Operating ManualTracer Gas Filler
Sensistor ILS500 F/FHP

Catalog No.
590-580, 590-581
Type No. ILS.210.307
From software version
4.00.00

ninp69en1-02-(2201)

INFICON AB
Wahlbecksgatan 25A
SE-58216 Linköping
SwedenINFICON

Table of Contents

Table of Contents
1 About this manual .......................................................................................................................................... 7
1.1 Target groups ........................................................................................................................................... 7
2 Safety............................................................................................................................................................... 8
2.1 Duties of the operator ............................................................................................................................... 8
2.2 Intended use ............................................................................................................................................. 8
2.3 Owner requirements ................................................................................................................................. 8
2.4 Dangers .................................................................................................................................................... 9
3 Description.................................................................................................................................................... 11
3.1 Intended Use .......................................................................................................................................... 11
3.2 Available Configurations ......................................................................................................................... 11
3.3 Front View............................................................................................................................................... 12
3.4 Rear View (Electrical) ............................................................................................................................. 13
3.5 Configuring Ports and Interfaces (Electrical) .......................................................................................... 13
3.6 Rear View (Pneumatical) ........................................................................................................................ 14
3.7 Configuring Ports and Interfaces (Pneumatical) ..................................................................................... 15
3.8 Labels ..................................................................................................................................................... 15
3.9 Technical Data........................................................................................................................................ 16
3.9.1 Electrical Specifications .............................................................................................................. 16
3.9.2 Pneumatic Specifications............................................................................................................ 17
3.9.3 Other Data .................................................................................................................................. 18
3.9.4 Interfaces and Connectors.......................................................................................................... 19
3.9.4.1

RS232 ................................................................................................................................ 19

3.9.4.2

Input 1 (Optional) ............................................................................................................... 21

3.9.4.3

Input 2 (Optional) ............................................................................................................... 22

3.9.4.4

Status Output ..................................................................................................................... 22

3.9.4.5

Tooling Interface ................................................................................................................ 23

3.9.4.6

Control Output.................................................................................................................... 24

3.9.4.7

Power Input ........................................................................................................................ 25

3.9.4.8

Safety Interface .................................................................................................................. 25

3.9.4.9

USB Port ............................................................................................................................ 26

4 Equipment and Storage ............................................................................................................................... 28
4.1 Supplied Equipment................................................................................................................................ 28
4.2 Required Equipment ............................................................................................................................... 29
4.3 Storage ................................................................................................................................................... 29

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

iii

Table of Contents

INFICON

5 Setup.............................................................................................................................................................. 30
5.1 Placement of the ILS500 F/FHP ............................................................................................................. 30
5.2 Electrical Connections ............................................................................................................................ 31
5.2.1 Setting Up an Emergency Stop................................................................................................... 31
5.2.2 Connecting to Mains ................................................................................................................... 31
5.2.3 Connecting Extra Features ......................................................................................................... 32
5.3 Pneumatic Connections.......................................................................................................................... 32
5.3.1 Connecting Compressed Air ....................................................................................................... 32
5.3.2 Connecting Tracer Gas............................................................................................................... 33
5.3.3 Connecting Exhaust to Air Vent .................................................................................................. 35
5.3.4 Connecting to Test Port 1 and 2 ................................................................................................. 36
5.3.5 Connecting Tooling ..................................................................................................................... 36
5.4 Set Up Test Area .................................................................................................................................... 37
6 Menu System ................................................................................................................................................ 39
6.1 ILS500 F/FHP Display ............................................................................................................................ 39
6.1.1 Menu Buttons.............................................................................................................................. 39
6.1.2 Navigation and Other Buttons..................................................................................................... 39
6.1.3 Entering Numbers and Text ........................................................................................................ 40
6.1.4 Screen Saver .............................................................................................................................. 40
6.2 Passwords .............................................................................................................................................. 41
6.2.1 Set Up New User ........................................................................................................................ 41
6.3 Menu Overview....................................................................................................................................... 41
7 Using the ILS500 F/FHP ............................................................................................................................... 47
7.1 Test Sequence........................................................................................................................................ 47
7.2 Run a Test .............................................................................................................................................. 48
7.2.1 Start Up....................................................................................................................................... 48
7.2.2 Place the Test Object.................................................................................................................. 48
7.2.3 Perform Tracer Gas Filling.......................................................................................................... 48
8 Recipes.......................................................................................................................................................... 50
8.1 Recipe Overview..................................................................................................................................... 50
8.2 Create a Recipe...................................................................................................................................... 51
8.2.1 New Recipe................................................................................................................................. 51
8.2.2 Modify a Recipe .......................................................................................................................... 52
8.3 Test Settings........................................................................................................................................... 52
8.3.1 Tooling Connection ..................................................................................................................... 53

iv

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Table of Contents

8.3.2 Pre Evacuation............................................................................................................................ 55
8.3.3 Gross Leak Tests........................................................................................................................ 56
8.3.4 Tracer Gas Filling........................................................................................................................ 58
8.3.5 Blockage Test ............................................................................................................................. 59
8.3.6 Gas Evacuation........................................................................................................................... 59
8.3.7 Tooling Disconnection................................................................................................................. 60
8.4 Optimizing the Test Cycle....................................................................................................................... 60
8.4.1 Optimizing the Pre Evacuation Step ........................................................................................... 61
8.4.1.1

Calculate Tracer Gas Concentration.................................................................................. 61

8.4.1.2

Example - Calculate Tracer Gas Filling.............................................................................. 62

8.4.2 Optimizing the Tracer Gas Filling................................................................................................ 63
8.4.2.1

External Pressure Regulation ............................................................................................ 63

8.4.2.2

Internal Pressure Regulation.............................................................................................. 63

9 Troubleshooting ........................................................................................................................................... 64
9.1 Fault Symptoms...................................................................................................................................... 64
9.2 Perform Hardware Test .......................................................................................................................... 64
9.2.1 Hardware Error Messages .......................................................................................................... 75
9.2.2 Interpretation of Hardware Test Results ..................................................................................... 75
10 Maintenance Instructions ............................................................................................................................ 78
10.1 Maintenance Plan ................................................................................................................................... 78
10.2 Maintenance ........................................................................................................................................... 78
10.2.1 Tools and Safety Equipment....................................................................................................... 78
10.2.2 Interior View ................................................................................................................................ 79
10.2.3 Removing the Cover ................................................................................................................... 80
10.2.4 Cleaning or Replacing the Venturi Pump.................................................................................... 80
10.2.5 Replacing Gas Valves................................................................................................................. 82
10.2.6 Replacing Pilot Valves ................................................................................................................ 82
10.2.7 Replacing Sensors...................................................................................................................... 83
10.3 Functional Verification ............................................................................................................................ 83
11 Service........................................................................................................................................................... 84
12 Spare Parts and Accessories ...................................................................................................................... 85
13 Support from INFICON ................................................................................................................................. 86
13.1 How to Contact INFICON ....................................................................................................................... 86
13.2 Returning Components to INFICON ....................................................................................................... 86
14 Disposal......................................................................................................................................................... 87

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)v

Table of Contents

INFICON

15 EU Declaration of Conformity ..................................................................................................................... 88
16 EC Declaration of Incorporation ................................................................................................................. 89
17 UK Declaration of Conformity ..................................................................................................................... 90
18 Appendix A.................................................................................................................................................... 91
18.1 Parameter Index ..................................................................................................................................... 91

vi

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

About this manual | 1

1 About this manual
The purpose of this manual is to:• Describe the working principles of the ILS500 F/FHP and its different parts• Show examples of different types of test stations• Teach the reader how to set up the ILS500 F/FHP for different test purposes

Document history
Revision

Date

Remarka

10-2014First editionb

10-2021

Second edition

Warnings
DANGER
Imminent hazard resulting in death or serious injuries

WARNING
Hazardous situation resulting in potential death or serious injuries

CAUTION
Hazardous situation resulting in minor injuries

NOTICE
Hazardous situation resulting in damage to property or the environment

1.1 Target groups
These operating instructions are intended for the owner and for technically qualified
personnel with experience in leak detection technology and integration of leakdetection devices in leak detection systems. In addition, the installation and use of thedevice require knowledge of electronic interfaces.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

7 / 94

2 | Safety

INFICON

2 Safety
2.1 Duties of the operator• Read, observe, and follow the information in this manual and in the work
instructions provided by the owner. This concerns in particular the safety andwarning instructions.
• Always observe the complete operating instructions for all work.
• If you have any questions about operation or maintenance that are not answeredin this manual, contact customer service.

2.2 Intended use
The ILS500 F and ILS500 FHP tracer gas fillers are used to fill test objects with tracer
gas in a safe and controlled manner in conjunction with the leak detectors.

Improper use• Use in radioactive areas• Use of accessories or spare parts, which are not included in this instruction
manual• Use outside the technical specifications, see Technical Data [} 16]• Aspiration of liquids into the device• Operation without exhaust line on gas detection system• Using the device in potentially explosive atmospheres• Using the device with detectable defects or defective power switch

2.3 Owner requirements
The following notes are for companies or any person who is responsible for the safety
and effective use of the product by the user, employees or third parties.

