LS182 H My Fukuda

OPERATION MANUAL
AIR LEAK TESTER

MODEL: LS-1822A
No. LS-1822A-941B1-B
COSMO INSTRUMENTS CO., LTD.

TABLE OF CONTENTS 1
TABLE OF CONTENTS
INTRODUCTION 5
Introduction......................................................................................................................................................5
Safety Precautions ..........................................................................................................................................5
Notes ...............................................................................................................................................................6
CHAPTER 1: GENERAL INFORMATION AND SPECIFICATIONS 7
1.1 Overview ................................................................................................................................................7
1.2 Features.................................................................................................................................................7
1.3 General Specifications ...........................................................................................................................8
1.4 Model Classifications .............................................................................................................................9
CHAPTER 2: LEAK TESTING OVERVIEW 11
2.1 Theory of Leak Testing ........................................................................................................................ 11
2.1.1 Stage Summary......................................................................................................................... 11
2.1.2 Internal pressure changes of the Work and the Master compared to leak rate ........................12
2.2 Leak Rate Conversion .........................................................................................................................12
2.2.1 Pressure and Volume Relationship ...........................................................................................12
2.2.2 Equivalent internal volume ........................................................................................................13
2.2.3 Calculation of a Leak Rate ........................................................................................................13
2.3 Estimating the Test Time......................................................................................................................14
2.3.1 Setting Charge (CHG) and Balance Delay (BAL1) timers ........................................................14
2.3.2 Limitation on the BAL2 timer setting..........................................................................................14
2.3.3 Setting the DET timer ................................................................................................................14
CHAPTER 3: FEATURE SUMMARIES 15
3.1 K(Ve) Calibration..................................................................................................................................15
3.1.1 Selecting a Leak Master............................................................................................................15
3.2 Compensation Features ......................................................................................................................18
3.3 Mastering Compensation.....................................................................................................................19
3.3.1 Theory of Mastering ..................................................................................................................19
3.3.2 When to execute a Mastering process......................................................................................19
3.3.3 Annotation for use of Mastering compensation feature ............................................................20
3.4 Auto-Drift Compensation (U.S. PAT. #4670847)..................................................................................20
3.5 Noise Reduction (NR) Mode................................................................................................................21
3.6 Air-Operated Valve Performance Check and DPS Sensitivity Check (standard circuit) .....................21
3.7 Air-Operated Valve Performance Check (A2 Option) ..........................................................................22
3.8 Sensor Protection ................................................................................................................................22
3.8.1 Cleaning pneumatic circuit by exhaust air blow ........................................................................22
3.8.2 External exhaust valve ready ....................................................................................................23
3.9 Exhaust Interference Prevention .........................................................................................................24
CHAPTER 4: INSTALLATION 25
4.1 Checking Supplied Accessories and Documents ................................................................................25
4.2 Installing the Unit .................................................................................................................................25
4.2.1 Using quick mounting brackets (standard)................................................................................25
4.3 Electrical Connection ...........................................................................................................................27
4.3.1 Connecting power .....................................................................................................................27
4.3.2 Connecting signals ....................................................................................................................27
4.4 Pneumatic Connection.........................................................................................................................28
4.4.1 Test pressure source .................................................................................................................28
4.4.2 Pilot pressure sources...............................................................................................................29
4.4.3 Annotation for air source ...........................................................................................................29
2 TABLE OF CONTENTS
4.5 Connecting Master and Work.............................................................................................................. 29

4.5.1 Annotation for designing a sealing fixture................................................................................. 29
4.5.2 Master installation ..................................................................................................................... 31
4.5.3 Choosing proper connections to Master and Work .................................................................. 32
4.6 Leak Tester Installation Environment .................................................................................................. 33
CHAPTER 5: PARTS IDENTIFICATION AND FUNCTIONS 35
5.1 External Appearance – Front panel..................................................................................................... 35
5.2 External Appearance – Rear panel ..................................................................................................... 36
5.3 Keyboard ............................................................................................................................................. 37
CHAPTER 6: COMPREHENSIVE SETUP PROCEDURE 41
6.1 Turning on Power ................................................................................................................................ 41
6.2 Unlocking the Keyboard ...................................................................................................................... 41
6.3 Switching Between Remote and Manual Modes ................................................................................ 41
6.4 Test Parameter Programming Procedure ........................................................................................... 41
6.5 Other Programming............................................................................................................................. 44
CHAPTER 7: MEASUREMENT (MEAS) MODE OPERATION 45
7.1 Description of MEAS mode screen ..................................................................................................... 45
7.2 Keyboard Operations .......................................................................................................................... 46
7.2.1 Contrast adjustment.................................................................................................................. 46
7.2.2 Zero check in WAIT .................................................................................................................. 46
7.2.3 Test pressure adjustment.......................................................................................................... 46
7.2.4 Test pressure limit (P.LIMIT) ..................................................................................................... 47
7.2.5 Pre-charge setting (P.CHG) ...................................................................................................... 47
7.2.6 Mastering .................................................................................................................................. 47
7.2.7 Calibration Valve Control (for functional specification J only)................................................... 47
7.2.8 K(Ve) check (for functional specification J only) ....................................................................... 47
7.2.9 To start and stop leak test......................................................................................................... 48
7.2.10 Charge hold .............................................................................................................................. 48
7.2.11 Test pressure confirmation........................................................................................................ 48
7.2.12 Printout...................................................................................................................................... 48
CHAPTER 8: SET MODE OPERATIONS 49
8.1 Programming Overview....................................................................................................................... 49
8.1.1 Data entry ................................................................................................................................. 49
8.1.2 Program limitation ..................................................................................................................... 49
8.1.3 Channel selection ..................................................................................................................... 49
8.1.4 Printout of settings .................................................................................................................... 49
8.2 Description of SET Mode Screen........................................................................................................ 50
8.2.1 COEF., TIME (leak coefficient and time) screen....................................................................... 51
8.2.2 EXTENSION TIME screen........................................................................................................ 53
8.2.3 UNIT, LIMIT (unit and limit) screen ........................................................................................... 54
8.2.4 COMPENSATION screen ......................................................................................................... 55
8.2.5 P-TYPE, SEQ screen ............................................................................................................... 55
8.2.6 MASTERING (Mastering factors) screen ................................................................................. 57
8.2.7 STATISTICS (Statistical counter) screen .................................................................................. 57
8.2.8 SWITCH TABLE #1 (Memory switch #1) screen ...................................................................... 58
8.2.9 SWITCH TABLE #2 (Memory switch #2) screen ...................................................................... 59
8.2.10 COM. PORT SETTING (Serial communications port setting) screen ...................................... 60
8.2.11 COPY SETTING (Channel copy) screen.................................................................................. 60
8.2.12 INITIALIZE (Initialization setting) screen .................................................................................. 61
8.2.13 SYSTEM SETTING (System settings) screen.......................................................................... 61
TABLE OF CONTENTS 3
CHAPTER 9: COMPENSATION 63
9.1 Compensation method and settings ....................................................................................................63
9.2 Compensation Screen .........................................................................................................................64
9.3 Mastering Setup Operation..................................................................................................................65
9.3.1 Mastering setup.........................................................................................................................65
9.3.2 Starting Mastering process........................................................................................................66
9.3.3 Setting Mastering factors...........................................................................................................67
9.4 No-Leak Test Using Mastering.............................................................................................................68
9.4.1 Preparation ................................................................................................................................68
9.4.2 Operation...................................................................................................................................68
9.5 Verifying Mastering Data......................................................................................................................69
9.5.1 Operation...................................................................................................................................69
9.6 Verifying No-Leak Data........................................................................................................................70
9.7 Auto-Drift Compensation Feature ........................................................................................................70
9.8 Constant Compensation ......................................................................................................................71
9.9 Example of Auto-Drift Compensation using Mastering value ..............................................................72
CHAPTER 10: K(Ve) CALIBRATION 73
10.1 K(Ve) Calibration using a Leak Master ................................................................................................73
10.1.1 Preparation ................................................................................................................................74
10.1.2 Key Operation (Three-phase method) ......................................................................................74
10.2 Automatic K(Ve) Calibration <functional specification J> ....................................................................76
10.2.1 Preparation ................................................................................................................................76
10.2.2 Operating procedure (3-phase method)....................................................................................76
10.3 Manual K(Ve) Calibration Operation Using Leak Calibrator ................................................................78
10.3.1 Operating procedure .................................................................................................................78
10.4 Causes of an Error or Inappropriate Measurement in K(Ve) Calibration.............................................79
CHAPTER 11: GRAPH MODE AND HELP MODE 81
11.1 Selecting a Graph and Deleting Data ..................................................................................................81
11.2 Control Chart (Quality Control Screen)................................................................................................81
11.2.1 Bar graph...................................................................................................................................81
11.2.2 Screen description.....................................................................................................................81
11.3 Mastering Data Screen ........................................................................................................................82
11.3.1 Mastering graphs.......................................................................................................................82
11.3.2 Screen description.....................................................................................................................82
11.4 HELP Mode Operation.........................................................................................................................82
11.4.1 I/O MONITOR............................................................................................................................82
11.4.2 COM. PORT MONITOR (Communications port monitor screen)..............................................84
11.4.3 SYSTEM VERSION ..................................................................................................................84
CHAPTER 12: INTERFACE 85
12.1 Control I/O Port....................................................................................................................................85
12.2 Specifications.......................................................................................................................................85
12.2.1 Connector pin assignment.........................................................................................................85
12.2.2 Power supply.............................................................................................................................86
12.2.3 Input circuit ................................................................................................................................86
12.2.4 Output........................................................................................................................................87
12.2.5 Typical PLC connection.............................................................................................................88
12.3 PNP Specifications of the Control I/O Port (available as an option)....................................................89
12.3.1 Connector pin assignment.........................................................................................................89
12.3.2 Power supply.............................................................................................................................90
12.3.3 Input circuit ................................................................................................................................90
12.3.4 Output circuit .............................................................................................................................91
12.3.5 Typical connection with PLC .....................................................................................................92
12.4 Channel Selection................................................................................................................................93
4 TABLE OF CONTENTS
12.5 Stage Number Output ......................................................................................................................... 93

