
For more information about the Hand Probe P50, refer to the Operating Manual and
Technical Reference Manual for Sensistor ISH2000.
4.3 Calibration
The probe needs to be calibrated for optimal accuracy. Make sure it is calibrated when
it is used for the first time. For more information about calibration, see on page 58.
Caution
Do not expose the probe to a hydrogen concentration greater than 0.1% when the
instrument is not operating, as this could damage or destroy the probe sensor.
Caution
Connection and disconnection of the sensor cable must be done with power OFF.
Sensor can be damaged if power is on.
1Hydrogen Sensor
2Indicator LED lamps
3Function Button
4Lamps
3
4
2
1
Notice The probe can be ordered with a flexible neck. For more information, see
on page 99.

20 System Examples
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5 System Examples
ILS500 is equipped with a large number of functions for connection and leak testing of
different kinds of objects. It is therefore possible to build a leak test station that suits the
tested object and the requirements on testing speed etc.
Three examples of test stations are given in the following sections.
5.1 Simple Hand Probe System
Simple Hand Probe System
In this system the operator is manually handling the Hand Probe for the leak test and
the test fixture (Tooling).
ILS500 ensures that the tracer gas correctly fills the entire object.
Filling and Gross Leak Test (if desired) are performed automatically and the gas leak
test is conducted manually by the operator.
An Active Holder for Hand Probe (option) can be used to ensure that the selected
minimum test time is used.
ILS500 will indicate LEAK if any of the tests fails.
1Power Connection
2Compressed Air Connection
3Tracer Gas Connection
4Evacuation and Gas Filling
5Test Object
6Hand Probe
7Active Probe Holder (optional)
2
1
3
4
7
5
6