Safety-conscious operation• Operate the device only if it is in perfect technical condition and has no damage.
• Only operate the device properly in accordance with this instruction manual, in asafety and risk conscious manner.
• Adhere to the following regulations and observe their compliance:– Intended use– Universally valid safety and accident prevention regulations– International, national and local standards and guidelines

8 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Safety | 2– Additional device-related provisions and regulations• Only use original parts or parts approved by the manufacturer.
• Keep this instruction manual available on site.

Personnel qualifications• Only instructed personnel should be permitted to work with and on the device. The
instructed personnel must have received training on the device.
• Make sure that authorized personnel have read and understood the instruction
manual and all other applicable documents.

2.4 Dangers• The ILS 500 F/FHP must never be introduced to pressures higher than thatapproved for the object to be tested and never beyond the ILS 500 F/FHP
specification.
• Be sure to have a pressure relief valve in case of accidental tracer gas pressure
increase.
• When dealing with high pressures, a blast protection is needed between the test
ports and the test object.
• When dealing with test objects that cannot stand high pressure increase, makesure to mount a flow control valve on the test ports.
• Make sure not to confound compressed air and tracer gas.
• INFICON can not take any responsibility for the consequences arising frominappropriate use of certain test pressures.

Failure to observe the following precautions could result inserious personal injury:• Tracer Gases can be flammable or asphyxiating. Use only ready-made Tracer
Gas mixtures.
• Since the tracer gas mix contains no oxygen, releasing large amounts of the gas
in a confined space may lead to asphyxiation.
• Compressed gases contain a great deal of stored energy. Always carefully securegas bottles before connecting a pressure regulator. Never transport gas bottles
with a pressure regulator fitted.
• Pressurizing objects at too high pressures can lead to the object bursting. This inturn can result in serious injury or even death. Never pressurize objects that havenot previously been burst-tested or have otherwise been approved for the test
pressure you intend to use.
• The ILS 500 F/FHP has no internal emergency stop circuit. The ILS 500 F/FHP is
prepared for integration into an external emergency stop circuit.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

9 / 94

2 | Safety

INFICON• Check that all relevant legislation and safety standards are complied with before
putting the ILS 500 F/FHP into service. See further information under Setup[} 30].

Failure to observe the following precautions could result indamage to the equipment:• If the tracer gas filler suffers external damage, it must be checked and repaired bya service organization authorized by INFICON.
• Always switch power off before connecting or disconnecting any cable.
• Before connecting the tracer gas, confirm that the connectors or test object isdesigned for operating at the test pressure to be used.

10 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Description | 3

3 Description
The Sensistor ILS500 F/FHP is a stand alone tracer gas filler with all necessaryfunctions integrated in one very compact housing. The purpose of the ILS500 F/FHP
is to make it possible to set up a fully automatic leak test system quickly, to a low cost.
The ILS500 F/FHP can also be combined with both hydrogen and helium INFICON
leak detectors.
All functions are accessible and programmable using a touch panel. The test
sequence is controlled by an integrated controller.
To make operation easier, a mouse or a keyboard can be connected to the USB port.

3.1 Intended Use
ILS500 F/FHP is designed for indoor use only.
ILS500 F/FHP is manually controlled using the START and STOP buttons and themenu system of the touch panel. The screen also shows the steps of the test
sequence graphically and in plain text.

3.2 Available Configurations
Configuration

PurposeSensistor ILS500 F

For common tracer gas leak detection

Sensistor ILS500 FHPHigh Pressure (HP)
When a higher tracer gas pressure is needed.

The actual configuration is shown on the display during start-up and in the menu whenclicking Setup >> Info.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

11 / 94

3 | Description

INFICON

3.3 Front View
3
2

4

1

5

Fig. 1: ILS500 F/FHP Front View

12 / 941

Red lamp

2

Green lamp

3

ILS500 F/FHP Touch panel

4

START button

5

STOP button

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Description | 3

3.4 Rear View (Electrical)
1

2

12

11
3
10
4
9

5
6

8

7

Fig. 2: Rear View (Electrical)

1(not used)2

USB Port

3

Safety Interface

4

Fuses

5

Power Switch

6

Power Input

7

Control Output

8

Tooling Interface

9

Status Output

10

Inputs 1 and 2 (optional)

11

Ethernet

12

RS232

For more information, refer to Technical Data [} 16].

3.5 Configuring Ports and Interfaces (Electrical)
Port/Interface

Connect

Safety Interface

Emergency Stop Circuit

Power Input

Power Cable

Control Output

Optional External Valves

Tooling Interface

External sensors for tooling control

Status Output

Light Tower etc.

Input 1 (optional)

Analogue Input (not supported by std software)
Digital Input (not supported by std software)

Input 2

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

Active Holder for Hand Probe

13 / 94

3 | Description

INFICON

Port/Interface

Connect(if ISH2000 Leak Detector is connected).

Ethernet

Ethernet (remote view and control of touch panel)

RS232

Serial Printer
Logging Device (e.g. PC).
Remote Control (START, STOP etc.).

USB

The USB port can be used to connect a mouse, anexternal keyboard, or a flash drive (for download andupload of recipes or to save screen dumps).

3.6 Rear View (Pneumatical)

9

8

7

1

6

2

5

3

4
Fig. 3: Rear View (Pneumatical)

1

Optional Port2

Test Port 2

3

Compressed Air Input

4

Tooling Valve Outputs 1-4

5

Vacuum Gauge Vent

6

Test Port 1

7

Tracer Gas Input

8

Plugged Port

9

ExhaustNOTICE► Do not remove the plug from the plugged port in pos. 8.

14 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Description | 3

3.7 Configuring Ports and Interfaces (Pneumatical)
Port/Interface

Port Thread

ExhaustBarb Fitting:ID 25 mm (1 in.)Tracer Gas Input

BSP 3/8" (NPT 3/8" adaptor included)

Test Port 1

BSP 3/8" (NPT 3/8" adaptor included)

Test Port 2

BSP 3/8" (NPT 3/8" adaptor included)

Compressed Air Input

BSP 3/8" (NPT 3/8" adaptor included)

Tooling Valve Outputs 1-4

Hose Connectors:
OD 4 mm (0.16 in.)

3.8 Labels

Fig. 4: Device Label

Fig. 5: Tooling LabelILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

15 / 94

3 | Description

INFICON

Fig. 6: Pneumatical label (left) and electrical label (right)

294 mm (11.6 in.)

3.9 Technical Data

275 mm (10.8 in.)

364 mm (14.3 in.)3.9.1 Electrical Specifications
Electrical Supply
Mains Voltage

16 / 94

Single Phase

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Description | 3

Electrical Supply
110-240VAC 50/60 Hz
Current

1.0 A at 100 VAC
0.45 A at 230 VAC

Power Rating

120 W max
33 W typical average

Inrush Current

Max 40 A

Mains Connector

IEC/EN 60320-1/C14

Recommended Fuse

2 A slow

Rating

6.3 x 32 mm, 0.2 x 1.3 in. (2 needed)

3.9.2 Pneumatic Specifications
Compressed Air Supply
Pressure

Std Model

0.35–0.7 MPag
(3.5–7.0 barg)(50–100 psig)
Reduced vacuum capacity
below:
0.5 MPag(5.0 barg)(70 psig)

HP model0.5–0.7 MPag
(5.0–7.0 barg)(70–100 psig)

Peak Consumption at 6240 l/min (508 SCFH)

barg (87 psig)
Quality

Oil free and filtered to 5 µm

Dew point

Max 10°C (50°F)

Tracer Gas Supply
Composition
Pressure

Inert non-condensing gas
Std Model

0.005–1.0 MPag
(0.05–10.0 barg)(0.72–145 psig)

HP model0.02–3.0 MPag
(0.2–30.0 barg)(3–435 psig)

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

17 / 94

3 | Description

INFICON

Tracer Gas Supply
Quality

Industrial grade purity(>95% purity)

ExhaustCapacity in Exhaust DuctMin 30 m3/h (1000 SCFH)

Dimensions of HoseID 25 mm (1 in.)Leading to Duct
Pneumatic
Valve bore*

7 mm (0.28 in.)*: Capacity is given for 500 mm (20 in.) of ID 10 mm (0.4 in.) hose between ILS500 F/
FHP and test volume.
Evacuation
Max vacuum-85 kPag (-0.85 barg, -12.3 psig)

Capacity

0.4 s/l to -50 kPag (-0.5 barg, -7.2 psig)
1.5 s/l to -80 kPag (-0.8 barg, -11.6 psig)

Filling
Capacity at 1 MPag supply 0.1 s/l to 0.6 MPag (6,0 barg, 87 psig)
Tooling Output Valves
Valve type

Normally closed, 3/2 valveQn

160 std l/min

Cv

0.16 USGPM/psig

Gas and Air Connection
Ports

Female ISO 3/8"
(ISO to NPT 3/8" adapter included)

Hose connector

4 of OD 10 mm (0.4 in.) connectors included

3.9.3 Other Data
General Data

18 / 94

Dimensions

295 x 275 x 330 mm (12 x 11 x 13 in.)

Weight15.1 kg (33.3 lb.)

Ambient temperature

10–40°C (50–100°F)

Ambient humidity

85% RH (non condensing)Protection

IP30

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Description | 3

3.9.4 Interfaces and Connectors
All interfaces signals except the serial. Communication interfaces are discrete 24 VDC
logic signals.
Output signals (OUT) are sourcing transistor outputs. Input signals (IN) are transistor
inputs.
Max current of each signal is given in the tables below. Total current (sum) must,however, be within instrument specification.