12.6 Signal Timing Charts ........................................................................................................................... 94
12.6.1 Leak test timing chart................................................................................................................ 94
12.6.2 Mastering timing chart .............................................................................................................. 94
12.6.3 Charge hold timing chart........................................................................................................... 95
12.7 Serial Communication Interface (COM1) ............................................................................................ 95
12.7.1 Interface specifications ............................................................................................................. 95
12.7.2 Interface cable wiring example ................................................................................................. 96
12.7.3 Output formats .......................................................................................................................... 96
12.7.4 Data representation .................................................................................................................. 97
12.7.5 Checksum ................................................................................................................................. 98
12.8 Printer Function................................................................................................................................... 98
12.8.1 Printer specifications (RS-232C serial interface)...................................................................... 98
12.8.2 Printout of leak test data ........................................................................................................... 99
12.8.3 Printout of settings of the SET mode ...................................................................................... 100
12.8.4 Printer interface cable specifications ...................................................................................... 100
CHAPTER 13: MAINTENANCE AND TROUBLESHOOTING 101
13.1 Daily Items to Check and Maintain.................................................................................................... 101
13.2 Monthly Items to Check and Maintain ............................................................................................... 101
13.3 Annual or Semiannual Inspection Items ........................................................................................... 101
13.4 DPS and PS Calibration.................................................................................................................... 102
13.4.1 Description of CALIBRATION MENU ..................................................................................... 102
13.5 DPS Offset Calibration ...................................................................................................................... 102
13.6 DPS Span Inspection and Calibration............................................................................................... 103
13.6.1 Preparation ............................................................................................................................. 103
13.6.2 Key operation.......................................................................................................................... 103
13.7 PS Offset Calibration......................................................................................................................... 104
13.8 PS Span Inspection........................................................................................................................... 104
13.8.1 Preparation ............................................................................................................................. 104
13.8.2 Key operation.......................................................................................................................... 104
13.9 No-Leak Check of LS-1822A Itself .................................................................................................... 105
13.10 NG Check Using a Leak Master........................................................................................................ 105
13.10.1 Preparation ............................................................................................................................. 105
13.10.2 Key operation.......................................................................................................................... 105
13.11 Locating Leaks by Means Other than the Leak Tester...................................................................... 105
13.11.1 Bubble test .............................................................................................................................. 105
13.11.2 Interchanging the Work and the reference Master part .......................................................... 105
13.12 Built-in Battery Discharge.................................................................................................................. 106
13.13 Error Display...................................................................................................................................... 107
13.13.1 Error messages and countermeasures .................................................................................. 107
13.13.2 Error messages and associated countermeasures .................................................................116
13.14 When NG Judgment Occurs Frequently ............................................................................................117
APPENDIX A1: EXTERNAL APPEARANCE ·································································· 119
APPENDIX A2: PNEUMATIC CIRCUIT·········································································· 120
APPENDIX A3: PRESSURE UNIT CONVERSION TABLE ············································ 123
APPENDIX A4: CE MARKING ······················································································· 123
APPENDIX A5: NOTICE TO USERS (FCC Rules) ························································ 123
APPENDIX A6: TEST PARAMETER BLOTTER ···························································· 124
INTRODUCTION 5
INTRODUCTION
Introduction
Thank you for purchasing the Air Leak Tester LS-1822A. This Operation Manual explains the functions and
operation of the LS-1822A, as well as precautions for its handling. Before using this product, read this
Operation Manual carefully and retain it for future reference.
Safety Precautions
The instructions that follow are to be abided by for the safe operation of the product, to avoid possible
physical injury to the operator or other persons, and to prevent property damage. Please handle the
product according to these instructions and observe the following symbols that appear in this manual:
[Explanations of the symbols used]
Symbol Explanation
Failure to take or avoid a specific action could result in death or serious physical
WARNING harm to the user.
Failure to take or avoid a specific action could result in minor physical harm to
CAUTION the user, or in property damage.
Δ This symbol denotes a warning to alert the user. A specific explanation of the potential danger and
what must be done to avoid it follows. (Example: Electrical shock hazard)
WARNING
A) Ground the instrument before plugging it into a power source. The unit, if not grounded, could be
liable to electrical shock hazards. Never ground the unit to a gas pipe. Doing so could result in fires
or electrical shock hazards.
B) If the metal part of the power plug or surrounding area is dusty, clean it thoroughly with a dry cloth.
Not doing so could result in fires or electrical shock hazards.
C) Never use voltages other than those for which the instrument is rated. Doing so could result in fires
or electrical shock hazards.
D) If the instrument has been dropped or damaged, switch it off and disconnect the power plug from the
receptacle. Not doing so could result in fires or electrical shock hazards.
E) Do not apply air pressure in excess of the pressure rating of the instrument. Excessive pressure
input could cause major component failure and/or injury.
F) Should foreign matter such as water or oil get inside the instrument, switch off the power immediately
and unplug it from the receptacle. Not doing so could result in fires or electrical shock hazards.
Use extra caution when installing the instrument in an environment where water or oil exists nearby.
G) The instrument should be located in a situation where the power plug can be accessed immediately in
case of an emergency.
H) This instrument is not customer-serviceable. Customer servicing could result in fires or electrical
shock hazards.
I) Do not replace a fuse before turning off the power of the main unit and disconnecting the power plug
from the receptacle. Doing so could result in fires or electrical shock hazards. Replace the installed
fuse with an equivalent one. Not doing so could result in fires or electrical shock hazards.
J) Discontinue using the instrument immediately under the following circumstances:
y The instrument smokes.
y The instrument emits abnormal noises.
y The instrument has developed problems not covered in the Operation Manual.
y The instrument cannot be operated as indicated in the Operation Manual.
To avoid electrical shock hazards or physical harm, disconnect the power cable and remove the
pressure source from the instrument. Not doing so could result in fires or electrical shock hazards.
6 INTRODUCTION
CAUTION
K) Do not use the unit in places that are damp, that are exposed to direct sunlight or that are outside the
temperature range of 5°C to 40°C. Using the unit in such environments could result in malfunctions
or failures.
L) To avoid damage to the power cable, which could result in fires or electrical shock hazards, observe
these precautions:
1) Do not damage, modify or apply undue force to the power cable.
2) Before servicing the unit, disconnect the power plug from the receptacle.
3) Do not handle the power plug with wet hands.
4) When disconnecting the power plug, do not pull on the power cable.
M) Ensure the correct connection of cables. Incorrectly connected cables could result in damage to the
instrument and surrounding hardware.
N) Mount the instrument securely to a platform or floor strong enough to withstand the weight of the
instrument. Avoid locating it in unstable places, such as locations subject to significant vibration or
having a slope. It could fall, leading to injuries.
O) Do not step on top of the unit or place containers filled with liquids, oil or soapy water, or the like on it.
Spills may result, causing physical harm, electrical shock hazard, rust or other damage.
P) Should the LCD become damaged, avoid skin contact with the liquid contained inside. It may cause
inflammation. Wash with running water in case of skin contact.
Q) Do not disassemble the unit as it could malfunction, resulting in physical harm or electrical shock
hazards.
R) Do not install or remove system tubing with the unit connected to an air pressure source. Physical
harm could result.
S) When a leak test has been completed, unclamp the tested part only after all pressure has been
released from the unit. Residual pressure could result in physical harm.
T) When carrying the unit, hold it by the bottom to keep the unit from dropping. If dropped, the unit
could be damaged , broken or cause physical harm.
U) To clean, wipe with a dry soft cloth. If surfaces are extremely dirty, wipe clean with a cloth which has
been dipped in a diluted solution of mild soapy water and wrung out. Organic solvent should not be
used.
Notes
A) The information in this document is subject to change without notice to allow for performance or
functional upgrades.
B) This document may not be reproduced in whole or in part without prior approval of the publisher.
C) We are not held responsible for the items tested using this unit or for any consequences resulting from
the tests.
D) To minimize incorrect test results, this unit comes complete with self-check functions to detect certain
improper settings and/or operations, and for any internal equipment malfunctions thereby preventing
incorrect judgments from being delivered. The scope of monitoring by self-checking, however, is limited.
Verification of the unit performance and operations using a separately specified apparatus is
recommended.
E) This unit performs measurements based on the principle of differential pressure detection, using the
Master comparison method. In addition to actual product leakage there are a number of additional
variables that can affect test results, the most common of which are temperature changes, volume
changes and system leakage (on either side of the DP sensor).
F) The user is encouraged to consult us directly (or your dealer) for any questions regarding the use of our
product.
CHAPTER 1: GENERAL INFORMATION AND SPECIFICATIONS
1.1 Overview
The LS-1822A is a differential-pressure air leak tester that tests the air tightness of various products and
parts. It is intended for professional and industrial use.
With the Mastering and Auto-Drift compensation features, the LS-1822A offers enhanced detection accuracy
and reduced test time that were not achievable by the conventional models. Feature enhancements
including quality control screens, multi-channel capability, improved differential pressure resolution and
greater ease of operation assure automatic leak tests of various Works.
1.2 Features
A) Differential-pressure reading resolution (0.1 Pa)
Higher differential pressure reading resolution offers better accuracy and speeds testing.
B) Mastering compensation feature (Patented)
Compensates for the drift errors caused by environmental changes and/or the adiabatic compression
effect thereby providing enhanced measurement accuracy and faster testing.
By using a Master chamber which has excellent thermal stability as a Master, it is no longer necessary to
use a Work, which minimizes adjustment and maintenance.
C) 2-level limit settings and Noise Reduction (NR) mode
When an NG judgment is received, the leak rate level can be checked.
For noise reduction, a strict limit can be set on the leak rate in the NR mode.
D) Leak Calibration feature (Patented)
Includes K(Ve) calibration, offset and span calibration for each differential pressure and test pressure
sensor.
In K(Ve) calibration, the Leak Master measures the equivalent internal volume, K (Ve), which is used to
convert the measured differential pressure into the leak rate (mL/min).
E) Multi-channel
Sixteen different sets of test parameters can be programmed independently. A channel copy feature
makes multi-channel setting easier.
F) Intelligent I pneumatic circuit with high performance differential pressure sensor (Patent pending)
Equipped with a small volume differential pressure sensor with high sensitivity and withstand pressure,
this pneumatic circuit offers a broad range of useful features despite its simple construction. The
Intelligent I pneumatic circuit uses dedicated air-operated valves with a high flow rate capacity and
thermal resistance. It has a self-cleaning feature that prevents the Work from being interrupted due to
water, oil, or foreign matter entering the Work interior. In each test, the sensitivity of the differential
sensor and valve operations are automatically checked.
G) Electropneumatic regulator (Available as an option)
A large flow rate electropneumatic regulator facilitates the setting of channel-dependent test pressures
and charging at high speed.
H) CAL ports
CAL ports for the Work and the Master are easily accessible on the front panel for daily sensitivity
checks, NG judgment checks or K(Ve) calibration when they are connected with a Leak Master. These
ports are also convenient for periodic calibration of the differential pressure and the pressure gauge.
Also, a volume variable type of leak calibrator can be used. When connected with a pressure standard,
it can be used for test pressure calibration.
I) Data graph display capability
Graphic data of up to 1000 Works can be displayed, which allows the monitoring of changes in their
characteristics and in the measuring environment. Mastering characteristic graphs are also available.
8 CHAPTER 1: GENERAL INFORMATION AND SPECIFICATIONS
J) An RS-232C interface serial communication port is equipped as standard.

