ILS500. Publication: Adixen Sensistor AB - Part number AS Ed 04-10/ All information can be modified without prior notice

Transcription

1 ILS500 Publication: Adixen Sensistor AB - Part number AS Ed 04-10/ All information can be modified without prior notice LEAK DE TECTION SYSTEM Technical manual

2 Contents 1. Optimising the Test Cykel Optimising the Connection of Test Object Optimising the Pre-Evacuation Step Optimising the Tracer gas Filling Adjusting the Parameters for internally regulated filling Push-Through filling Optimising the Removal of Tracer gas Interfaces and Connectors APC HMI Panel External Control Panel Printer and RS232 Interface H2000 Serial Option Option Option Safety Tooling ILS Printer / RS232 Specification Service Menu Outputs Inputs Analogue Inputs Configuration System Reset H2000 Settings RS Service Run Hardware Test Interpretation of hard ware results Hardware error messages Pneumatic Components Overview Maintenance Toolkit Maintenance plan Venturi Pump Gas Valves Pilot Valves Technical Specification Electrical Specifications Pneumatic specifications Evacuation and Filling capacity General Adixen Sensistor - Technical Manual ILS500

3 1. Optimising the Test Cycle 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. 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 Hydrogen Method. 1.1 Optimising the Connection of Test 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: 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. Length of tubing between ILS500 and tested object. Inner diameter of tubing between ILS500 and tested object. Consider the smallest diameter in the connection. If object has more than 2 ports. Connect to ports on opposite sides of object. This minimises the need for pre-evacuation. Adixen Sensistor - Technical Manual ILS500 3

4 1.2 Optimising the Pre-Evacuation Step 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 preevacuation. 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. preevacuating): 1) The actual hydrogen concentration will be reduced 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: Fill pressure (Fill pressure + 1 atm) 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: = 0.8 = 80% I.e. the average hydrogen concentration will be 0.8 x 5% = 4% which is almost twice of that achived with no pre-evacuation. = = 1/3 = 33% Fill pressure + Evacuation pressure (Fill pressure atm) 0.05 ( ) = = ,07 ( ) = 2) The tracer gas does not reach all parts of the object The 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: 1 atm (Fill pressure + 1 atm) 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: 0.3 atm (Fill pressure atm) 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. = = 0.17 = 17% = = = 5.6% 0.1 ( ) 0.03 ( ) = = 4 Adixen Sensistor - Technical Manual ILS500

5 Testing need for pre-evacuation. By far the best way to establish the need for preevacuation is to make a realistic test. 1. Find a test object with a small leak in a difficult position. 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 ILS Register the Signal from the leak. The gas signal should stabilise quickly and the maximum achieved signal 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 registred 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. Adixen Sensistor - Technical Manual ILS500 5

6 1.3 Optimising the Tracer gas Filling 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 standard 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 proceeding 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. HAZARD Never pressurise system or object above approved pressure. Too high pressure can result in death or serious injury! The ILS500 regulation is a simple and robust ON/OFF regulator 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. 6 Adixen Sensistor - Technical Manual ILS500

7 1.4 Adjusting the parameters for internally regulated filling Optimal filling is when: Filling is fast. Resulting pressure is within ±5% of the Fill Setpoint. 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. 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. Greater risk for over filling. Increase for large objects. Bigger pressure steps Greater risk for over filling. Increase for large objects. 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. Set Pulse Fill from (%) of Pressure Setpoint to 100 in order to disable pulse filling. Adixen Sensistor - Technical Manual ILS500 7

8 1.5 Push-through 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). 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: 1.2 x ( ) V > 5 = 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. ILS500 must be set to fill through Test Port 1 only. This option can be found under Advanced Setup / Parameters / Options, Section The added volume should be: V 2 > 1.2 x V 1 P fill Where V 2 is added volume V 1 is sum of volumes of object and connection tubing/piping bar P fill is fill pressure (Fill Setpoint) given in atmospheres (see example below). 1.2 is given for margin. Added volume Long tube shaped object 8 Adixen Sensistor - Technical Manual ILS500