NOTICE
Outputs are not relay types.
► Do not connect external drive source such as 24 V or 100/230 VAC.

3.9.4.1 RS232

Connector:

9 pin male D-sub

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

Cable:

Standard female to female file transfer cable (null modem)

Baud Rate:

9600 default (1200 - 115200 selectable)

Pin

SignalSpecification1

Not usedStandard

RS232C

2

RD

Data rate

9600 baud

3

TD

Data bits

8

4

Not used

Stop bits

1

5

SG

Paritynone

6

Not used

Flow ctrl

none

7

Not used8

Not used9

Not used

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

19 / 94

3 | Description

INFICON

Printing of results
The printer port prints the result of every test. In hand probe mode the result printed is“ACCEPT” or “REJECT” followed by date & time and recipe name (if used) and end
Char New Line (0A, LF).<09> (Char Tab, 09) is used as a separator.
For Example: "TEST_ACCE<09>2013-09-04 13:23:03<09>Factory Default<0A>"
If the test cycle is rejected by any other test this will be printed. Followed with date,time and recipe name. Hardware error prints “ERROR”.
For example: “ERROR<09>2013-09-04<09>Factory Default<0A>”.
On the ILS500 (Service/RS232), you can choose if you want to include time and datein every result from the ILS500 or not. If it’s on the result will be:"TEST_ACCE<09>2013- 09-04 13:23:03<09>Factory Default<0A>" and if it’s off:
“TEST_ACCE<0A>".
When filling is successfully completed FILL OK is printed. No information about timeand date is printed.

Results from ILS500 F/FHPResults

Explanation

TEST_ACCE

Test accepted (if a leak detector is connected)

TEST_REJE

Test rejected (if a Leka detector is connected)

USER_FAIL

User has pressed stop

EVAC_FAIL

Evacuation failed

VDEC_FAIL

Vacuum decay test failed

FILL_FAIL

Tracer gas filling failed

PDEC_FAIL

Pressure decay test failed

BLOC_FAIL

Blockage test failed

REFI_FAIL

Tracer gas refill failed

TEST_STRT

Test cycle started

TEST_DONE

Test cycle finished

FILL_DONE

Filling completed

RECH_DONE

Recipe change done

RECH_FAIL

Recipe change failed

ERROR

Hardware error on ILS500

Commands
The printer port can also be used to control the ILS500 F/FHP. The most commonlyused functions can be started/configured over the RS232 interface. Always use New
Line (0A,LF) as end character.

20 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Description | 3

Command

ActionM<0A>

Start measurement

Q<0A>

Stop measurement

S<0A>

Statistics (see table below)

RS<0A>

Reset statistics

R<09>Factory Default <0A> loads a recipe. For example“R<09>Factory Default” loads the recipe Factory
Default. When the recipe is loaded the recipe name isechoed back. If a recipe name isn’t in the ILS500 F/
FHP, the answer from the ILS500 F/FHP will be “Not a
recipe name!”

Statistics

Printed data

Explanation

REC:AP29

Recipe namePrinted if recipes is
activated

TOT:00031

Total

ACC:00009

Accepted

REJ:00022

Rejected

EVA:00001

Evacuation

VDE:00000

Vacuum decay

BLO:00006-Blockage test

FIL:00001-Gas filling

PRE:00000-Pressure decay

GAS:00014

Gas detector

The number printed behind the colon represents the number of occurrences. For
example: TOT:00031 means that 31 total tests have been made.

3.9.4.2 Input 1 (Optional)

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).

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

21 / 94

3 | Description

INFICONPin Signal

Type

Load

Comment

1+24 VDC

SUPPLY

250 mA

Option supply.

2

VIN1

IN

-60 mA

Voltage input: Digital 24 VDC or
analogue 0-10 VDC.

3

IIN1

IN

+/-30 mA

Current input: 0-20 mA.

4

COM1

IN

-250 mA

Signal common (GND).

5

COM/SHLD

GND+/-30 mA

Shield.

3.9.4.3 Input 2 (Optional)

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+24 VDC

SUPPLY

250 mA

Option supply.

2

VIN2

IN

-60 mA

Voltage input: Digital 24 VDC or
analogue 0-10 VDC.

3

IIN2

IN

+/-30 mA

Current input: 0-20 mA.

4

COM2

IN

-250 mA

Signal common (GND).

5

COM/SHLD

GND+/-30 mA

Shield.

3.9.4.4 Status Output

22 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Description | 3

Connector:

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

Purpose:Test Status Outputs. Sourcing 24 VDC transistor outputs.

Pin Signal

Type

Load

Comment

1

RUNNING

OUT

0.5 A

Cycle running.

2

ACCEPTOUT

0.5 A

Tested part accepted.

3

REJECTOUT

0.5 A

Tested part rejected.

4

ERROR

OUT

0.5 A

Summing error.

5

EOT/FILLED

OUT

0.5 A

End of test or gas filled indicator(selectable).

6

COM

GND

-2.0 A

Common GND.

NOTICE
Gas filling status is available on the STATUS connector (pin 5) on the back of the unit.
Connect to a lamp for easy notification of “End of test” status.

3.9.4.5 Tooling Interface

Connector:

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

Purpose:Electrical tooling interface.

Pin Signal

Type

Load

Comment

1

SUPPLY

300 mA

Tooling switch supply (e.g.

+24 VDC

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 markon REJECT or ACCEPT.

7

COM

GND

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)-1.0 A

Common GND.
23 / 94

3 | Description

INFICONPin Signal

Type

Load

Comment8

GND-1.0 A

Common GND.

COM*: MARKER output (Tooling Connector, pin 6) can be used to send a start pulse tomarking 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.

3.9.4.6 Control Output

Connector:

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

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

Pin Signal

Type

Load

Comment

1+24 VDC

SUPPLY

2.0 A

Start and stop switch and supply.

2

EXTSTART

IN

-7 mA

Start button return (NO contacts)
or contact to +24 VDC.

3EXTSTOPIN-7 mA

Stop button return side (NOcontact) or contact to +24 VDC.

24 / 94

4

EVAC1

OUT

0.5 A

Venturi valve output.

5

EVAC2

OUT

0.5 A

Evacuation valve output.

6

GASFILL

OUT

0.5 A

Fill valve output.

7

OPTOUT

OUT

0.5 A

8

COM

GND

-1.0 A

Common GND for outputs.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Description | 3

3.9.4.7 Power Input
Specification
AC mains voltage

110-240 V 50/60Hz.

AC mains current

Typically 1 A (2 A pulse at power on).

3.9.4.8 Safety Interface
Risk assessment is the sole duty of the user of the ILS500 F/FHP.

Connector:

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

Purpose:Emergency stop interface.

Pin Signal

Type

Load

1

+24 VDC

SUPPLY

2.5 A

2

AUX1

-

+/-1-5 A*

Comment

Terminal 1 of safe relay contacts
for auxiliary external use.

3

AUX2

-

+/-1-5 A*

Terminal 2 of safe relay contacts
for auxiliary external use.

4

ESTATUS

OUT

0.5 A

Internal emergency circuit
stopped. Use for reset lamp or
PLC monitoring.

5

SAFESPLY** SUPPLY-2.5 A

24 VDC supply from EXTERNAL
emergency stop circuitry.

6

COM

GND

1.0 A

Common GND.

*: 250 VAC 5 A cosj =1; 30 VDC 5 A L/R = 0 ms; 240 VAC 2A cosj = 0.3; 24 VDC 1A
L/R = 48 ms**: SAFESPLY feeds risk associated loads inside the ILS500 F/FHP. These include allgas and tooling valves.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

25 / 94

3 | Description

INFICON

3.9.4.9 USB Port

Connector:

USB

Purpose:Used for import and export of recipes.

USB is connected

USB Memory connected

Import from USB
Export to USB

An icon for USB is shown when installing the USB flash drive.

26 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Description | 3

Import Recipe from USB
Importing database tables Recipe1 from csv-file...

USB Memory connected

Import from USB
Export to USB

When importing recipes all recipes are imported from a file named Recipe1.csv.

Export Recipe to USB
Exporting database tables Recipe1 to csv-file...

USB Memory connected

Import from USB
Export to USB

When exporting recipes all recipes are exported to a file named Recipe1.csv.
See also
2 Removing the Cover [} 80]

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

27 / 94

4 | Equipment and Storage

INFICON

4 Equipment and Storage
4.1 Supplied Equipment
NOTICE► When receiving the equipment, check that it has not been damaged duringtransport.

1

2

9

OM
ILS500 F

3

8

4

7

6

5

Fig. 7: Supplied Equipment

1

1×Sensistor ILS500 F (590-580)
Sensistor ILS500 FHP (590-581)

2

1×Power cables (EU, UK, US) (592-082)

3

1×

Screw terminal connectors for external I/O signals (591-617,
591-633, 591-634)

4

4×Thread converter set (ISO to NPT Conversion) with steel
gasket28 / 9454×

10 mm hose connection female

6

1×Safety override loopback

7

1×

USB flash drive with relevant manuals (592-095)

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Equipment and Storage | 4

81×Operating manual Sensistor ILS500 F/FHP (this manual,592-121)

9

1×Return Product Condition Report

Some pneumatic ports are plugged upon delivery.
► Store the removed plugs. They are used for future hardware testing.
Refer to Spare Parts and Accessories [} 85] for accessories to the ILS500 F/FHP.