K) I/O signal monitor screen
Visual display of the operating status makes the checking of I/O signals easier.
L) Quick Mounting Bracket
The main body of this tester can easily be removed from the unit or mounted on the front side of the unit
when this bracket is installed. Also, space for maintenance is not required on the lateral side of the
LS-1822A, contributing to space saving.
M) External pressure (Secondary pressure) detection method (Option)
Method to detect pressure changes inside the capsule that covers the Work by pressurizing or
evacuating inside of the Work.
1.3 General Specifications

Minimum reading Standard: 0.1 Pa (0.01 kPa)
Display range Standard: ±999 Pa (±1.5 kPa)
Differential
pressure
Guaranteed accuracy range Standard: ±1000 Pa

Sensor range Standard: ±2000 Pa
Sensor proof pressure 5 MPa
Reading accuracy ±5% of R.D. ±1 Pa (within guaranteed accuracy range)
Test pressure kPa, MPa, PSI, kg/cm2, bar, mbar, mmHg, cmHg, inHg
Display
unit
Leak rate Pa, kPa, mmH2O, mmHg, mL/s, mL/min, in3/min, in3/d, L/min
Leak rate display 3 digits (floating point), Sampling rate: 10 times/s

Leak rate limit Standard: ±999.999 Pa or lower (±001.000 kPa or lower)
Number of channels 16 (CH# 0 to 15)
Timer setting 999.9 s (Resolution 0.1 s)
Hardware 16 BIT CPU
100 to 240 V AC ±10% at 50/60 Hz, 100 VA max
Power supply Dielectric strength voltage and resistance: 1390 V AC 10 sec, 500 V
DC 50 MΩ
Clean air whose pressure is regulated to the test pressure is used.
The original pressure must be sufficiently higher than the test
Test pressure source
pressure.
Be sure to connect regulator to eliminate fluctuation of plant air.
Pilot pressure source Clean air regulated from 400 to 700 kPa
Rc (PT) 1/4 (Pressure source, Work and Master ports)
Tubing port inner diameter
Rc (PT) 1/8 (Pilot pressure port)
Operating temp: 5 to 40°C, Storage temp: -20 to 60°C
Ambient temperature
NOTE: Please consult manufacturer for high temperature
applications.
Ambient humidity 80% RH or less, no condensation
Weight Approx. 12 kg
I/F fixed length Leak rate and test parameters are transmitted.
Leak rate and test parameters are transmitted.
Serial Communication port ID/F fixed length
(Manufacturer setting)
(COM1)
(Output format is selectable) T/F fixed length Only leak rate data are transmitted.
In addition to leak rate data, drift error, judgment,
Printer
and the like are transmitted.
Control I/O port Current sink Open Collector Outputs: DB-37P Male connector
Calibration output (CAL. port) Work and Master-side connection diameter: M10 × 1.5 (o-ring seal)
Filter regulator for pilot pressure (with a rear panel), quick mounting
brackets
Standard accessories
High voltage power cord (withstandability: 125 V AC, 3 m)
and components
Connectors for interface ports
Inspection record and Operation Manual
Power cord (CE-compliant, withstandability: 240 V AC max, length: 2
m), Export specifications (the screen text is English)
Optional accessories
Leak Master, fitting for CAL port, Master Chamber
remote controller and external exhaust valve
• Overvoltage category: II
• Degree of contamination: 2
Environmental characteristics (IEC
• Maximum mount height: 2000 m
61010-1)
• Class 1 protection
• Area to be installed: indoors
NOTE: When the power source is high voltage (125 V AC or above), use of a power cord compliant with
the laws and regulations of the EU or the country where it is being used is recommended.
NOTE: The inner diameter of the tubing ports for the testers for U.S. customers will meet NPT
specifications.
1.4 Model Classifications

LS-1822A- c
Low L 10 to 100 kPa PS: 100 kPa

Medium M 50 to 700 kPa PS: 1 MPa
Test pressure selection
Precision
High H15 0.1 to 1.5 MPa PS: 2 MPa
regulator
High H20 1 to 2.0 MPa PS: 2 MPa
Vacuum V -5 to -100 kPa PS: -100 kPa
Low LR 10 to 95 kPa PS: 100 kPa
EP regulator Medium MR 50 to 700 kPa PS: 1 MPa
Vacuum VR -5 to -75 kPa PS: -100 kPa
NOTE: PS: Pressure sensor range

NOTE: EP regulator: Electropneumatic regulator
NOTE: The maximum pressure for the vacuum pressure model (V) is constrained by atmospheric pressure
conditions.
10 CHAPTER 1: GENERAL INFORMATION AND SPECIFICATIONS
Options
Intelligent II pneumatic circuit Works of all volumes can be tested due to the large air flow
rate capacity. In each leak test, the self-check function checks
A2 the operation of the differential pressure sensor and valves,
and cleaning is automatically performed by the air blow
function.
Small volume pneumatic circuit Recommended for a Work whose internal volume is 50 mL or
(Intelligent pneumatic circuit) smaller and leak rate limits are particularly small.
Test pressure selection: Low, Medium or Vacuum
A01
NOTE: Stop valves for Master and Work sides are
removable.
Tester internal volume: 6 mL
(4 mL without stop valves)
External pressure detection Test pressure selection (primary side): Low, Medium, High or
method Vacuum
(Secondary pressure method) C
NOTE: If the test pressure is controlled externally, a standard
(internal pressure) pneumatic circuit can be used.
Stop valve check switch W Checks the opening and closing of the Work-side stop valve.
Wide range display Differential pressure sensor range: ±10 kPa
D4 Display range: ±10 kPa
Minimum reading: 1 Pa
External equipment available for Compatible with external exhaust valve: G-3ME; Remote
standard models controller: RC-12B
CHAPTER 2: LEAK TESTING OVERVIEW
2.1 Theory of Leak Testing

After a tested part (Work) is charged with air pressure, the resulting change in its internal pressure is
measured to detect a leak. A non-leaking reference part (Master) simultaneously supplies regulated air to
the Work as well as to itself, and the Master is charged with a pressure concurrently with the Work in Leak
Testing. After air supply to the Work and the Master is stopped, a high sensitivity differential pressure
sensor (DPS) detects the internal pressure change resulting from a leak. This is the pressure difference
between the Work and the Master.
2.1.1 Stage Summary

Stages
Start After clamping and sealing a Work, initiates a start signal.
Charge (CHG) Pressurizes or evacuates the Work and the Master for testing.
Balance delay (BAL1) Stops supply of test pressure. Waits for decrease in pressure changes caused
by valve operation.
Balance (BAL2) Isolates the Work and the Master from each other to detect the pressure
difference between them. Detects large leaks.
Detection (DET) Detects small leaks. Drift compensation will be performed.
Air blow, Exhaust and Transmits judgment signal, and exhausts air from inside the Work and Master
End (BLW, EXH, END) from the exhaust port. Simultaneously, air blow is performed to clean inside the
tester.
Basic Type Pneumatic Circuit (Medium pressure)

SV4-2 P.S F2 V2
MASTER
AV1 AV3
V1
F1
S1
PRESSURE DPS EXHAUST
SOURCE
O O
F3 V3
WORK
CAL
PORT
SV2
SV4-1
F4 G
PILOT EXHAUST
PRESSURE
Timing Chart
BAL1 END
CHG BAL2 DET BLW
Solenoid valve DL1 Balance Exhaust
Charge Balance Detection Air blow
delay End
SV4-2
SV2
SV4-1
12 CHAPTER 2: LEAK TESTING OVERVIEW
2.1.2 Internal pressure changes of the Work and the Master compared to leak rate
The figure on the right shows the pressure changes inside the CHG and BAL1 BAL2 DET
Work and the Master. Pressure change
Internal pressure
using non-leaking
Work and Master
Pressure change
Valve using leaking
closed W ork
In the BAL2 and the DET stages, the differential pressure Auto-zero Auto-zero
Differential pressure
resulting from leaks rises at a constant rate over time. In the
reading
DET stage, the differential pressure sensor (DPS) output must P P Differential pressure
be zeroed through an automatic zero operation before a change using
leaking Work
differential pressure reading is produced. Æ T
Leak rate is calculated using the following equation:
Leak rate reading

Q = K·ΔP/ΔT Auto-zero
Q
Where: Auto-zero
Leak rate
Q: Leak rate (mL/min)
K: Leak coefficient (equivalent internal volume)
ΔP: Differential pressure
ΔT: Time
2.2 Leak Rate Conversion

Detected differential pressure can be converted into leak rate (mL/min) using a conversion equation derived
from Boyle's Law. Using the unit's leak calibration facility makes calculations based on the conversion
equation unnecessary.
2.2.1 Pressure and Volume Relationship

The relationship between pressure and volume is stated in Boyle’s law, which establishes that, for an ideal
gas, pressure multiplied by volume is constant at a constant temperature. Boyle’s law can be represented
by the following equation:
PV = constant (where P is absolute pressure)
The amount of leakage to atmosphere is calculated and expressed by the following equation derived from
Boyle’s law.
Leakage (ΔVL ) = Ve × ΔP / Patm
Where:
Ve: Equivalent internal volume
ΔP: Pressure drop due to a leak
Patm: Atmospheric pressure
NOTE: The definition of internal equivalent volume (Ve) is the volume of air of the entire Work-side
pneumatic circuit at a particular test pressure. It also includes a diaphragm deformation factor of
the DPS. Ve is used as leak coefficient K(Ve) in the leak rate calculation.
2.2.2 Equivalent internal volume
1) Equation for calculating equivalent internal volume