9 1.6 Optimising the Removal of the Tracer gas. 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 operator testing manually can normally interpret spurious signals as irrelevant. The computer controlling an automatic test does not have that capability and background noise can result in false leak signals. 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. 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. 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. Adixen Sensistor - Technical Manual ILS500 9

10 2. Interfaces and Connectors The ILS500 is equipped with a number of interfaces for interaction with indicating, supervising and registering equipment. The details of these are specified below. 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. N.B. that outputs are not relay types. Do not connect external drive source such as 24 V or 100/230 VAC. 2.1 APC (Two ports) Connector: 25 pin female D-Sub. Purpose: Connection of APC units. Pin Signal Type Load Comment 1 COM GND -1A Common GND for outputs 2 COM GND -1A Common GND for outputs 3 COM GND -1A Common GND for outputs 4 IN_0 IN -0.5 ma Input of H2000 APC system 5 IN_1 IN -0.5 ma Input of H2000 APC system 6 IN_2 IN -0.5 ma Input of H2000 APC system 7 IN_3 IN -0.5 ma Input of H2000 APC system 8 IN_4 IN -0.5 ma Input of H2000 APC system 9 CAL_CONF OUT 0.5A Output of H2000 APC system 10 OUT_6 OUT 0.5A Output of H2000 APC system 11 COM GND -1A Common GND for outputs 12 COM GND -1A Common GND for outputs 13 COM GND -1A Common GND for outputs 14 DET_ERROR OUT 0.5A Output of H2000 APC system 15 LEAK_OUT OUT 0.5A Output of H2000 APC system 16 DET_ON OUT 0.5A Output of H2000 APC system 17 DET_SIGNAL OUT 0.5A Output of H2000 APC system 18 DET_WAIT OUT 0.5A Output of H2000 APC system 19 OUT_0 OUT 0.5A Output of H2000 APC system 20 OUT_1 OUT 0.5A Output of H2000 APC system 21 OUT_2 OUT 0.5A Output of H2000 APC system 22 OUT_3 OUT 0.5A Output of H2000 APC system 23 OUT_4 OUT 0.5A Output of H2000 APC system 24 OUT_5 OUT 0.5A Output of H2000 APC system VDC OUT OUT 0.5A Supply for switches etc. connecting to inputs. Do not feed 24V here! For further information about APC system refer to Technical Manual of H2000 (TM-H2000). 10 Adixen Sensistor - Technical Manual ILS500 APC Ports

11 2.2 HMI Panel Connector: 37 pin female D-Sub Purpose: For external connection of HMI panel. Do not connect to anything other than Adixen Sensistor original HMI panel. Pin Signal Type Load Comment 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. 13 RJ45-2 Internal Ethernet bridge. 14 RJ45-3 Internal Ethernet bridge. 15 RJ45-4 Internal Ethernet bridge. 16 RJ45-5 Internal Ethernet bridge. 17 RJ45-6 Internal Ethernet bridge. 18 RJ45-7 Internal Ethernet bridge. 19 RJ45-8 Internal Ethernet bridge. 20 RS232GND Internal RS232 bridge. 21 RS232TX Internal RS232 bridge. 22 RS232RX Internal RS232 bridge. 23 RS422 Internal RS422 bridge 24 RS422 Internal RS422 bridge 25 RS422 Internal RS422 bridge 26 RS422 Internal RS422 bridge 27 RS422 Internal RS422 bridge 28 RS422 Internal RS422 bridge 29 RS422 Internal RS422 bridge 30 RS422 Internal RS422 bridge 31 RS422 Internal RS422 bridge 32 RS422 Internal RS422 bridge 33 RS422 Internal RS422 bridge 34 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. Adixen Sensistor - Technical Manual ILS500 11

12 2.3 External Control Panel HMI Panel and External Control Panel connector Connector: 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 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 11 ESTOP2 - * Emergency relay control: Terminal 2 of channel 1 input 12 ESTOP3 - * Emergency relay control: Terminal 1 of channel 2 input 13 ESTOP4 - * Emergency relay control: Terminal 2 of channel 2 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. * Connections are designed for safety relay included in Adixen Sensistor original part: External Control Panel with Emergency Stop (90660) 12 Adixen Sensistor - Technical Manual ILS500