4.2 Required Equipment
1

3

2

5

4

6

Fig. 8: Required Equipment

1

Tracer Gas

2

Compressed Air

3

Two-Step Gas Regulator

4Compressed Air Filter

5

Exhaust Hose

6

Emergency Stop Circuit (recommended)

4.3 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.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

29 / 94

5 | Setup

INFICON

5 SetupCAUTION► Check that you comply with all relevant legislation and safety standards before
putting your ILS500 F/FHP into service.

5.1 Placement of the ILS500 F/FHP

Place the ILS500 F/FHP on a flat surface, as close as possible to the test fixture andventilation system.

Some free space must be provided around the ILS500 F/FHP to enable maintenanceand service access.

Ensure that there is at least 350 mm (14 in.) of free space behind the ILS500 F/FHP toenable removal of service hatches, connection of supplies, test fixture etc.

NOTICEThe front feet under the ILS500 F/FHP can be flipped out to raise the front for a better
viewing angle.

30 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Setup | 5

5.2 Electrical Connections
5.2.1 Setting Up an Emergency StopNOTICE► To short-circuit is not recommended and should only be made for preliminary
testing before connecting compressed gases or test tooling with moving parts.

You have the following two options to prepare the ILS500 F/FHP for start:• Connect the ILS500 F/FHP through an external emergency stop relay.
• Short circuit the SAFE SPLY terminal to “+24 V” on the Safety Connector.
Use the Safety Override Loopback delivered with the unit.

NOTICEILS500 F/FHP will not start testing unless an emergency circuit has been installed.
This can be ordered separately. For more information, see Spare Parts andAccessories [} 85].

5.2.2 Connecting to Mains► Plug the Power Cable into the Power Inlet of the ILS500 F/FHP and into thenearest socket.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

31 / 94

5 | Setup

INFICON

5.2.3 Connecting Extra Features
When using the ports for Options, Status, Tooling and Control, make sure to mountthe connectors as shown below.

Top pin is number 1

For more information about the connection ports, see Technical Data [} 16].

5.3 Pneumatic Connections
5.3.1 Connecting Compressed Air
NOTICE► Make sure that compressed air is dry, well filtered and oil free. Recommended filter
grade is 5 µm or finer. Inadequate filtering will result in increased maintenance.
► Make sure to use adequate pressure and flow. For more information, see
Pneumatic Specifications [} 17].
► Use the hose to connect the compressor and the ILS500 F/FHP.

32 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Setup | 5

5.3.2 Connecting Tracer Gas
WARNING
Pressurizing objects at too high pressures can result in a burst object. This in turn can
result in serious injury or even death.
► Never pressurize objects that have not previously been burst tested or otherwise
approved for the chosen test pressure.

WARNING
Tracer Gases can be flammable or asphyxiating.
► Use only ready-made Tracer Gas mixtures.
1

Secure gas cylinder safely.

2

Open the cylinder valve briefly to blow out dirt that may have collected in theoutlet.

3

Install the two stage gas regulator on cylinder.

4

Turn regulator fully counterclockwise for zero output pressure.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

33 / 94

5 | Setup

INFICON

5

Connect a regular welding gas hose or similar between the Tracer Gas Portand the pressure regulator. Check that the hose is certified to withstand the
maximum output pressure of the regulator.

34 / 94

6

Open cylinder valve and set regulator to desired pressure. See warning banner!

7Open regulator outlet valve (if any).

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Setup | 5

5.3.3 Connecting Exhaust to Air Vent
Min. 2 m (6.5 ft.)

Ø 100 mm (4 in.)Max. 10 m (30 ft.)

Ø ≥ 25 mm (1 in.)

3

2
1

Fig. 9: Exhaust Recommendation

1

ILS500 F/FHP

2

Exhaust Hose

3

Bleed Air• The exhaust gas must be directed out of the building.
It is best placed on the roof of the building, far away from the fresh air intake of thetest station.
• It is recommend that a dedicated duct is installed. Install an electric duct fan andan optional wind extractor.
• It is not recommended to use the general ventilation system to ventilate theexhaust. If the ventilation system is equipped with energy recirculation there is a
big risk that large amounts of tracer gas will be carried back to the test room thus
disturbing the testing.

NOTICE
Inadequate exhaust installation is the most common reason for problems with tracer
gas leak testing.
Too narrow or too long exhaust line will result in reduced evacuation capacity andthereby increased cycle time.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

35 / 94

5 | Setup

INFICON

5.3.4 Connecting to Test Port 1 and 2• Use both Test Ports if applicable.
• Hose ø ≥ 8 mm (0.31 in.).
• The hoses should be as short as possible.
If the test object has 2 or more ports, connect to ports on opposite sides of object.

NOTICEThe larger the test object, the more important to follow the recommendations above.

5.3.5 Connecting Tooling
WARNINGBe aware 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.

Tooling Valve Outputs 1-4 is available for connection of external Tooling.

36 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Setup | 5

5.4 Set Up Test Area
Large distance

4

1

2

3

Fig. 10: Test Area Recommendation

1

Fresh Air Fan

2

Exhaust Fan

3

Test Area

4

Test Building• Place fresh air intake on outer wall of building.
• Place air intake far away from tracer gas exhaust, cargo bays, and other tracer
gas sources.
• Already tested objects may contain small amounts of tracer gas, which may
interfere with next measurement.
• Do not use compressed air as fresh air supply when a hydrogen mixture is usedas tracer gas. Industrial compressed air can contain varying and substantial
amounts of hydrogen.

1

4

2
3

Fig. 11: Fresh Air Curtain Recommendation

1

Fan

2

Local Air Jet

3

Test Object

4

Filter• Try to create a laminar flow over the test area.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

37 / 94

5 | Setup

INFICON• Curtain should cover the entire test area (test hood or sample point) and extend at
least 0.5 m outside the area.
• Air speed in curtain should be rather low, typically 0.1 m/s.
• Additional small fan(s) can be set up within the curtain for directional purging oftest chamber etc.

38 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Menu System | 6

6 Menu System
6.1 ILS500 F/FHP Display
1
–0+

5,00

–0,70

bar

2

Ready for Start

3

1

Status Bar

2

Main Display

3

Navigation Button Bar (varies depending on menu)

6.1.1 Menu Buttons
Use the menu buttons for quick navigation.
Home

Load Recipe

Settings

6.1.2 Navigation and Other Buttons
Go Back

EscapeESC
Previous Page

(changes will not be saved)
Next Page(changes will be saved)
Activated

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

Unactivated

39 / 94

6 | Menu System

INFICON

Selected

Deselected

Save

Load

(only shown if USB isconnected)
Open switch

Closed switch

6.1.3 Entering Numbers and Text
To change a value:
1

Click on the value. A numeric or alphanumeric on-screen keyboard will open.

2

Enter the desired digits or characters.

3

Click on the enter symbol to store the new value.
1

2

1

3
Esc

a

b

c

d

e

f

Del

g

h

i

j

k

l

m

n

o

p

q

r

s

t

u

v

w

x

y

z

,

.

?

Shift

A..1

7

8

9

4

5

6

1

2

3

-

0

,

Esc

2

4

Ctrl

Del

3

5

1

Escape2

Delete

3

Enter

4

Control5Upper/Lower Case and Numbers

6.1.4 Screen Saver
If no operation takes place for a period of 20 minutes, the screen will automatically belocked. The display can be unlocked by one of the following actions:• user touches the display• user presses START or STOP button• a start or stop command is sent by an external system

40 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Menu System | 6

6.2 Passwords
To access the menus, use default password "1234" for "Service". The password canbe changed under Settings / Advance Settings / Passwords.

Passwords
Calibrate

Log InSelect Recipe
Log Out
Setup excl. ToolingAdv. Setup excl. Service
Setup User

Service Menu

NOTICE
Remember to change the passwords of all menus you want to protect. Anyone using
this manual can access the system if you keep the default password.

6.2.1 Set Up New User
1

Click Settings >> Advance Settings >> Passwords to enter Passwords
menu.

2

Click Log In and log in as Service.

3

Click Setup User.

4

Click Add.

5

Fill in user name and password for new user.

6

Click Next.

7

Select Security Group by checking the appropriate boxes.

8

Click Finish.

6.3 Menu Overview
For information about parameter factory default settings, see Parameter Index [} 91].
Load Recipe

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

41 / 94

6 | Menu System

Settings

INFICON

Test Settings

Tooling Connection
Pre Evacuation
Gross Leak Test

Vacuum Decay Test
Pressure Decay Test

Tracer Gas Filling
Blockage Test
Tracer Gas Test
Gas Evacuation
Tooling Disconnection
Advanced Settings

TimersPressures
Options
Service Menu

Outputs
InputsAnalog Inputs
System Reset
ILS500 F/FHP
RS232
Service Run
Hardware Test

Passwords
IP-Settings
Recipes
Statistics
RegionTime Zone, Region and Daylight
Time and Date
LanguageInfo

42 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Menu System | 6

Settings

Settings
Test Settings

Statistics

Advanced Settings

Region Settings

Recipe Settings

Info

Test Settings

Test Settings
Tooling Connection
Pre Evacuation
Gross Leak Test
Tracer Gas Filling

For more information see Recipes [} 50].