Equivalent internal volume can be calculated with the following equation:
Ve = Vw + Vt + {Ks × (Vw / Vm) + Kw} × (101.3 + P ) A
Where:
Ve: Equivalent internal volume [mL]
Vw: Internal volume of the Work and the tubing [mL]
Vm: Internal volume of the Master and the tubing [mL]
Vt: Tester internal volume [mL] (= 11 mL) (Standard pneumatic circuit)
Ks: Change in internal volume of the sensor per unit pressure change [mL/kPa] (= 0.005 mL/kPa)
Kw: Change in internal volume of the Work per unit pressure change [mL/kPa]
P: Test pressure [kPa]
Tester internal volume, Vt, of pneumatic circuit (including CAL port)

y Standard: 11 mL
y Intelligent II pneumatic circuit, A2: 13 mL
y Small volume pneumatic circuit, A01, with stop valves: 6 mL
y External pressure detection method C: 7 mL
2) Equivalent internal volume when the internal volume of the Master is almost equal to that of the Work
(Vw = Vm)
(In other words, the Master side has the same internal volume as the Work side, and both are rigid
enough that the test pressure does not physically alter their dimensions.)
If the internal volume of the Work remains unchanged (Kw = 0) during detection even though charged
with pressure, Equation A can be simplified to Equation B:
Ks(1 + Vw/Vm) + Kw = 2Ks = 0.01 [mL/kPa]
Ve = Vw + Vt + 0.01 × (101.3 + P) B
3) Equivalent internal volume when a Master Chamber (e.g., MC-F02A, whose internal volume is 109 mL)
is used as a Master
If the internal volume of the Work remains unchanged (Kw = 0) during detection even though charged
with pressure, Equation A can be simplified to Equation C:
Ve = Vw + Vt + 0.005 × (1+ Vw/109) × (101.3 + P) C
NOTE: When the volume of the Master is smaller than that of the Work, Ve increases, and DPS
sensitivity decreases.
2.2.3 Calculation of a Leak Rate

The relationship between differential pressure and leak rate per unit time is given by the following equation:
ΔP 60
Q = Ve × 5
× D
1.013 × 10 T
Where:
Q: Leak volume per unit time (leak rate) [mL/min]
P: Pressure drop due to a leak [Pa]
Ve: Equivalent internal volume [mL]
T: Detection time(s)
The LS-1822A uses the above equation to calculate the leak rate. Note that the tester uses standard
atmospheric pressure for this calculation.
14 CHAPTER 2: LEAK TESTING OVERVIEW
2.3 Estimating the Test Time

The required measurement time must be set for longer under the following conditions:
y Test pressure is quite high.
y Internal volume of the Work is large.
y Internal surface area of the Work is small.
y Leak specification is small.
y Pressure deformation of the Work and/or the clamp seal occurs.
y Work temperature is different from the ambient temperature, as well as from the temperatures of the
other parts.
2.3.1 Setting Charge (CHG) and Balance Delay (BAL1) timers

Generally, the longer the time to wait for pressure stabilization in the CHG and BAL1 stages, the smaller the
noise ratio in the DET stage, contributing to better measurement accuracy. Set the timers with reference to
the general timer ratio suggested below.
General timer ratio: CHG timer : BAL1 timer : BAL2 timer = 10 : 0.5 : 5
After Mastering is performed, the DP curve graph, which shows the level of measurement stability, can be
used to find the appropriate CHG and BAL1 timer settings.
NOTE: When the BAL1 timer is used in an Intelligent II pneumatic circuit, the timer ratio is 5 : 5 : 1.
NOTE: Under A2 specifications, the BAL1 timer does not usually have to be set if the Work volume is
small. The value to be set to the BAL1 timer should be smaller than the value in the general timer
ratio in the above suggested equation, or set to zero.
2.3.2 Limitation on the BAL2 timer setting

The leak-caused differential pressure is limited for the combined duration of the BAL2 and DET timer settings.
The longer the BAL2 timer setting, the greater the differential pressure. The value of the differential value
could increase beyond the measurement range over the duration of the DET timer setting. Be aware that
this is likely to occur when K(Ve) calibration is performed using the Leak Master.
In the A2 specifications, the BAL1 is used in the balance process for pressure stabilization, and the BAL2
setting should be 2-3 seconds to address detection delay.
NOTE: When the test pressure is high and the volume difference between the Master and Work is large,
the value of the BAL2 timer should be somewhat longer.
2.3.3 Setting the DET timer

The LS-1822A is highly sensitive in detecting differential pressure. Even when the DET timer setting is
short, the LS-1822A is effective in leak detection. Typically the DET timer setting should be 1-10 seconds.
If the DET timer setting is proper, the differential pressure should be in the range of 10-100 Pa.
General guidelines for the charge and balance timer settings

CHG timer + BAL1 timer + BAL2 timer
0s 10s 20s 30s 40s 50s
20mL
50mL
Internal volume
100mL
200mL
500mL
1L
2L
5L
10L
Low Å Test pressure Æ High Low pressure (0.01 to 0.1 MPa) High pressure (0.1 to 0.6 MPa)
CHAPTER 3: FEATURE SUMMARIES
3.1 K(Ve) Calibration

To obtain a volumetric leak rate, mL/min, the relationship between the pressure change caused by a leak and
the volume of leakage from the Work must be known. The K(Ve) Calibration feature gives a known leak to
the Work-side pneumatic that creates a measurable differential pressure in order to measure its equivalent
internal volume. The definition of internal equivalent volume (Ve) is the volume of air of the entire Work-side
pneumatic circuit at a particular test pressure. It also includes a diaphragm deformation factor of the DPS.
Ve is used as leak coefficient K(Ve) in the leak rate calculation.
Once equivalent internal volume is measured, the differential pressure detected in the leak test DET stage
can be displayed in mL/min.
Leak calibration is normally carried out using a Leak Master (reference leak generator). The equivalent
internal volume is calculated from the Leak Master flow rate and the measured differential pressure.
3.1.1 Selecting a Leak Master
1) Sizes of standard Leak Masters

LM-1B-J1-
Leak rate at 100 kPa

1 2 5 10 20 50 100 200
(mL/min)
Test pressure range
20 to 600 20 to 300 20 to 200 20 to 100
(kPa)
2) Leak Master selection graphs

Select a Leak Master from the graph that corresponds to your test pressure range and the internal Work
volume. The optimal differential pressure generated by Leak Master is 250 Pa when the DET timer
setting is 5 seconds. The upper limit is 500 Pa and the lower limit is 100 Pa.
If the internal Work volume is 2000 mL or larger (Fig. 3), the optimal differential pressure is 250 Pa when
the DET timer setting is 10 seconds.
3) For vacuum models
A Leak Master must be made to order so it can be used with Cosmo’s vacuum model testers. Refer to
the Fig. 3 or Fig. 5 for selection. Regarding the test pressure, refer to the scales in the negative value
range (from 0 to -100). In the vacuum pressure range, flow rate data are available down to -90 kPa.
4) How to use the graphs
Example
When the internal Work volume (Vw) is 500 mL and the test pressure is 300 kPa:
In Fig. 1, find the intersection (Point a), where the line representing Vw = 500 mL intersects the line
running right in the middle of the upper boundary line and the lower boundary line (center line) in the
working region. Draw a straight horizontal line from Point A to the vertical axis, which represents leak
rate (Q). The point where that horizontal line intersects the vertical axis is Point B, whose value
indicates the optimum leak rate for calibration.
Then extend the straight line further to the left and find the points where the straight line intersects with
the curves of Leak Masters J1-1, J1-2, J1-5, and J1-10. Among those intersections, find the one
nearest to test pressure 300 kPa. In this example, the intersection with the curve of Leak Master J1-5
(Point C in Fig. 1) is the nearest one, so Leak Master J1-5 is the most appropriate Leak Master.
16 CHAPTER 3: FEATURE SUMMARIES
Sizes of Leak Masters
J1-10 Q
Upper boundary
J1-5
J1-2 Working region
J1-1 c b Center line

a
Lower boundary
? P 300 0 500 Vw ?
(kPa) Internal volume (mL)
Test pressure
Fig. 1
For medium pressure range models, and an internal Work volume of 1000 mL or less
Medium Q 70
pressure J1-20
range J1-10
60
J1-5 50 Upper boundary
40
30 Working region
J1-2
20
J1-1 Center line
10
Lower boundary
700 600 500 400 300 200 100 0 500 1000

ÅP Vw Æ
Test pressure (kPa) Internal volume (mL)
Fig. 2
For low or vacuum pressure range models, and an internal Work volume of 2000 mL or less
Low and Vacuum 70 Upper boundary

Q
pressure range 60
J1-200
J1-100
50 Working region
J1-50
40
30 Center line
J1-20
20
J1-10
10 Lower boundary
100 90 80 70 60 50 40 30 20 10 0 1000 2000

ÅP Vw Æ
-100 -50 -20 0
Test pressure (kPa) Internal Volume (mL)
Fig. 3
For medium pressure range models, and an internal Work volume of 2500 mL or less
Medium 100
Q
pressure 90 Upper boundary
range J1-20
80
J1-10
70
60 Working region
50
J1-5
40
Center line
J1-2 30
J1-1 20
Lower boundary
10
700 600 500 400 300 200 100 0 500 1000 1500 2000 2500
ÅP Vw Æ
Test pressure (kPa) Internal volume (mL)
Fig. 4
For low or vacuum pressure range models, and an internal Work volume of 10 L or less
Low and Vacuum 100 Upper boundary

Pressure J1-200 Q
90
Range
80
Working region
J1-100 70
60
50 Center line
J1-50
40
30
Lower boundary
J1-20
20
J1-10
10
10 90 80 70 60 50 40 30 20 10 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
ÅP -100 -50 -20 0 Vw Æ
Test Pressure (kPa) Internal volume (mL)
Fig. 5
5) Composition of Leak Master
Front panel
Filter (Ф8.5, t=2.0 Material: PVF) Manifold for
Leak Master
Filter joint connection port
Leak Master
O-ring (S12) O-ring (S12)

O-ring (P18)
NOTE: A Leak Master contains a filter. Check it periodically and replace as needed.
3.2 Compensation Features

The compensation features detect pressure variations (drift) due to causes other than leakage and subtract
them from the measured value. This improves measurement accuracy and reduces test time. It also
eases Master adjustment, allowing a single Master to deal with a variety of Works. Select a type of
compensation that is most suitable for your test application, referring to the table below. For most typical
cases, the combined use of Mastering and Auto-Drift Compensation is recommended.
Mastering Method Feature Summary Compensation