13 2.4 Printer and RS232 Interface 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 2.5 H2000 Serial 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 Adixen Sensistor - Technical Manual ILS500 13

14 2.6 OptIn 1 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 +24VDC SUPPLY 250 ma Option supply 2 VIN1 IN -60 ma Voltage input: Digital 24VDC 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/screen connection. 2.7 OptIn 2 Connector: 5 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal included. Purpose: Options port 2. Used for Active Holder for Hand Probe (90630). Pin Signal Type Load Comment 1 +24VDC SUPPLY 250 ma Option supply 2 VIN2 IN -60 ma Voltage input: Digital 24VDC or analogue 0-10 VDC. 3 IIN2 IN +/- 30 ma Current input: 0-20 ma 4 COM2 GND -250 ma Signal common (GND) 5 COM/SHLD GND +/- 30 ma Shield/screen connection. 2.8 Status Connector: 6 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal included. Purpose: Test Status Ouputs. Sourcing 24VDC transisor 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 for status signals. IMPORTANT: Mount the 5, 6 and 8-pin female connectors for Options, Status, Safety, Tooling and Control as shown in the picture below. Top pin is number 1 14 Adixen Sensistor - Technical Manual ILS500

15 2.9 Safety Connector: 6 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal included. Purpose: Emergency stop interface. Pin Signal Type Load Comment 1 +24VDC SUPPLY 2.5 A 2 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 * 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. IMPORTANT: Mount the 5, 6 and 8-pin female connectors for Safety, Tooling and Control according to the instructions on previous page. Safety, Tooling and Control Connectors Adixen Sensistor - Technical Manual ILS500 15

16 2.10 Tooling Connector: 8 pin male Weidmüller, Omnimate BL3.5. Mating screw terminal included. Purpose: Electrical tooling interface. Pin Signal Type Max load Comment 1 +24VDC 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 Connection of proximity switch (sensor) Pin Signal +V, Brown 1 +24VDC Out, Black 2 TS1 3 TS2 4 TS3 5 TS4 6 MARKER 7 COM 0V, Blue 8 COM PNP type, NO * 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. Control Connector: 8 pin male Weidmüller, Omnimate BL3.5. Mating screwterminal included. Purpose: External start and stop. Control of optional external valves. Pin Signal Type Load Comment 1 +24VDC SUPPLY 2.0 A Start and stop switch and supply. 2 EXTSTART IN - 7 ma Start button return (NO contacts) other contact to +24VDC 3 EXTSTOP IN - 7 ma Stop button return side (NO contacts) other contact to +24VDC 4 EVAC1 OUT 0.5 A Venturi valve output (Exhaust on high vac model) 5 EVAC2 OUT 0.5 A Evacuation valve output 6 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. 16 Adixen Sensistor - Technical Manual ILS500

17 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 results The 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. Adixen Sensistor - Technical Manual ILS500 17

18 Commands The printer port can also be used to control the ILS500. The most commonly used functions can be started/configured over the RS232 interface. Command M<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> Action Start Print request Stop Calibrate Statistics Reset statistics Recipe 1 Recipe 2 Recipe 3 Recipe 4 Recipe 5 Recipe 6 Recipe 7 Recipe 8 Explanation Same function as START button. Starts test cycle Returns H2000 Analysis value. Same function as STOP button. Used to stop or terminate test cycle and/or acknowledge a rejected test. Starts calibration if the H2000 PLUS has an active probe. Prints statistics. Clears the statistics. Activates recipe number 1. Recipe must exist and recipe function must be on. Activates recipe number 2. Recipe must exist and recipes must be on. Activates recipe number 3. Recipe must exist and recipes must be on. Activates recipe number 4. Recipe must exist and recipes must be on. Activates recipe number 5. Recipe must exist and recipes must be on. Activates recipe number 6. Recipe must exist and recipes must be on. Activates recipe number 7. Recipe must exist and recipes must be on. Activates recipe number 8. Recipe must exist and recipes must be on. Respons MS Ex. 0.0E+00A See below. R1 when download starts. OK when download finished or if R1 is already active. NO if R1 doesn t exists. R2 when download starts. OK when download finished or if R2 is already active. NO if R2 doesn t exists. R3 when download starts. OK when download finished or if R3 is already active. NO if R3 doesn t exists. R4 when download starts. OK when download finished or if R4 is already active. NO if R4 doesn t exists. R5 when download starts. OK when download finished or if R5 is already active. NO if R5 doesn t exists. R6 when download starts. OK when download finished or if R6 is already active. NO if R6 doesn t exists. R7 when download starts. OK when download finished or if R7 is already active. NO if R7 doesn t exists. R8 when download starts. OK when download finished or if R8 is already active. NO if R8 doesn t exists. Statistics Printed data Explanation REC:AP29 - recipe name. Printed if recipes is activated TOT: total ACC: accepted REJ: rejected EVA: evacuation VDE: vacuum decay BLO: blockage test FIL: gas filling PRE: pressure decay GAS: gas detector 18 Adixen Sensistor - Technical Manual ILS500