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

43 / 94

6 | Menu System

INFICON

Advanced Settings

Advanced Settings
TimersService Menu

Pressures

Passwords

Options

IP-settings

Advanced settings to fine tune the fill cycles and settings for service staff.

Recipes

Recipes
Use Recipes
Choose at startup
Load Recipes
Save Recipes

Delete Recipes

For more information, see Maintenance Instructions [} 78].

44 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Menu System | 6

Statistics

Statistics
Total:
Accepted:
Rejected:000

Evacuation:

0

Vacuum Decay:0

Blockage:0

Gas Fill:0

Pressure Decay:0

Gas Test:

0

Print
Reset
Press 3 sec

Information about test statistics and number cycles events during a test period.
For more information see Test Sequence [} 47].

RegionRegion Settings

Time Zone, Region and Daylight
Time and Date
Language

Regions settings.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

45 / 94

6 | Menu System

INFICON

Language

Language
EnglishSwedishJapanese

ItalianGermanLanguage settings.

Info

Info
Type: ILS500 F
Serial number: 1500
CPU software v 3.00.08
Display version: 3.00.09
Backup Battery Level (3,0 V)
Brightness display

Instrument information, software versions, battery status and display light settings.

46 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Using the ILS500 F/FHP | 7

7 Using the ILS500 F/FHPNOTICE► Ensure that the tracer gas supply pressure (feeding the ILS500 F/FHP tracer gas
inlet) is set up properly.
To abort a test sequence and reset to standby, press STOP for 3 s.
The following description is an example for illustration only. The design of the text
fixture, the use of probe(s) and tooling functions etc. should be adapted to suit yourparticular application.

7.1 Test Sequence
Step

Comment

1

Standby

ILS500 F/FHP is idle waiting for Start Signal.

2

Tooling Connection

Four Air Valves and four Proximity Switch Inputs can be set up to control
moderate test fixtures. Controller can be expanded for more demanding
fixtures.

3

Pre Evacuation

The air is evacuated from the test object and a first gross leak test is made

Gross Leak Test 1-

simultaneously. The Gross Leak tests are used to detect larger leaks by

Evacuation Timeout

pressure changes. Evacuation is often necessary to ensure that the Tracer
Gas reaches all parts of the tested object, and to secure that the tracer gas
concentration is as high as possible.
Applicable for:• very long objects (e.g. pipes or heat exchangers).
• low fill pressures (<1 atm).
Less appropriate:• if the test object does not tolerate underpressure.
• at higher test pressures (Fill Setpoint).

4

Gross Leak Test 2-

Can be used to reveal leaks before filling with gas. This minimizes spillage

Vacuum Decay Test

from gross leaks.

5

Tracer Gas Filling

Tracer gas filling before gas test.

6

Blockage Test

• Reveals internal blockages in tested object.
• Ensures that connection lines and test fixture are correctly connected.
The test object is filled through Test Port 1 while the pressure is recorded in
Test Port 2. Practical for testing e.g. capillaries etc.

7

Gross Leak Test 3-

Performed in parallel with tracer gas test.

Gas Pressure Decay

Can be used for integral testing in parallel with a more sensitive gas test at

Testselected points.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

47 / 94

7 | Using the ILS500 F/FHP

INFICON

Step
8

Comment
Leak detect pressurized Perform leak detection on the test object, pressurized with tracer gas.
test object

9

Gas Evacuation

For a fast removal of tracer gas after test. Can also include an efficient air
purge.

10

Tooling Disconnection

Disconnection of test fixture.

NOTICE
Several of the steps are optional and can be turned off.
► Chosen settings can be saved as a recipe. For more information, see Recipes[} 50]. It is also possible to combine two recipes in one test sequence. Contact
your local supplier for more information and individual settings.

7.2 Run a Test
The ILS500 F/FHP will communicate through the lamps and messages on the display.
Lamp

StatusIndication

Red

ON

Acknowledge a leak.
Tested object rejected.
General error.

Green

ON

Test sequence is over (and the tested object
accepted if Leak Detector is connected.)

YellowON

The test sequence is running.

(START Button)

7.2.1 Start Up
1

Turn the ILS500 F/FHP on.

2

Wait for Ready to Start to show on the display.

3

Click Load Recipe and choose a preset recipe, or follow the instructions in
Recipes [} 50].

7.2.2 Place the Test Object
1

Place the test object in the Test Chamber or connect it to one, two or moreconnection ports.

2

Connect any extra equipment needed.

7.2.3 Perform Tracer Gas Filling1

48 / 94

Press Start on the ILS500 F/FHP.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Using the ILS500 F/FHP | 72

Perform a tracer gas leak test.

3

Press Stop on the ILS500 F/FHP to remove the tracer gas.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

49 / 94

8 | Recipes

INFICON

8 Recipes
A recipe is a collection of settings suited for a particular test setup. This is used tohave different settings for different test objects.

8.1 Recipe Overview► Click Settings >> Recipes to enter the three Recipe Setup menus.

Recipe Setup
Use Recipes
Choose at startup
Load Recipes
Save Recipes

Delete Recipes

Recipe Setup
Connect with recipe
Use from list

0
Factory Default

Keep Tooling in Test Step
Keep Pressure in Test Step

50 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Recipes | 8

Recipe Setup

USB Memory connected

Import from USB
Export to USB

Use Recipes

Select the box to activate the recipe handling.

Choose at Startup

When power is switched on, the ILS500 F/FHP prompts the operator tochoose recipe.

Load Recipe

Loads the parameters of chosen recipe. A new window will open.

Save Recipe

Saves the current settings under chosen recipe name.
A new window will open.

Delete Recipe

Deletes the chosen recipe.
A new window will open.

Connect with Recipe

Connects two recipes to form one test cycle.
Write the name of the recipe to be included, or choose one from the list in
Use from list.

Use from list

Shows all saved recipes.
By clicking the blue button the recipe displayed is added to Connect withrecipe.

Keep Tooling in Test Step

Excludes the disconnection step in the first recipe when two recipes areconnected as described above.

Keep Pressure in Test Step

Retains gas pressure between two recipes.

Import from USB

Imports recipes from connected USB memory.

Export to USB

Exports all recipes to an editable file on connected USB memory.

8.2 Create a Recipe
8.2.1 New Recipe1

Set all ILS500 F/FHP settings for the test sequence.
For more information, see Test Settings [} 52].

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

51 / 94

8 | Recipes

INFICON

2

Click Settings >> Recipes to enter the three Recipe Setup menus.

3

Click Save Recipe.

4Enter a name for the recipe.

5

Click Save.

8.2.2 Modify a Recipe
1

Click Settings >> Recipes >> Load Recipe.

2

Select the recipe to modify from the list and click Load.

3

Adjust the ILS500 F/FHP settings to suit the new recipe. For more information,
see Test Settings [} 52].

4

Click Settings >> Recipes >> Save Recipe.

5Enter the name of the new recipe.

6

Click Save Recipe.

8.3 Test Settings
1

Click Settings >> Test Settings to enter the two Test Settings menus.

Test Settings
ON

Setup

Tooling Connection
Pre Evacuation
Gross Leak Test
Tracer Gas Filling

52 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Recipes | 8

Test Settings
ON

Setup

Blockage Test
Tracer Gas Test
Gas Evacuation
Tooling Disconnection

2

Set which steps to include in the test sequence by selecting the ON boxes.

3

Click Setup to the right of each selected step to enter the Setup menus.

NOTICEFor more information about each step, see Test Sequence [} 47].

8.3.1 Tooling Connection
Connection Sequence menu shows the settings made for Tooling Connection.

Connection Sequence
1

Tooling Outputs
2
3

4Stand by
Step
Step
Step
Test

1
2
3

ON
ON
OFF

► Click on the Settings symbol to edit the settings.

NOTICEUp to four connection steps can be programmed.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

53 / 94

8 | Recipes

INFICON

Stand-By

STAND-BY
Tooling Outputs
ON
Go to next step with

Start Button

and Tooling Inputs

Delay

1

Click on the Tooling Outputs to be activated in stand-by (between tests).

2

Choose how to move on to the next step.
Set action in list.
Select Tooling Inputs.

3

Set desired delay time.

Connection Step 1 — 3Connection Step 1
ONTooling Outputs
ON
Go to next step withAuto

and Tooling Inputs

Delay

54 / 94

1

Select the ON check box to activate the step.

2

Click on the Tooling Outputs to be activated.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Recipes | 8

3Choose how to move on to the next step.
Set action in drop-down-list.
Select the appropriate check box(es) for the Tooling Inputs.
Then set “Open” or “Closed” status for each switch symbol.

4Enter a text to describe the step (click the Info field to activate the on-screen
keyboard).

5

Set desired delay time.

Test Step

Test Step
Tooling Outputs
ON
Condition for starting test
and Tooling Inputs

Info

Delay

► See Connection Step 1 - 3 above and follow the instructions.

8.3.2 Pre Evacuation
Pre Evacuation
Pre Evacuation Setpoint

–0,70

bar

Extended Pre Evacuation

0,0s

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

55 / 94

8 | Recipes

INFICON

Pre Evacuation Setpoint

A value of -0.70 barg (-0.07 MPag, -10 psig) is adequate
for most applications. This creates 70% vacuum.