Mastering The compensation value is Compensates for the effects of
Compensation extracted by comparing the adiabatic changes due to
(Patented) measured values of normal cycle pressurization to speed up
time with that of extended cycle measurement times.
time, where the air inside is
Compensates for test parameter
completely stable. The resulting is
changes, such as timer settings.
then used for compensating for the
errors during normal testing. A non-leaking Work as a Master is
A
no-longer required. Nor are the hours
A Mastering process should be
of labor for making fine adjustments of
executed whenever test conditions,
internal volumes.
such as the Work volume, have
changed. The Mastering process can detect
fixture and connection leakage.
This feature is available with the
Intelligent I pneumatic circuit and
the Intelligent II pneumatic circuit.
Auto-Drift The average of the actual Compensates for moderately varying
Compensation measurement (raw) data for a drifts, slow environmental changes,
(U.S. PAT. #4670847) predetermined number of samplings such as room temperature.
is subtracted as a compensation
Drift compensation can effectively
value from the next measurement
compensate for the drift portion caused
(raw) data. Also, by taking a
by a relatively small temperature
running average, the system
difference.
B constantly refreshes its
compensation value.
Normally used in conjunction with
Mastering, in which case upper and
lower limits are set with respect to
the Mastering compensation values
to sample only the data that falls
within their range.
Constant Shifts data using operator Compensates for data deviations.
C
compensation programmed constant values.
NOTE: The compensation features normally correct data deviations, but overcompensation must be
avoided.
3.3 Mastering Compensation
3.3.1 Theory of Mastering

The measured pressure change in a leak test typically contains both the true leakage and drift errors due to
adiabatic compression and changes in the ambient temperature. The pressure change due to leakage
remains constant, while the drift portion decreases to zero. In other words, it reaches a completely stable
state, over time. Therefore, when the detect stage is repeated a number of times, the measured pressure
changes become more and more stable, and thus the true leak rate amount (b) is finally measured.
The amount of the drift portion can be calculated by subtracting the true leakage (b) from the initially
measured data (a). This value (a-b) is called the Mastering value. See Fig. 6.
During Mastering, normal measurement is conducted first, and then the MB1 and MB2 (auto zero delay)
processes must be performed in between the DET stages. The DET stage is repeated for the specified
number of iterations (LOOP#).
If compensation is performed during normal measurement using the Mastering value, the accuracy of the
Leak Tester results is improved.
Drift error + True leak rate

Pressure change
Drift error
True leak rate
Drift error
+ Measured value (a)
True leak rate
Differential
Pressure
Mastering value (a-b)
CHG DET 1 DET 2 DET (n) True leak rate (b)

BAL1+BAL2
Normal leak test cycle
(n): Number of iterations of DET stage (LOOP#)
Mastering Cycle
Fig. 6
3.3.2 When to execute a Mastering process

A Mastering process must be executed when the test parameters change, environmental conditions change,
or the drift portion shifts significantly. The Leak Tester does not automatically execute the Mastering
process unless it is directed to do so from the PLC of the machine. Execution of the Mastering process is
recommended under any of the following conditions:
1) Beginning of the first shift
At the beginning of the morning shift (when the machine is turned on) it is expected that environmental
conditions will be significantly different from those at the time when the last Mastering was performed on
the previous working day. Also the first two hours of the morning shift are typically when these
conditions may change frequently, therefore, the Mastering Process may need to be initiated a few times
during this period.
2) After a long break
During shift changes, breaks, or long waits for Works, etc., the ambient air temperature, fixtures, or
conditions of the Works themselves may vary. After such occasions, executing a Mastering process is
recommended.
3) Production Work Changeover
For production lines that produce multiple Works, each Work should be assigned to a specific leak tester
channel (CH). Therefore, a Mastering process is required on the new channel immediately after the
model changeover.
4) When No-Go judgments occur consecutively

The seals in the fixture may be damaged in this case, assuming that a production line is unlikely to
produce defective Works consecutively. Since the test result of a Mastering process shows almost true
leakage, it would help in determining if these No-Go Judgments are from leaks or from fluctuations due
to drift.
5) When the test parameters may have been altered
When settings such as stage timers are changed, the execution of a Mastering process is required.
3.3.3 Annotation for use of Mastering compensation feature
1) As the measured data during the BAL2 stage is not compensated for, its leak limit and timer should be
programmed taking the drift portion into account.
2) The Mastering process clears previous compensation data. If Mastering does not complete
successfully (e.g., due to NG judgment), use another Work to complete the Mastering process.
3) Do not execute the Mastering process with Works that are different from the normal production parts.
4) The Mastering process requires a longer cycle time than the normal leak test process, so the PLC
should disable its “Leak Tester Overrun” error if originally programmed to do so. Equivalent internal
volume is measured using a Leak Calibrator.
3.4 Auto-Drift Compensation (U.S. PAT. #4670847)

Auto-Drift Compensation is a statistical compensation method. A running average of the latest good Works
is used as a compensation value to keep track of moderate changes in the drift portion, such as those
caused by gradual room temperature changes. When accurate data is not available or the test environment
changes rather rapidly, the combined use of Mastering compensation is recommended. This generates the
Mastering value that can be used as the initial compensation value for the Auto-Drift compensation.
A) Compensation value and number of samples
A running average value of the previously sampled leak test data of good Works is assumed as a
measurement error, and used as a compensation value. The value is subtracted from the measured
leakage of the current leak result. The number of sampled data on good Works used for this calculation
is referred to as number of samples. The sampled data on good Works is updated when there is new
data.
B) Compensation value calculation
Q=(Q1+Q2+...+Qn) ×1/n
Where:
n: Number of samples
Q1: Raw leak test data n pieces before
Qn: Current raw leak test data
Q: Drift compensation value for the next leak test
C) Compensation limitation
Limits for good Work data can be set to prevent data exceeding the limit from being saved as good Work
data even if a good judgment is given.
D) Constant drift compensation
Sampling of data can be disabled in order to compensate for data using a constant value. The value is
operator programmable.
3.5 Noise Reduction (NR) Mode

This leak tester permits a Hi-No Go limit and a HH -No Go limit (Work-side) to be set in the DET stage.
During a normal leak test, No-Go Works can be sorted out according to leak rate. In the NR mode, the
HH-NG range is regarded as an NR limit and the range between HH-NG and Hi-NG
is regarded as an uncertain judgment region. If the leak test data during the DET HH-NG range
Leak
stage falls in this range, a DET stage preceded by a longer stabilizing period to
cancel the noise interference is repeated. This feature is useful where there is a Hi-NG range
high percentage of noise presence caused by temperature or volume changes. It
helps obtain more critical judgment. The NR feature can be used in conjunction OK range
0
with any compensation feature.
Lo-NG and LL-NG limit settings on the Master-side are the same as those on the
Work-side. See Section 8.2.5 (4).
3.6 Air-Operated Valve Performance Check and DPS Sensitivity Check (standard
circuit)
During the BLW stage, air is exhausted from the Master and
the Work, while air is blown from the pressure source. If Master
the air-operated valves are functioning normally, the orifice
difference between the exhaust ports of the Master and the
Work introduces a pressure difference. This pressure DPS
difference is used to check the sensitivity of the DPS. The Exhaust
performance of the air valves is simultaneously checked.
Work
NOTE: The pressure difference may not be introduced
when the test pressure is low or in a vacuum state,
causing error #15, “Air Valve Inactive. C4.” If extending the BLW timer does not cure this error,
turn off this feature with memory switch AIR VALVE CHECK. See Section 8.2.8.
NOTE: This feature is not available for C type circuits and Intelligent II pneumatic circuits at high pressures
(H15 and H20).
3.7 Air-Operated Valve Performance Check (A2 Option)

Air-operated valve malfunction can lead to serious errors in testing. In order to prevent such failures the
performance of the air-operated valves (AV1, AV2, and AV3) is automatically checked at the end of each
CHG, BAL1, BAL2 and DET stage to ensure the reliability of leak testing. This feature can be disabled
using the memory switch.
NOTE: This feature is not available for C type circuits and Intelligent II pneumatic circuits at high pressures
(H15 and H20).
Intelligent II pneumatic circuit

Master
AV1 AV2 AV3

PS
Pressure source Exhaust

DPS
Work
Pressure detection Air blow
DL1 Auto-zero Test pressure detection
Air-operated valve
PCHK CHG BAL1 BAL2 DET BLW END
(driving solenoid valves)
Start
AV1 (SV2)
AV2 (SV3)
AV3 (SV4)
Fixed at 0.2 s.
Air-operated valve check description

1) The pressure sensor offset value is checked in the PCHK stage. If the offset value is out of its range,
AV2 (normally open) may not be performing properly.
2) The test pressure exerted on the pressure sensor during the BAL1 stage is checked by the P sensor. If
there is no test pressure detected, there is a possibility of one of the following errors:
y AV1 does not open.
y AV2 is closed.
y AV3 does not close.
3.8 Sensor Protection

If the Work contains water or oil, or if the Leak Tester is used during a water dunk test, water and/or oil may
enter the tester from the Work during the exhaust stage causing malfunctioning. The sensor protection
feature protects sensors from such contamination.
3.8.1 Cleaning pneumatic circuit by exhaust air blow

Air blow during the BLW stage is used to clean the pneumatic circuit and prevent the DPS from becoming
contaminated by blowing off water, oil and other foreign matter inside the pneumatic circuit, during the self
check mentioned in Section 3.7. Air blow can be disabled by setting the BLW timer to zero.
NOTE: This feature is not available on the high pressure models (H15 and H20).
3.8.2 External exhaust valve ready

An air-operated valve is installed between the Work and the Master so that the Leak Tester can be
exhausted externally. An external exhaust valve unit (G3-ME) is separately required.
G3- ME can be controlled by a standard Leak Tester.
NOTE: This feature is not available for vacuum pressure models.
External
exhaust
valve
Master
LS-1822A
W ork
3.9 Exhaust Interference Prevention