19 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 Outputs The 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 Inputs The 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. Adixen Sensistor - Technical Manual ILS500 19

20 3.3 Analogue Inputs Configuration This 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. 20 Adixen Sensistor - Technical Manual ILS500

21 3.4 System Reset A system reset will set all current parameters to factory default as given in the Parameter Index in the User Manual. 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 configuration. 3.5 H2000 Settings This 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. Adixen Sensistor - Technical Manual ILS500 21

22 3.6 RS232 This 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: Analysis Mode. Detection Mode: Hand Probe: Active Probe: Sets the H2000 PLUS in Sets the H2000 PLUS in Detection Mode. Sets Probe Type to Hand Probe. Sets Probe Type to loaded driver, for example AP29. Printer: Activates printer type Analysis Data Output. Measure: Calibrate: Stop: Starts an active hydrogen measurement / sampling. Starts the H2000 PLUS calibration routine. 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 restarting the ILS500. Data received on the Printer / RS232 port is shown in the input windows. 22 Adixen Sensistor - Technical Manual ILS500

23 3.7 Service Run This menu is intended for remote trouble shooting performed by an authorised service centre. 3.8 Hardware Test 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 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. Adixen Sensistor - Technical Manual ILS500 23

24 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 different 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 Pressure and Vacuum Sensors Zero 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 24 Adixen Sensistor - Technical Manual ILS500

25 3.8.2 Evacuation Valve Evacuation 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 Venturi Pump Checking max vacuum of Venturi pump. Possible results: Max Vacuum OK Poor Max Vacuum Poor max vacuum can result in: Failed pre-evacuation Slower evacuation 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: False vacuum decay rejects Increased gas consumption Minor external leakage will be found later during the gas test step. Adixen Sensistor - Technical Manual ILS500 25

26 3.8.5 Vacuum Sensor Valve This checks that the valve shuts to protect vacuum sensor before filling. Possible results: Valve works Faulty! Malfunction can result in: Damage to vacuum sensor Failed pre-evacuation Tracer Gas Fill Valve The step tests the gas fill valve for internal leakage by registering pressure rise behind the valve. Possible results: No Internal Leakage Internal Leakage Internal leakage can result in: Erroneous pressure decay results False vacuum decay rejects Increased gas consumption Test Port 2 Valve N.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 Internal leakage can result in: False blockage test accepts 26 Adixen Sensistor - Technical Manual ILS500

27 3.8.8 Tracer Gas Fill Valve 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: Failed gas filling External gas leaks The 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 ILS 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 Adixen Sensistor - Technical Manual ILS500 27

28 Evacuation Valve This step tests that evacuation valve opens to release tracer gas to exhaust. Same test as previously but under pressure instead of vacuum. Possible results: Valve works Faulty! Malfunction will result in: Failure to terminate test cycle Indicator Lamps This 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) Tooling Outputs 1-4 This 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 START and STOP buttons 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. 28 Adixen Sensistor - Technical Manual ILS500