Extended Pre Evacuation

To ensure a complete filling. Evacuation will continue forthe set time after Evacuation Level has been attained.

8.3.3 Gross Leak Tests
Gross Leak Test
Evacuation Timeout

10.0

s

Vacuum Decay test
– before gast test
Pressure Decay test
– during gast test

Evacuation Timeout

Object will be rejected if Pre Evacuation Setpoint is not
attained within time set.

Vacuum Decay Test

If to be included in the test sequence, select the box andclick the blue button to enter Pressure Decay Test setup
menu (see below).

Pressure Decay Test

If to be included in the test sequence, select the box andclick the blue button to enter Pressure Decay Test setup
menu (see below).

56 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Recipes | 8

Vacuum Decay Test

Vacuum Decay Test
Vacuum Stabilisation Time

5.0

sVacuum Decay Test Time

5.0

sVacuum Decay Limit

0.10

bar

Vacuum Stabilisation Time Delay time before Vacuum Decay test begins.
Vacuum Decay Test TimeTime during which pressure rise is recorded.

Vacuum Decay Limit

Allowed pressure rise during test time.

Pressure Decay Test

Gas Pressure Decay Test
Pressure Stabilisation Time

5.0 s

Pressure Decay Test Time

5.0 s

Pressure Decay Limit

0,05 barPressure Stabilisation

Delay time before Pressure Decay test begins.

Time
Pressure Decay Test Time Time during which pressure drop is recorded.
Pressure Decay Limit

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

Allowed pressure drop during test time.

57 / 94

8 | Recipes

INFICON

8.3.4 Tracer Gas Filling
WARNINGThe ILS500 F/FHP must never be introduced to pressures higher than that approved
for the object to be tested and never beyond the ILS500 F/FHP specification.

NOTICE
Ensure that the test object has time to become filled before Fill Time Out expires. In
particular long narrow objects, as pipes, may need long filling time.

Tracer Gas Filling
Fill Setpoint

0,30

bar

Fill Timeout

10,0

s

External Fill Regulation
Pressure Unit

bar

Fill Setpoint

Desired tracer gas fill pressure.

Fill Timeout

Object will be rejected if Pressure Setpoint has not been
attained within this time.
Cancels the fill if the test object has a major leak, opens,
or if there are loose connections.

External Fill Regulation

If selected, this is the setpoint of fill pressure alarm.
Internal pressure regulation is disengaged and pressure
will be that of the gas supply line. ILS500 F/FHP checks
that fill pressure is above Pressure Setpoint before
proceeding to gas test step.

Pressure Unit

58 / 94

Select desired unit.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Recipes | 8

8.3.5 Blockage Test
NOTICE
This test can only be performed if both test ports are used and connected on eitherside of the possible blockage.

Blockage Test
Blockage Test Pressure

0,30 bar

Blockage Test Time2,0 s

Blockage Test Pressure

Minimum pressure to be attained at Test Port 2 during
Blockage Test time.

Blockage Test TimeTime within which Blockage Test Pressure must be
attained at Test Port 2.

8.3.6 Gas Evacuation
Gas Evacuation
Gas Evacuation Setpoint–0,50 bar

Extended Gas Evacuation

0,0 s

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

59 / 94

8 | Recipes

INFICON

Gas Evacuation Setpoint

Set desired level of Gas Evacuation.
-30 kPag (-0.3 barg, -4.4 psig) creates 30% vacuum,
which is adequate for most applications.

Extended Gas Evacuation

Extends time for gas evacuation, after Gas Evacuation
Setpoint has been reached.

8.3.7 Tooling Disconnection
Disconnection Sequence
1

Tooling Outputs
2
3

4

Test
Step

1

OFF

Step

2

OFF

Step

3

OFF

Stand-bySame function as Tooling Connection but in revers order. For information about thisstep, see Tooling Connection [} 53].

8.4 Optimizing the Test Cycle
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 optimizing step 2, 3 and 5.

60 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Recipes | 8

8.4.1 Optimizing the Pre Evacuation StepNOTICEThe fastest way to fill a pipe like object is to use push-through filling. That does not
require pre evacuation.
Begin to determine how deep the pre evacuation needs to be, or if it can be skipped
altogether. To do this it is important to fully understand the role of pre evacuation.
When the test object is connected it holds one atmosphere of ambient air. It is often
necessary to remove some or most of this air before filling with tracer gas.
There are two effects of not removing the air (i.e. pre evacuating):
1. the actual tracer gas concentration will be reduced
2. tracer gas does not reach all parts of the object

8.4.1.1 Calculate Tracer Gas Concentration
Example:The fill pressure is 0.05 MPag (7.2 psig) above atmosphere (gauge pressure). The
object has 1 atm = 0.1 MPag of air before filling.
Leaving this air in the object means the average tracer gas concentration will be:
A = Fill Pressure
B = 1 atm
C = Tracer Gas Fill Factor

A
A+B

= C

0,05
0,05 + 0,1= 0,33

The average tracer gas concentration in this example is only a third (33%) of what
expected.
When using a tracer gas mix of 5% the result will be:
0.33 x 5% = 1.7%
Pre evacuating down to -0.7 atm (-0.07 MPag) means there will be 0.3 atmospheres(0.03 MPag) of residual air in the object before filling. This gives the following average
concentration:
A = Fill Pressure
B = 1 atm
C = Tracer Gas Fill Factor
D = Evacuation Pressure

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

61 / 94

8 | Recipes

INFICON

A+D
A+B

= C

0,05 + 0,07
0,05 + 0,1= 0,8

The average tracer gas concentration in this example will be 0.8 (80%). When using a
tracer gas mix of 5% the result will be:
0.8 x 5% = 4%This is almost twice of that achieved with no pre evacuation.

8.4.1.2 Example - Calculate Tracer Gas Filling
The air left in the object can not always be expected to mix evenly with the injectedtracer 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 injectedtracer 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 MPag (72 psig). Length is 10 m (33 ft.). Skipping pre evacuation wewill have:
A = Fill Pressure
B = 1 atm
E = Air left in the object

B
A+B

= E

0,1
0,5 + 0,1

= 0,17of air left in the pipe. This is equivalent to 1.7 m (5.7 ft.) of the total length if noturbulence 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 MPag) means there will be 0.3 atmospheres(0.03 MPag) of residual air in the pipe before filling.
We will now have:

B
A+B
0,03
0,5 + 0,03

62 / 94= E= 0,056

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Recipes | 8

of air left in the pipe. This is equivalent to 0.57 m (1.9 ft.). This air volume is normallysmall enough to be mixed into the tracer gas by turbulence and diffusion.

8.4.2 Optimizing the Tracer Gas Filling
Regulation of the tracer gas pressure can either be controlled by:• the ILS500 F/FHP• an external pressure regulator

NOTICEThe ILS500 F/FHP is set to regulate internally as default.

8.4.2.1 External Pressure Regulation
NOTICE
External Pressure Regulation does not support recipes with different test pressure (i.e.
Fill Setpoints).
External regulation is recommended mainly for very small objects (<50 cc).
Tracer gas pressure is controlled by external regulator. ILS500 F/FHP 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 F/FHP
checks that the fill pressure is above Fill Setpoint before proceeding to the next teststep.

8.4.2.2 Internal Pressure Regulation
Tracer gas pressure can be set to be controlled by the ILS500 F/FHP. Internallyregulated filling is generally faster than externally regulated. The reason for this is thatthe feeding pressure can be set higher than Fill Setpoint which results in a higher fill
flow.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

63 / 94

9 | Troubleshooting

INFICON

9 Troubleshooting
9.1 Fault Symptoms
Fault Symptom

Fault

Measures

Evacuation Failed

Failed to reach vacuum within the

Check the compressed air supply.

specified time.
Large leak on Test Object orconnections.
Gas Fill Failed

Failed to fill to the right pressure

Check the incoming gas pressure.

within the specified time.
Large leak on Test Object orconnections.
Gas Refill Failed

Failed to refill the object. Large leak Check the incoming gas pressure.
on Test Object or connections.

Gas Evac Failed

Failed to reach vacuum within thespecified time.

HW Error During Test

Test Timeout

Serious error has occurred during

Check external equipment, e.g

test.

Active Probe.

Maximum time for the test was

Check that time is correctly set.

exceeded.

9.2 Perform Hardware Test
NOTICE
Before performing the hardware test, carefully check that your tracer gas andcompressed air feed pressures are correct. Wrongly set pressure can cause
erroneous test results.

64 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Troubleshooting | 9

Hardware Test
Press "TEST"OUTPUTSILS500 F plugged

Vacuum:0.00

bar

ILS500 F + Object

Pressure:

0.00

bar

TEST

STOP

• For troubleshooting and testing of the system, use Service menu.
• For remote troubleshooting, use Service Run menu.
• Venturi Pump and all Gas Valves can be tested automatically.
The hardware test is a diagnostic tool helping you in preventive maintenance as well
as service and repair. The test takes you through a number of steps testing all units
that are subject to wear and should thereby help you to find almost any problem in the
ILS500 F/FHP system.