When using several Leak Testers to measure different cavities on the same part simultaneously, some
interference may occur when one Leak Tester finishes its cycle while the other(s) are still in the leak test
process. This is called “Exhaust Interference.” Exhaust interference can cause jumps in the Leak Tester
readout during the exhaust of one of the other testers, both in normal leak tests and in Mastering processes.
In order to prevent this, all Leak Testers on the station must be synchronized with one another before
exhausting air. With this software, the Leak Testers will continue holding the test pressure in the part even
after it makes a judgment as long as the START signal is turned on. As soon as the START signal turns off,
the test pressure will be vented to the atmosphere. In order to utilize this feature, the PLC must be
programmed in such a way that it will hold the START signal until it receives the judgment signal of every
tester in its control (see Section 8.2.9).
All the testers have made judgment.
START 1
BUSY 1 Tester 1 has made judgment.
Judgment sig. 1
Extension
END 1
START 2
Judgment sig. 2
Extension
END 2
START 3
Judgment sig. 3
END 3
Judgment of
All testers has been made.
Start of exhaust Measurement cycle of all

testers completed
NOTE: “Extension” is the length of time that exhaust is delayed due to this feature.
NOTE: T, which stands for WAIT, appears on the Leak Tester display for 999.9 seconds during the DEL
stage.
CHAPTER 4: INSTALLATION
4.1 Checking Supplied Accessories and Documents

Unpack and check the Air Leak Tester and the supplied accessories.
y Power cord 1
y Connectors (DB-37P and DB-25P) 1 each
y Fuse 1
y Operation manual 1
y Inspection record 1
4.2 Installing the Unit

CAUTION: When relocating the Leak Tester, hold it by the bottom to keep from dropping it. Do not lift
the Leak Tester by gripping its components, such as the rear panel-mounted stop valve or
regulator. Doing so may cause damage to the hardware or result in physical injury.
CAUTION: Mount the Leak Tester on a frame that is fully capable of withstanding its weight. Never
mount it in an unstable or inclined place that is subject to vibration. Doing so may result in
the unit being overturned or falling, and may result in physical injury.
4.2.1 Using quick mounting brackets (standard)

The LS-1822A comes with mounting brackets that can be attached or detached with two front panel screws.
Using these mounting brackets allows for better space utilization to install another tester alongside the first
one by making it unnecessary to use a screwdriver on its lateral side.
1) Components
The components comprise a mounting base, mounting bracket A, and mounting bracket B. Attach the
mounting base where the tester is to be mounted. Mounting brackets A and B are affixed to the bottom
of the tester body.
Mounting base Mounting bracket A Mounting bracket B

(Front) (Rear)
26 CHAPTER 4: INSTALLATION
2) Mounting base
Attach the mounting base where the tester is to be mounted using four M4 screws. The surface that the
mounting base is to be mounted to should be flat and smooth. The drawing below shows the position
of the LS-1822A positioned on the mounting base.
Screw the mounting base onto the surface. The M4 screws are not provided. Use screws appropriate
for the base to which the unit is to be affixed.
Front Top of LS-1822A Rear

4-M4, 5(Mounting hole)
Mounting base
195
18 300 50
331.5
3) Mounting procedure
The mounting brackets A and B are assembled on the bottom of the front and rear panels of the
LS-1822A.
The drawing below is a side view of LS-1822A.
Mounting bracket A Mounting bracket B
Mounting base
Attach the mounting base to a machine or test bench.

y Place the LS-1822A that has been fitted with mounting brackets A and B somewhat in front of the
intended installation site.
y Slide the LS-1822A back to force the tip of mounting bracket B into the square holes in the mounting
base.
y Slide the LS-1822A back until mounting bracket A touches the mounting base.
y Align the hole in mounting bracket A and the screw hole in the mounting base, and secure them with
an M4 screw.
4.3 Electrical Connection
4.3.1 Connecting power

This tester can be used with a 100-240 VAC ±10% at 50/50 Hz single-phased power supply. Make sure the
unit is properly grounded. If the tester cannot be plugged into a grounded power receptacle, connect the
ground conductor to terminal F.G. The standard power cord supplied with the Leak Tester is rated for
100-125 V AC. A special power cord for 200-240 V AC is available upon request.
CAUTION: Electrical Shock Hazard

Operating the Leak Tester from a non-standard power source can result in electrical shock
hazards or fire.
CAUTION: Use a power line free from noise. If the power line crosses a path of noise propagation,
use an insulating transformer or noise-cutting transformer for their noise cancellation effect.
Insulating transformer
LS-1822A
Shield GND
F.G.
GND
4.3.2 Connecting signals

Connect the Leak Tester to an external controller such as a PLC, by means of the I/O port connector.
Turn off the main power before making the connection.
y Use a shielded cable for wiring. Keep the signal and power supply lines apart within the equipment.
y Keep the wiring to the minimum length required. Never leave a slack loop in the pathway.
y Twisting the common line with the signal lines will help reduce noise.
4.4 Pneumatic Connection

CAUTION: Shut off the pressure source before connecting or disconnecting it.
4.4.1 Test pressure source
1) Connection port: PRESSURE SOURCE (oil mist separator IN port)

Port diameter: Rc 1/4
Connect to a clean air source free from water, oil, and dust.
NOTE: High pressure models must be connected to an air filter.
2) Test pressure source
Test pressure Pressure source

Connect a pressure source meeting the following L:
L/LR (low pressure Up to requirements: Up to 500 kPa
type) 100 kPa y Sufficiently higher than the test pressure and LR:
does not fluctuate Up to 150 kPa
y Clean and dry
M:
y Sufficient flow capacity for the test Up to 1 MPa
M/MR (mid pressure Up to
y Put another pressure regulator inline before
type) 700 kPa MR:
the Leak Tester to regulate the pressure 100
Up to 800 kPa
kPa higher than the test pressure.
H15 (high pressure Up to 1.5 Connect a pressure source whose pressure is sufficiently higher
type) MPa than the test pressure. Up to 2.0 MPa.
Connect a pressure source whose pressure is sufficiently higher
H20 (high pressure Up to 2.0 than the test pressure.
type) MPa
Connect a vacuum pump.

V/VR (vacuum Up to
pressure type) 100 kPa CAUTION: Prevent tester from being contaminated with water
and oils.
NOTE: Pressure source stability influences measurement accuracy. If a Master whose volume or
shape is different from that of the Work, such as a Master Chamber, is used, the effects of
source pressure changes will be more pronounced. Connecting a well regulated pressure
source to the regulator eliminates these effects.
4.4.2 Pilot pressure sources

Connection port: PILOT PRESSURE PORT
Port diameter: Rc 1/8
Supplies air to PILOT PRESSURE PORT to activate air operated valves. Use a pilot pressure source that
supplies clean air whose pressure is in the range of 0.4 - 1.0 MPa. Also, use the filter regulator at the rear
of the unit to regulate the output pilot pressure to a range of 400 - 700 kPa.
4.4.3 Annotation for air source
1) The pressure source must provide test pressure using clean and dry air. Water or oil penetrating inside
of the Leak Tester may cause malfunction of the DPS. Install an additional oil mist separator or air
dryer as a pre-filter to completely prevent contaminants from entering the tester.
2) Symptoms of a differential pressure sensor failure caused by water and/or oil.
Water or oil present in the source air may result in a significant shift of the DPS offset value and produce
an offset error or major leak failure, requiring repair by the manufacturer.
3) Keep the tubing free from condensation. If the tubing is installed in areas subject to direct air current
from heating and cooling vents, the temperature difference between the room and inside the tester may
promote condensation.
Good Air leak
4) Do not connect air passing through a driving tester
lubricator to the Leak Tester as shown in the
diagram. Never connect a pressure source Filter
Driving cylinder
containing oils.
5) Notes on using a vacuum pump Lubricator
If an oil rotating vacuum pump is used, install
an air release solenoid valve to prevent oil No Good Air leak
back flow with the pump turned off. Have the tester
Leak Tester installed at a height above the Driving cylinder
vacuum pump. Filter
Lubricator
4.5 Connecting Master and Work
4.5.1 Annotation for designing a sealing fixture
1) Internal and external leaks

The seal must be designed to prevent leaks from inside the Work such as from other sealed spaces,
gaps between the Work and the seal and cavities that are not open to the atmosphere, as well as
external leaks.
Since these internal leaks are hardly noticeable visually, this requires extra vigilance.
2) Reducing internal volume of Work Air cylinder
A smaller internal volume allows a shorter test time and gives Work
better sensitivity. A spacer and/or a filler can be used to reduce
the internal volume of the Work. The material of the insert can
be resinoid but should not be plasterboard, wood or any porous Insert
material.
3) Effects of plant temperature on leak testing

Temperature changes in the Work cause drift in measurement. In order to prevent these effects, the
Work temperature must be stabilized.
Please take the following into consideration when installing the Leak Tester.
y Do not use the leak test station just after it has been subjected to heating, cooling, welding or
washing processes. The Leak Tester works best with Works that are at ambient temperature.
y Avoid fluctuations in temperature while testing.
y When the temperatures of the floor and the test bench are different, and the Work is taken from the
floor and then tested on the test bench, heat transfer will take place between the Work and the
fixture. The Works should be located at the same level as the test bench in order to keep the
temperatures the same.
4) Seal packing deformation
Beware that clamping deforms seals, which causes changes in internal Work volume and erratic reading
especially in cases where the sealing surface area is large.
5) Use of O-ring
Design the groove so that no part of the O-ring is compressed due to internal pressure. Also, the O-ring
must not protrude horizontally from the groove, or it will become stuck between the Work and the edges
of the groove.
Good: No Good: No Good:

If a taper is used, the O-ring will The groove is so tight that the The O-ring moves inside the
stay in place when unclamped. fixture cannot touch the metal groove and causes a pressure
(5 - 15 degrees) surface of the Work drop.
6) Use of flat rubber seal

Use a positive stop to prevent deformation of the seal packing when
using air or oil cylinders as a clamping mechanism. A metal stopper
Stopper Rubber seal
helps seal packing stabilize completely. Normally the clamping
pressure added to the seal packing causes the packing to move
intermittently.
7) Combining with water dunk test
Temperature effects
Temperature changes of the Work and/or fixture after submerging them under water may temporarily
affect tester reading.
Tester malfunction due to water intrusion
The tester may become contaminated by water, resulting in tester malfunction during the exhaust
process of the water dunk test. To avoid this problem, use the following precautions:
y While the Work is submerged, the tester should always be on charge hold. Never exhaust air while
the Work is submerged under water.
y Put an external exhaust valve between the tester and the Work.
y Install the Leak Tester at a level higher than the water surface.
8) Installing multiple testers in a machine
Build a clamping system for each tester independently to avoid having them interfere with each other.
The regulators for each clamping pressure valve should be separated as well.
9) Testing multiple independent measurement points (Exhaust interference prevention)