29 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. Tested Feature Zero point. Reason for error Broken / Disconnected cable. Wrongly set A/D parameters. Action Check cable of sensors. Check and adjust Analog Input settings. Replace sensor if m value needs more than 20% change. Broken vacuum or pressure Replace sensor. sensor. Evacuation Valve. Venturi Pump. Internal leaks. Maximum vacuum. Dirty or worn valve seals. Compressed air pressure too Replace or clean evacuation valve. Adjust compressed air pressure. low or too high. See section 5.2. Dirt inside Venturi. Remove and clean Venturi. No signal to Venturi pilot Check Venturi Pump output. valve. Send in for repair. No signal to Evacuation pilot Check Evac Valve output. valve. Send in for repair. Dirty or broken Venturi pilot Replace two upper valves in pilot ramp. valves. Dirty or broken Evacuation Replace fourth valve from bottom in pilot pilot valves. valve ramp. Gas Valve Manifold. Leaks from outside. Leaks to outside? Check for leaks with Hand Probe (later in hardware test sequence). If no gas leaks. Check internal leaks in tracer gas fill valve. If no internal leaks in tracer Replace/clean vacuum sensor protection gas valve. valve. Vacuum Sensor Protection Valve. Function. No signal to pilot valve. Check Sensor Protect output. Send in for repair. Dirty or broken pilot valve. Replace valve third valve from bottom in pilot ramp. Vacuum sensor protection Replace valve. valve broken. Tracer Gas Fill Valve. Internal leaks. Dirty or worn valve seals. Leaking pilot valve. Replace or clean tracer gas fill valve. Replace fourth valve from bottom in pilot valve ramp. Test Port 2 Valve. Function. No signal to pilot valve. Check Test Port 2 output. Send in for repair. Dirty or broken pilot valve. Replace third valve from bottom in pilot ramp. Test port 2 valve broken. Replace valve. Adixen Sensistor - Technical Manual ILS500 29

30 Tested Unit Tested feature Reason for error Action Tracer Gas Fill Valve. Function. No signal to pilot valve. Check Fill Valve output. Send in for repair. Dirty or broken pilot valve. Replace valve fourth valve from bottom in pilot ramp. Tracer gas fill valve broken. Replace valve. Gas Valve Manifold. Leaks to outside. Wrongly assembled gas Remove leaking valve. Clean and grease valve valve. seal before installing again. See instructions Wrongly installed Remove leaking unit. Clean and grease o-ring connectors / plugs. before installing again. Units lacking o-ring seal should be sealed with Loctite 577 or similar. Evacuation Valve. Function. No signal to Evacuation Check Evac Valve output. Send in for repair. pilot valve. Dirty or broken Evacuation Replace fourth valve from bottom in pilot valve pilot valves. ramp. Lamp. Function. Disconnected cable. Check cable to HMI and External Control Panel Broken Lamp. Replace lamp. No signal from PLC. Check PLC output. Send in for repair. Tooling Valves. Function. Dirty or broken pilot valve. Replace valve first or second valve from bottom in pilot ramp. No signal from PLC. Check PLC output. Send in for repair. Buttons. Function. Disconnected cable. Check cable to HMI and External Control Panel. Broken switch. Send in for repair. 30 Adixen Sensistor - Technical Manual ILS500

31 3.10 Hardware error messages Message Detector 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 error No 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. Adixen Sensistor - Technical Manual ILS500 31

32 3.11 Pneumatic Components Overview Pilot Valve 6 Pilot Valve 1 Venturi Pump Evacuation Valve Tracer Gas Fill Valve Test Port Valve 2 Vacuum Sensor Control Valve Vacuum Sensor Pressure Sensor HP model Pressure Sensor fitted here 3.12 Pilote Valv Ramp Overview Valve positions: 5A+6 AMain Air Valve 5B+6B Venturi Pump supply 4A Evacuation Valve 4B Tracer Gas Fill Valve 3A Test Port 2 Valve 3B Sensor Protection Valve 2A Tooling Valve 1 2B Tooling Valve 2 1A Tooling Valve 3 1B Tooling Valve 4 32 Adixen Sensistor - Technical Manual ILS500 Valve number LEDs A B A B A B A B A B A B Side view of ports B row (top) A row (bottom)