NOTICERun through the whole sequence to interpret the results correctly.
You will need the reference table at the end of this section to help you interpret thetest results correctly. Keep this manual at hand when performing the test.
You can choose to test according to the limits of your specific application.
1

Setup all parameters for your test object (or load desired recipe) and connect aleak free sample.

2

Set test selection switch to ”ILS500 F/FHP + Object” for application specifichardware test. You can also test the ILS500 F/FHP against factory
specification. In this case you should plug both test ports using the plugsdelivered with the units. Remove ISO to NPT converters if installed and install
the blind plugs. Set test selection switch to ”ILS500 F/FHP plugged” for factory
specified hardware test.

3

The ”Continue” button will be displayed at the end of each test step. Press”Continue” for next test step.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

65 / 94

9 | Troubleshooting

INFICON

Pressure and Vacuum Sensors

Hardware Test
Pressure and Vacuum Sensors
Zero Points are OK

CONTINUE

Vacuum:0.00

bar

Pressure:

0.00

bar

STOP

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

Evacuation Valve

Hardware Test
Evacuation ValveNo Internal Leakage
Vacuum: –0.03 bar
Pressure:

CONTINUE

0.00

bar

STOP

Evacuation valve is checked for internal leakage. Possible results:• No Internal Leakage• Internal Leakage

66 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Troubleshooting | 9Internal leakage can result in:• False vacuum decay rejects• Increased tracer gas consumption

Venturi Pump

Hardware Test
Venturi Pump
Max Vacuum OK
Vacuum: –0.88 bar
Pressure:

CONTINUE

0.00

bar

STOP

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)

Hardware Test
Manifold Tightness
No Leakage from Outside
Vacuum: –0.82 bar
Pressure:

CONTINUE

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

0.00

bar

STOP

67 / 94

9 | Troubleshooting

INFICON

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.

Vacuum Sensor Valve

Hardware Test
Vacuum Sensor Valve
Valve works!

CONTINUE

Vacuum:0.00

bar

Pressure:

0.00

bar

STOP

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

68 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Troubleshooting | 9

Tracer Gas Fill Valve

Hardware Test
Tracer Gas Fill ValveNo Internal Leakage

CONTINUE

Vacuum:0.00

bar

Pressure:

0.00

bar

STOP

The step tests the gas fill valve for internal leakage by registering pressure rise behindthe 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

Hardware Test
Test Port 2 Valve
Valve works!

CONTINUE

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

Vacuum:0.00

bar

Pressure:

0.00

bar

STOP

69 / 94

9 | Troubleshooting

INFICONNOTICE
This test will fail if both test ports are connected to a test object. Proceed and thenrepeat 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 risebehind the valve.
Possible results:• No Internal Leakage• Internal Leakage
Internal leakage can result in:• False blockage test accepts

Tracer Gas Fill Valve

Hardware Test
Tracer Gas Fill Valve
Valve works!

CONTINUE

Vacuum:0.00

bar

Pressure:

0.50

bar

STOP

This step tests that tracer gas fill valve opens to fill gas. Test will fail if tracer gas feed
pressure is too low. If this is the case, adjust pressure and restart hardware test frombeginning.
Possible results:• Valve works• Faulty!
Malfunction will result in:• Failed gas filling

70 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Troubleshooting | 9External Gas Leaks

Hardware Test
Check for Leaks with Hand Probe

CONTINUE

Vacuum:0.00

bar

Pressure:

0.50

bar

STOP

The ILS500 F/FHP is now prepared for a manual test for external leakage. Use a Leakdetector with hand probe to check for leakage.
• Start by checking all connections between the ILS500 F/FHP and your test object.
Follow each test line carefully and check every joint.
• Proceed to check around the gas valves and manifold inside the ILS500 F/FHP.

Manifold Tightness (gross)

Hardware Test
Manifold Tightness
Internal Leakage

CONTINUE

Vacuum:0.00

bar

Pressure:

0.46

bar

STOP

The overall tightness of the manifold is tested using the pressure decay method. Thisis a complement to the gas test, revealing leakage out, through the exhaust etc.
Possible results:• No Internal Leakage• Internal Leakage

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

71 / 94

9 | Troubleshooting

INFICONInternal leakage can result in:• False pressure and vacuum decay rejects• Increased tracer gas consumption

Evacuation Valve

Hardware Test
Evacuation Valve
Valve works!

CONTINUE

Vacuum:0.00

bar

Pressure:

0.00

bar

STOP

This step tests that evacuation valve opens to release tracer gas to exhaust. Sametest as previously but under pressure instead of vacuum.
Possible results:• Valve works• Faulty!
Malfunction will result in:• Failure to terminate test cycle

72 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Troubleshooting | 9

Indicator Lamps

Hardware Test
Lamp in Start Button
OK?

CONTINUE

Vacuum:0.00

bar

Pressure:

0.00

bar

Vacuum:0.00

bar

Pressure:

0.00

bar

STOP

Hardware Test
Green Lamp (Top Left)OK?

CONTINUE

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

STOP

73 / 94

9 | Troubleshooting

INFICON

Hardware Test
Red Lamp (Bottom Left)OK?

CONTINUE

Vacuum:0.00

bar

Pressure:

0.00

bar

STOP

This is a “manual” test. The ILS500 F/FHP lights up one lamp at the time. Simply
check that the right lamp comes on.
► Check function of each lamp by pressing “Continue”.

START and STOP buttons

Hardware Test
Press Start Button (Top Right)
OK?
Vacuum:0.00

bar

Pressure:

0.00

bar

STOP

74 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Troubleshooting | 9

Hardware Test
Press Stop Button (Bottom Right)
OK?
Vacuum:0.00

bar

Pressure:

0.00

bar

STOP

This is a “manual” test. The test continues when the correct button is pressed. The
test checks the activated START and STOP buttons only. Use INPUT menu underService menu to check buttons that are turned off.

9.2.1 Hardware Error Messages
Error Message

Reason for Error

Corrective Action*

Hardware Error

No power to vacuum sensor.

Check cable to sensor.

Vacuum Sensor Error

Sensor not connected to AD.

Check connection to AD.

Damaged vacuum sensor.

Send in for repair.

Hardware Error

No power to pressure sensor.

Check cable to sensor.

Pressure Sensor Error

Sensor not connected to AD.

Check connection to AD.

Damaged pressure sensor.

Replace sensor.

No power to AD module.

Check power cable on left side of

Analog Inputs Power Off

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

9.2.2 Interpretation of Hardware Test Results
Use the table below, to correct errors detected by the hardware test routine.
Tested Unit

Tested Feature

Reason for Error

ActionEvacuation Valve

Internal leaks

Dirty or worn valve seals.

Replace clean evacuation
valve.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

75 / 94

9 | Troubleshooting

INFICON

Tested Unit

Tested Feature

Reason for Error

ActionVenturi Pump

Maximum vacuum

Compressed air pressure

Adjust compressed air

too low or too high.

pressure.

Dirt inside Venturi.

Remove and clean
Venturi.

Dirty or broken Venturi

Replace two upper valvespilot valves.

in pilot ramp.

Dirty or broken Evacuation Replace fourth valve fromGas Valve Manifold

Leaks from outsidepilot valves.

bottom in pilot valve ramp.

Leaks to outside.

Check for leaks with Hand
Probe (later in hardware
test sequence).

If no gas leaks.

Check internal leaks intracer gas fill valve.

Vacuum Sensor

Function

If no internal leaks in

Replace/clean vacuum

tracer gas valve.

sensor protection valve.

No signal to pilot valve.

Check ”Sensor Protect”

Protection Valveoutput.
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.

Replace or clean tracer
gas fill valve.

Leaking pilot valve.

Replace fourth valve frombottom in pilot valve ramp.

Test Port 2 Valve

Function

Dirty or broken pilot valve. Replace third valve frombottom in pilot ramp.
Test port 2 valve broken.

Tracer Gas Fill Valve

Function

Replace valve.

Dirty or broken pilot valve. Replace fourth valve frombottom in pilot ramp.
Tracer gas fill valve

Replace valve.

broken.

76 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Troubleshooting | 9

Tested Unit

Tested Feature

Reason for Error

ActionGas Valve Manifold

Leaks to outside

Wrongly assembled gas

Remove leaking valve.

valve.

Clean and grease valve
seal before installingagain. See instructions.

Wrongly installed

Remove leaking unit.

connectors/plugs.

Clean and grease o-ringInstall again.
Units lacking o-ring seal
should be sealed with
Loctite 577 or similar.

Evacuation Valve

Lamp

Function

Function

Dirty or broken Evacuation Replace fourth valve frompilot valves.

bottom in pilot valve ramp.

Broken lamp.

Replace lamp.
Send in for repair.

Tooling Valves

Function

Dirty or broken pilot valve. Replace first or second
valve from bottom in pilot
ramp.

ButtonFunction

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

Broken switch.

Send in for repair.

77 / 94

10 | Maintenance Instructions

INFICON

10 Maintenance Instructions
There are three different parts that needs regular maintenance:• Venturi Pump
Needs regular cleaning.
• Gas Valves
Needs regular cleaning and wears out.
• Pilot Valves
Maintenance free if incoming compressed air is dry and filtered to 5 µm.
Changing Venturi Pump and all Gas Valves takes less than 15 minutes.
Cleaning of the instrument is done with a moistened cloth.