If one Leak Tester exhausts while measurement is in progress, variations in the clamp seal could
influence the measurement accuracy of the other Leak Testers. Mutual exhaust interference can be
prevented by performing exhaust on all Leak Testers concurrently. This model of Leak Tester allows for
external control of the exhaust timing.
10) Works subject to deformation
Install a stopper to prevent deformation.
11) Fixture pressure supply port
Provide a port in an area not subject to exposure to dust, oil or water.
If the angles of a sealing surface of the Work vary, have a floating mechanism mounted on the clamp
shaft.
4.5.2 Master installation

Generally, the Master uses one of the following:
y A known non-leaking Work
Choose a non-leaking Work.
If the Work is subject to fluctuation due to pressurization, it cannot be used as a Master.
y A Master Chamber (sold separately)
Various master chambers are available depending on the internal volume of the Work. If a
Master-Preset compensation is used, Cosmo recommends MC-F02A-200C, which has excellent thermal
stability and is compatible with a broad range of internal volume, from small to large.
69
1) Master Chamber specifications
Model: MC-F02A-200C
Internal volume: 109 mL
non-adjustable Rc(PT)1/8
2) Advantages of using a Master Chamber

156
Capable of high speed temperature stabilization

which results in excellent pressure stability and 2- 4.5
withstands repeated use over long term periods. 85

Furthermore, it is inexpensive and compact.
105
3) Location of Master
y Install the Master where there will be minimal effects due to vibration from motors, heat, air current
from fans, air conditioning, or heating vents. In cases where these situations cannot be avoided,
use a curtain or screen. However, do not cover the whole test stand area completely because of
temperature fluctuations that could occur in the Master. Proper ventilation of the area must be
maintained.
y Because floor temperature changes very rapidly, avoid installing the Master close to the floor.
y Use of an intermediate insulator, such as a rubber mat is recommended to avoid heat transfer from
the mounting surface to the Master.
4.5.3 Choosing proper connections to Master and Work
1) Recommended nylon tubing types

y Use of rigid nylon tubing that is less subject to expansion from pressure is recommended.
y Select a tubing type to suit the volume of the Work and the test pressure. See the table below for
general guidelines.
y Choose tubing whose thickness is proportional to the test pressure, and with an inner diameter that
is proportional to the inner volume.
Work Test pressure

volume Up to 50 kPa 51 - 200 kPa 201 - 500 kPa
Inner diameter: 1.6 - 3.3 mm
20 mL
Thickness: 0.7 - 1.6 mm
Inner diameter: 3.2 - 3.5 mm Inner diameter: 2.4 - 3.3 mm
200 mL
Thickness: 0.8 - 1.6 mm Thickness: 1.0 - 1.6 mm
Inner diameter: 3.2 - 6.4 mm
500 mL
Thickness: 1.2 - 1.6 mm Inner diameter: 3.2 - 4.9 mm
Inner diameter: 4.8 - 6.4 mm Thickness: 1.5 - 2.4 mm
1000 mL
Thickness: 1.2 - 2.4 mm
2000 mL
5000 mL
Tubing grouped by inch

Manufacturer: Nitta-Moore Company
N2 tubing group 1 (N2-1) Inner diameter (2.36 - 9.56 mm), thickness (0.41 - 1.57 mm)
Used in the low and mid test pressure ranges. Test pressures up to 200 kPa.
N2 tubing group 2 (N2-2) Inner diameter (1.60 - 6.40 mm), thickness (0.79 - 3.15 mm)
Used in the mid and high test pressure ranges. Test pressures up to 3 MPa.
Tubing grouped by millimeter
Manufacturer: Nitta-Moore Company
N2 tubing group 4 (N2-4) Inner diameter (2 - 13 mm), thickness (1.00 - 1.50 mm)
Manufacturer: SMC
T Series tubing Inner diameter (2.5 - 13 mm), thickness (0.75 - 1.5 mm)
CAUTION: In cases where the test pressure exceeds that listed in the table above, choose a
tubing from the N2 tubing group 2 (N2-2) or use a tubing made of metal.
2) If copper or steel tubing is used, cover it with a heat insulator because it’s easily affected by temperature
changes.
3) Do not use push-on fittings. Instead use compression fittings for small-volume Works (up to 1000 mL),
because O-ring deformation may affect tester readings. With tubing that is 1/2 inch (outer diameter 12
mm) or larger in diameter, compression fittings may become loose over extended periods of time. In
such cases use one-touch fittings.
4) For a vacuum type test, tubing with larger inner diameters should be used. For a high vacuum, tubing
or piping with a relatively smooth inner surface should be used.
5) Keep tubing length as short as possible. Also, the smaller the internal Work volume, the smaller the
internal tubing diameter.
6) If Master-Preset compensation is not used, the Work and Master tubing should be approximately the
same length and of the same type of material.
7) Keep the tubing stationary while leak testing is in progress.
4.6 Leak Tester Installation Environment

Location of Leak tester to Avoid Temperature Fluctuation
A) Avoid direct sunlight.
B) Avoid direct air current contact due to doors opening and closing.
C) Avoid direct air current from heating and cooling vents.
When the above cannot be avoided, use a curtain or screen. However, do not cover the whole test
stand area completely because of temperature fluctuations that could occur in the Work. Proper
ventilation of the area must be maintained.
Temperature changes in Works
D) Do not use the leak test station just after it has been subjected to heating, cooling, welding or washing
processes.
The Leak Tester works best with Works that are at ambient temperature.
E) If the temperature of the floor and test bench are different, and the Work is taken from the floor and then
tested on the test bench, heat transfer will take place between the Work and the fixture.
This will result in errors. The Work should be located at the same level as the test bench in order to
keep the temperatures the same.
Air Leak Tester
E
CHAPTER 5: PARTS IDENTIFICATION AND FUNCTIONS
5.1 External Appearance – Front panel
A LED Indicators
CPU RUN Lights while CPU is running normally.
CHG Lights during CHG stage.
BAL Lights during the Balance Delay (BAL1) and Balance (BAL2) stages.
DET Lights during DET stage.
END Lights during BLW, EXH and END stages.
LO NO GO Lights when the Master is rejected as Lo or LL No-go.
HI NO GO Lights when the Work is rejected as Hi or HH No-go.
GO Lights when the test result was Good.
KEYBOARD UNLOCK Lights while the keyboard is unlocked.
B Keyboard
C Calibration (CAL) ports
For K(Ve) calibration, the inspection and calibration of DPS and PS are performed, and NG judgement is
checked.
Plugs are supplied (connector M10 x 1.5). Remove the plugs for inspection or calibration.
See CHAPTERS 10 and 13.
D LCD
CAUTION: Never press the LCD panel with excessive pressure. Malfunction could result.
36 CHAPTER 5: PARTS IDENTIFICATION AND FUNCTIONS
5.2 External Appearance – Rear panel
H
A
I
B
C J
D K
A Ground terminal (FG)

F G
B Fuse (T2.5A)
C Test pressure inlet (PRESSURE SOURCE)
WARNING: Be sure to shut off the pressure source before connecting or disconnecting.
D Electropneumatic regulator connector (Option)
E Work-side (Tested part) stop valve
This valve serves as a piping port to which the Work is connected and can be left open except during
testing.
CAUTION: Beware of pressure
F Exhaust port (Exhaust silencer)
Exhausts pressure from the Master and the Work at the end of the leak test cycle.
G Master-side stop valve
This valve serves as a piping port to which the Master is connected and can be left open except during
testing.
H Power inlet
This inlet can be used with a 100 - 240 VAC at 50/60 Hz single-phased power supply, 100 VA max.
Make sure the unit is properly grounded.
I Power switch (POWER)
J Pilot pressure inlet (PILOT PRESSURE INLET)
Connect to a clean air source with pressure regulated to the specified range.
K Pilot pressure outlet for external exhaust valve (EXHAUST)
L Control I/O port (open collector output) (CONTROL I/O)

This port is used for remote control of the LS-1822A.
CAUTION: Never short pins. Malfunction could result.
M Serial communication port (COM1)
CAUTION: Never short pins. Malfunction could result.
5.3 Keyboard
A Numeric keys D E F E Cursor keys

7 8 9
A B C
4 5 6
SPAN + - . F
UP
1 2 3 SHIFT
DOWN
PAGE
G
ZERO REMOTE CHARGE
0 ENTER GRAPH MEAS
MANUAL
HOLD
H
INDEX I
PRINT CALIB SET STOP START
B HELP
J
C Mode keys
CAUTION: Never press multiple keys simultaneously. Malfunction could result.

A Numeric keys (0 - 9)
Used to enter numeric values.
B ENTER key
Used to complete programming or selection.
In Set mode, if this key is pressed after settings are changed, a Mastering request signal will be
transmitted.
38 CHAPTER 5: PARTS IDENTIFICATION AND FUNCTIONS
C Mode keys
Key Mode Operation

Leak test
Charge hold
Mastering
MEAS
K-check
MEAS
(Measurement)
Tester is in Leak data printout
this mode when the
Test pressure adjustment
power is turned on.
CAL valve control
Zero check in WAIT
LCD contrast adjustment
K(Ve) calibration
DPS offset calibration
CALIB DPS span calibration

CALIB.
(Calibration) PS offset calibration
PS span calibration
No-leak test
Equivalent internal volume and stage timer setting
Leak rate limit and unit settings
Compensation, Mastering and calendar
Pneumatic circuit selection (A/B), Pre-charge
Number of Pre-exhaust (SEQ. LOOP), Noise reduction
Statistical counter
Judgement timing, Leak calibration
Memory switch
SET
PS auto-zero, Air-operated valve performance
mode to program
settings
Stop signal format, Pilot pressure check

items on the right
SET
Stop valve check, Exhaust interference prevention
Start condition after rejection, K-check limit
Blow check DPS limit
Communication port
Channel copy
Initialization
System setting
Leak test data graph display
GRAPH GRAPH Mastering graph display
Waveform graph display
I/O monitoring
INDEX
.
HELP
INDEX / HELP Communication port monitoring
Version information
PRINT PRINT Printer output to serial communication port

D SHIFT key ([s] appears)