33 4. Maintenance ILS500 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 Toolkit Below 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 Maintenance plan The 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. Part Venturi pump Evacuation, Fill and Test Port 2 Valves Interval 3 months 3-6 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. Vacuum Sensor Valve Pilot Valves 12 months 12 months 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. Gas sensor 3 months** Check sensitivity and response time. See manual for H2000 PLUS and/or active probe used. * 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. Adixen Sensistor - Technical Manual ILS500 33

34 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 Pump The 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 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. 34 Adixen Sensistor - Technical Manual ILS500

35 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. Adixen Sensistor - Technical Manual ILS500 35

36 4.4 Gas Valves 1) Use a T25 key to remove the two screws holding the right hand cover (next to gas ports).. 2) Slide the cover back and lift it off. Rock the rear end 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). 36 Adixen Sensistor - Technical Manual ILS500

37 4.5 Pilot Valves 1) Use a T25 key to remove the two screws holding the right hand cover (next to gas ports). 2) Slide the cover back and lift it off. Rock the rear end 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 ) 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. 2 8) Replace the cover. 3 1 Adixen Sensistor - Technical Manual ILS500 37

38 5. Technical specification 5.1 Electrical Specifications Electrical supply Mains Voltage: Current: Power Rating: Inrush Current: Mains Connector: Recommended Fuse Rating: Single Phase, VAC / Hz VAC / VAC 120 W max / 33 W typical average max 40 A IEC/EN /C14 2 A slow / 6.3 x 32 mm (2 needed) I/O Port Connectors External 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 Signals Signal specification: Output Voltage: Output Capacity: Input Voltage HI Input Voltage LO Input Current HI/LO 24 VDC logic 23 ±1 VDC Max 0.5 A / output (max 2.5 A total) Min 16 VDC Max 4 VDC Max 7 ma Communication Ports Ethernet: 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 38 Adixen Sensistor - Technical Manual ILS500

39 HMI Panel (if externally mounted) External Control Panel PrinterIlogger (RS232) H2000 Serial (if externally mounted H2000) Also used for APC driver download Ethernet Hydrogen Probe Options Inputs 1 and 2 Status Outputs Fuses Safety interface Power Switch Tooling Interface Power Inlet Control Outputs APC Ports Adixen Sensistor - Technical Manual ILS500 39

40 5.2 Pneumatic Specifications Compressed air supply Pressure Std model: MPa ( psi) Reduced vacuum capacity below 0.5 MPa (70 psi) HP model: MPa ( psi) Peak 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 Recommended Composition: 5% H 2 / 95% N 2 Pressure Std model: MPa ( psi) HP model: MPa (3 652 psi) Quality: Industrial grade purity (>95% purity) Exhaust Capacity in Exhaust Duct: Min 30 m 3 /h (1000 SCFH) Dimension of Hose Leading to Duct: 25 mm ID (1 ) Pneumatic Capacity is given for 500 mm of 10 mm ID hose between ILS500 and test volume. Valve bore: 7 mm (0.28 ) Evacuation: Max Vacuum: Capacity: Filling: Capacity at 1 MPa supply: Tooling Output Valves: Valve type: Q n : C v : 85 kpa ( 12.3 psi) 0.4 s/l to 50 kpa ( 7.2 psi) 1.5 s/l to 80 kpa ( 11.6 psi) 0.1 s/l to 0.1 MPa (14.5 psi) 0.5 s/l to 0.6 MPa (87 psi) Normally closed, 3/2 valve 160 std l/min 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 40 Adixen Sensistor - Technical Manual ILS500

41 Exhaust ID 25 / 1 hose External Vacuum Pump (Vac. model only) Tracer gas ISO 3/8 female Optional Port Test Port 1 ISO 3/8 female Test port 2 ISO 3/8 female Vacuum Gauge Vent (Emits small amount of Tracer gas) Compressed Air ISO 3/8 female Tooling Valve Outputs 1 4. OD 4 mm hose connectors. Adixen Sensistor - Technical Manual ILS500 41