10.1 Maintenance Plan
Part

Interval

ActionVenturi Pump

3 months

Perform a Hardware Test. Check Ultimate Vacuum.
Clean venturi nozzles when necessary.

Evacuation, Fill and3-6 months*

Test Port 2 Valves
Vacuum Sensor Valve

Perform a Hardware Test. Check condition of valves.
Replace or clean valves when necessary.

12 months

Perform a Hardware Test. Check condition of valve.
Replace or clean valve when necessary.

Pilot Valves

12 months

Change valve if unexpected pressure builds.

*: Depends on the amount of particulates in the objects tested. Metal burrs and othersharp particles will wear the valves down, requiring shorter maintenance intervals.

10.2 Maintenance10.2.1 Tools and Safety Equipment
When performing regular maintenance of the ILS500 F/FHP the following equipment isneeded.
Description

Note

Allen Keys (Hexagonal 3 and 4 mm)
Torx Key (T25)
Screwdriver (Philips 1 or Pozidrive 1)

78 / 94

Protective Eyewear

When performing tooling output test.

Protective Ear Plugs

When performing tooling output test.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Maintenance Instructions | 10

10.2.2 Interior View
1

2

3

4
5
6
7

9

10

8

1

Pilot Valve 62

Pilot Valve 1

3

Venturi Pump (Ejector)

4

Evacuation Valve5

Tracer Gas Fill Valve6

Test Port Valve 2

7

Vacuum Sensor Control Valve8

Pressure Sensor (HP model
only)

9

Vacuum Sensor

10

Pressure Sensor

Pilot Valve Ramp
The pilot valves are characterized by a dual function. They can be used separately or
combined for higher capacity.
Position

Valve

6

Main Air Valve

5

Venturi Pump Supply

4

Evacuation Valve and Tracer Gas Fill

3

Test Port 2 Valve and Sensor Protection Valve2

Tooling Valve 1, 2

1

Tooling Valve 3, 4

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

79 / 94

10 | Maintenance Instructions

INFICON

10.2.3 Removing the Cover1

Use a T25 key to remove the two screws holding the right hand cover (next togas 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 below.

10.2.4 Cleaning or Replacing the Venturi Pump
1

Remove the exhaust hose from the barbed hose fitting.

2

Unscrew and remove the barbed hose fitting and the plastic washer.

3

Use a 4 mm Allen key to remove the four screws holding the Venturi pump.

4

Remove the o-ring under the Venturi. Remove the hose from Venturi inlet.
Push hose into connector and press orange ring down to release hose, thenpull hose out.

80 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Maintenance Instructions | 10

5

Remove the hose fitting from the Venturi.

6

Install new Venturi or use compressed air jet and a cotton bud, pipe cleaner orsmall brush to clean the nozzles inside the Venturi.

7

Replace hose fitting on Venturi inlet.

8

Reconnect inlet hose.

9

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

10

Reinstall and tighten the four screws.

11

Put plastic washer inside Venturi outlet and reinstall barbed fitting. Tighten withspanner.

12

Reconnect the exhaust hose.

13

Run through the hardware test again to test that the Venturi delivers adequate
max vacuum.

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

81 / 94

10 | Maintenance Instructions

INFICON

10.2.5 Replacing Gas Valves1

Use a 3 mm Allen key to remove the four screws holding the valve to bechanged.

2

Lift the old valve out and put the new valve in. Notice the correct orientation in
the picture below.

3

Tighten the screws 2-3 mm (0.08-0.12 in.) at a time moving the key from screw
to screw so that the valve doesn’t tilt much.

4Tighten the screws and replace the cover.

5

Run through the hardware test again to test that the changed/removed valve(s)perform as required.

6

Use hand probe to check that there is no external leakage (this part of
Hardware Test is routine).

10.2.6 Replacing Pilot Valves1

Use small screw driver to loosen the screw holding the valve. You must backthe screw all the way out until you feel it “jumping” in the thread entrance.

2

Push down on the LEDs while pressing the screw down until you feel thelocking mechanism “snap”.

82 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Maintenance Instructions | 10

3

Lift the old valve out from the coil side. If the valve does not come off, repeat
steps 3 and 4 making sure the screw is completely backed out.

4

Push the screw in while inserting the new valve. Insert the end facing the screw
first and then push the coil side down.

5

Tighten the screw.

6

Replace the cover.

10.2.7 Replacing Sensors
CAUTION
Service of the sensors may only be carried out by service organizations authorized forthis purpose by INFICON.

10.3 Functional Verification
See Perform Hardware Test [} 64].
ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

83 / 94

11 | Service

INFICON

11 Service
In case of a dysfunctional Sensistor ILS500 F/FHP, please send the product forservice at your most convenient service facility. Please visit http://www.inficon.com foraddresses.

84 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Spare Parts and Accessories | 12

12 Spare Parts and Accessories
1

2

Pos.

Part

Type

Part No.

1

Power Cables

EU

591-146UK

591-147US

591-853

2

No-Stop Maintenance Kit,
Standard Model

590-680
Part
Ejector E240

591-422

1

Valve 3/2 10 bar

591-419

4

Valve to valve block VQC1000

591-630

1

Fuse 2A T

591-5782

Allen Key (Hexagonal) 3 mm

591-8641

Allen Key (Hexagonal) 4 mm

591-865

1

Torx T25

591-866

1

Screwdriver Philips 1

591-8671

No-Stop Maintenance Kit,
HP ModelQty.

590-685
Part

Qty.

Ejector E240

591-422

1

Valve 3/2 HP 30 bar

591-621

4

Valve to valve block VQC1000

591-630

1

Fuse 2A T

591-5782

Allen Key (Hexagonal) 3 mm

591-8641

Allen Key (Hexagonal) 4 mm

591-865

1

Torx T25

591-866

1

Screwdriver Philips 1

591-8671

For a complete list of all spare parts and accessories, please contact:
support.sweden@inficon.com

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

85 / 94

13 | Support from INFICONINFICON

13 Support from INFICON
13.1 How to Contact INFICONFor Sales and Customer Service, contact your nearest INFICON Service Center. The
address can be found on the website: www.inficon.com
If you are experiencing a problem with your instrument, please have the following
information readily available before contacting Customer Service:• A serial number and firmware version for your instrument,• A description of your problem,• A description of any corrective action that you may have already attempted, andthe exact wording of any error messages that you may have received.

13.2 Returning Components to INFICON
Please use the Product Return Form that was included with the product on delivery.
Do not return any component of your instrument to INFICON without first speaking
with a Customer Service Representative. You must obtain a Return Material
Authorization (RMA) number from the Customer Service Representative.
If you deliver a package to INFICON without an RMA number, your package will beheld and you will be contacted. This will result in delays in servicing your instrument.
Prior to being given an RMA number, you may be required to complete a Declaration
Of Contamination (DOC) form if your instrument has been exposed to processmaterials. DOC forms must be approved by INFICON before an RMA number isissued.

86 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Disposal | 14

14 Disposal
According to EU legislation, this product must be recovered forseparation 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
Wahlbeckgatan 25A
S-58216 Linköping
SwedenILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

87 / 94

15 | EU Declaration of Conformity

INFICON

15 EU Declaration of Conformity

88 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICONEC Declaration of Incorporation | 16

16 EC Declaration of Incorporation

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

89 / 94

17 | UK Declaration of Conformity

INFICON

17 UK Declaration of Conformity

90 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

INFICON

Appendix A | 18

18 Appendix A
18.1 Parameter Index
Parameter

Range

Factory Default

Customer
Modification

Abort Above Fill Setpoint

20 %Block Test Pressure

0.3 barBlockage Test Time

2s

Blockage Test

OFF

Choose at startup

OFF

Demo ModeOFF

End of Test Signal

1s

Evacuation Timeout

10.0 sExtended Gas Evacuation

0s

Extended Gas Fill0s

Extended Pre Evacuation

0s

External Acknowledge

OFF

External Gas Regulation

OFF

External Start/Stop

OFF

Fill Pulse Open

20 ms

Fill Pulse Closed

200 msFill Setpoint

0.3 barFill Signal Filter

0.0 sFill Timeout

10 s

Gas EvacuationON

Gas Evac. Setpoint

0.3 barGas Evac. Test Port 1

OFF

Gas Fill Test Port 1

OFF

Marker Output

0sMarker Output High if LeakOFF

Pre Evac Test Port 1

OFF

Pre EvacuationON

Pre Evacuation Setpoint–0.7 barPressure Stabilisation Time

5s

Pressure Decay Limit

0.1 barPressure Decay TestOFF

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)

91 / 94

18 | Appendix A

Parameter

INFICON

Range

Factory Default

Customer
Modification

Pressure Decay Test Time

5s

Pressure Unit

bar

Pulse Fill from (%) of Setpoint

90%

Purge Level

0.001

Purge Object

0s

Refill Hysteresis

0.2 barRefill Timeout

5s

Status - pin 5

End of Test

Test Timeout

10 minTooling Connection

OFF

Tooling DisconnectionOFF

Two-Hand Control

OFF

Use Recipes

OFF

Vac. Stabilisation Time

5s

Vacuum Decay Limit

0.1 barVacuum Decay Test

OFF

Vacuum Decay Test Time5s

92 / 94

ILS500 F_FHP-Operation-manual-ninp69en1-02-(2201)