Launches various functions when used in combination with another key.
Pressing the key once turns it on, and pressing it again turns it off.
To zero clear, press SHIFT and 0.
To change a negative value to positive, press SHIFT and 1. To change a positive value to negative,
press SHIFT and 2.
To clear the display to zero in CALIB mode, press SHIFT and 0.
E Cursor keys ( )
Used to move the cursor within a page during programming and calibration.
Also used for setting the EP regulator pressure and LCD contrast adjustment.
F UP PAGE DOWN key
Used to scroll the pages up or down. Used only in SET mode programming and when accessing HELP
screens.
G REMOTE/MANUAL
Used to switch the leak tester mode to remote [REM] or manual [MAN]. When the power is turned on,
the mode is [REM].
H CHARGE HOLD
Used to continuously pressurize (or evacuate for vacuum models) the Master and the Work.
I STOP
Used to stop a leak test or charge hold, or to clear the error displays in manual mode.
J START
Used to start a leak test in manual mode.
CHAPTER 6: COMPREHENSIVE SETUP PROCEDURE
6.1 Turning on Power

Turn the power on by pressing the rear panel power switch. The leak tester beeps three times, and then all
LED indicators on the front panel blink. The leak tester defaults to Measurement (MEAS) mode and remote
control. (The leak tester takes five seconds to start up after turning on the power.)
6.2 Unlocking the Keyboard

Input one of the following passwords to enable keyboard operation.
A) To view programmed settings
Enter the password 2 4 6 8. (KEYBOARD UNLOCK LED blinks.)
To view programmed settings on the SET mode screen, press 2 4 6 8 and then press SET key.
Settings cannot be reprogrammed.
Pressing the keys in the same sequence locks the keyboard. (KEYBOARD UNLOCK LED turns off.)
B) To program settings
Enter the password 1 3 5 7. (KEYBOARD UNLOCK LED lights.)
To program the settings in the SET mode screen, enter the password 1 3 5 7 and press the SET key.
Pressing the keys in the same sequence locks the keyboard. (KEYBOARD UNLOCK LED turns off.)
6.3 Switching Between Remote and Manual Modes

When the power is turned on, the leak tester automatically defaults to remote mode, and <REM> is displayed
in the upper right corner of the LCD panel. Testing can only be started or stopped by external signals.
To start, stop or charge hold using the keyboard, enter the password 1 3 5 7 or 2 4 6 8 and press the
REM/MAN key to switch modes. <MAN> is now displayed in the upper right corner of the LCD panel.
6.4 Test Parameter Programming Procedure

A) Preparation
Operation Note Refer to
Preparation of Master Connect a Work which is known to be non-leaking or a
1 Master Chamber, to the Master-side port on the rear 4.5.2
panel.
Preparation of a sample Prepare as many non-leaking parts as possible for
2 Work sampling, and connect one to the Work-side port on the
rear panel.
Preparation of Leak Prepare Leak Master for leak data and NG judgment
4.5
3 Master accuracy verification (NG check)
Prepare Leak Master for leak calibration 3.1
42 CHAPTER 6: COMPREHENSIVE SETUP PROCEDURE
B) Before programming
Channel selection Use different channels for different Works or test
1 8.1.3
parameters.
Test Precision Use the Charge Hold function and the pressure regulator
pressure regulator valve to set the test pressure according to the pressure 4.4
2 reading on the LCD.
7.2.3
EP regulator Keyboard programming in MEAS or SET mode
Test pressure upper and Set the appropriate test pressure limits.
3 8.2.3
lower limits
C) Preliminary programming of basic test parameters

Preliminary stage timer Set CHG timer sufficiently long (60 seconds or longer). 2.3
1 setting 8.2.1
Preliminary leak rate First set relatively large leak rate limits. Use Pa for
2 8.2.3
limit setting Leak unit until equivalent internal volume is measured.
NOTE: There are several programming limitations due to the interrelationship of leak rate units to
timers and leak rate limits. See section 8.1.2.
D) Leak test and timer adjustment
Adjust timers by executing a leak test without Mastering compensation to determine the actual tester
readout.
Bubble test Check the leak integrity of the leak test system. Use
1 13.11.1
Charge hold for this test.
No-leak test Set the CHG timer sufficiently long, and check whether
2 7.2.9
the leak data in pressure unit, Pa, is small enough.
Timer verification Change the timer setting and execute a leak test using a
Work that is known to be non-leaking. Determine the
3 8.2.1
shortest possible test time where the value of the data
becomes constant near zero.
E) Mastering
In most cases, the test time is required to be shorter than the timer setting referred to in the previous
section. A shorter test time with high accuracy can be achieved by using the Mastering compensation
feature to compensate for the measured leak data. However, if the test time is sufficiently long, and a
Work is used for a Master, Mastering is not necessary.
Mastering stage timers Set each test timer according to the desired total leak
8.2.1
test time.
1 Mastering setup Set Mastering to be effective in COMP mode.
Auto-Drift compensation will be ineffective. Set stage 9.3.1
timers for Mastering and the number of iterations.
Mastering process Check the Mastering setting on the Mastering graph. If
9.3.2
2 execution the graph is not appropriate, change the CHG and the
9.5
BAL1 timer settings and execute Mastering again.
Leak data verification Carry out a leak test and check whether the tester
3 reading is similar to the leak data measured in the 9.6
previous section, 6.4 d) 2.
F) K(Ve) calibration
Refer to
Calculate the equivalent internal volume, K(Ve), in order to display the measured leak in Chapter
volumetric flow rate, mL/min. 10
G) Final programming and verification

1 Stage timer The channel copy feature is useful when setting several 8.2.1
reprogramming channels at one time. 8.2.11
2 Leak unit selection and The measured value can be displayed in a volumetric
leak rate limit flow rate such as mL/min. 8.2.3
programming
3 NR condition This is useful when the measured leak rate contains a 3.5
programming large ratio of noise or drift. 8.2.3
8.2.5
4 Leak rate limit Determine the best limits by comparing the results of
8.2.3
verification leak tests conducted with a non-leaking Work and leak
13.10
tests with Leak Master.
44 CHAPTER 6: COMPREHENSIVE SETUP PROCEDURE
6.5 Other Programming

Operations Notes Refer to
Pneumatic Pre-pressurization and Pressurization by quick charge, 8.2.2
circuit pre-exhaust setting pre-charge and pre-exhaust 8.2.5
External exhaust valve type In cases where tested parts contain
water and/or oil, and when leak tests 3.8.2
are combined with water dunk tests
Quality control data Statistical counter displays Quantity of total parts, good parts
8.2.7
and display clear and rejected parts
X-CONTROL CHART screen Bar graph display of latest 100 data 11.2
Maintenance Daily and periodic inspection Items requiring inspection 13.1
and
Calibration of differential Checking DPS offset 13.5
trouble shooting
pressure and test pressure
Checking PS offset 13.7
I/O signals Monitoring signals 11.4.1
Error display during leak test Displays and causes of errors 13.13
Charge hold Visually locate the leak by immersing 7.2.10
the leaking part under water 13.11.1
No-leak test of leak tester Check for leaks in the leak tester by
13.9
itself conducting the No-leak check
CHAPTER 7: MEASUREMENT (MEAS) MODE OPERATION
7.1 Description of MEAS mode screen

NOTE: The items marked with * are displayed only when Mastering or Automatic drift compensation is
used.
A LEAK: leak rate

B Leak rate unit
C Horizontal Scale Indicator (HSI)
Upper line is the current leak rate, and lower line is the compensation value.
Following example is a case where the Mastering value (M.CMP) is 0.
Leak rate Leak rate limit
1000
Comp. limit Comp. value
D LIMIT: Leak rate limit

During the BAL stage, the leak rate limits for the BAL stage are displayed, and during the DET stage, the
limits for DET are displayed. The lower limit is displayed on the left and the upper limit is on the right.
E PRESS: Test pressure
Current test pressure is displayed until the end of the CHG stage. After that the last test pressure value
in the CHG stage is displayed.
F P.LMT: Test pressure limits
The lower limit is displayed on the left and the upper limit is on the right.
G LOOP#: Number of iterations for Mastering compensation
H C.VAL: Current compensation value
I M.CMP: Mastering (compensation) value
J K(Ve): Equivalent internal volume (Used as a leak coefficient for calculation)
46 CHAPTER 7: MEASUREMENT (MEAS) MODE OPERATION
K Master-side No-Go counter, H: Work-side No-Go counter, G: Good part counter, T: Total counter
When an error occurs, its error code and description will be displayed.
L WAIT: Wait
The current stage name is displayed during measurement.
C: Stage timer
T: Total test timer during Wait. Remaining test time during measurement.
M CH: Channel number
N Mode display
[S]: When SHIFT is pressed.
< >: Manual <MAN> control mode.
(): Remote <REM> control mode.
<P>: When PRINT is pressed.
(E): Displayed while an exhaust interference countermeasure is taken.
(K): When a K(Ve) signal has been received.
(*): When a calibration valve operation signal has been received.
O Remote/Manual
REM and MAN stand for the Remote control mode and the Manual control mode, respectively.
P HSI full-scale (Pa)
Q Compensation method
This is not displayed when compensation is off.
R a2: DPS raw output before compensation (Pa)
S S#: Number of samples for Automatic drift compensation
The number of samples is displayed so that it can be referred to for determining the drift value.
7.2 Keyboard Operations

7.2.1 Contrast adjustment
Also operable when the keyboard is locked.
Press for brighter, and press for dimmer.
7.2.2 Zero check in WAIT

Pressing 0 and holding it for 3 seconds displays the zero of the DPS and PS. The display will be
automatically cleared 30 seconds later, or can be cleared manually by pressing 0 or STOP.
7.2.3 Test pressure adjustment

On the regulator model, turn the knob for adjustment.
On the EP regulator model use the keyboard for adjustment.
< Operation>
1) Switch to manual (MAN) by pressing REM/MAN.
2) Close both the Work and Master-side stop valves.
3) Press CHARGE HOLD.
4) Use 0 - 9 for rough adjustment (output in the unit of 10% of test pressure sensor F.S.).
5) Use and for fine adjustment.
6) Press ENTER to complete the setting.
NOTE: For a tester equipped with an EP regulator the test pressure may also be set in the SET mode.
If the value set in the SET mode does not agree with the pressure due to an electrical error, go
to the MEAS mode and use and to make the fine adjustment. Press ENTER to
complete the setting.
7.2.4 Test pressure limit (P.LIMIT)

Pressing CHARGE HOLD, SHIFT and ENTER automatically sets the test pressure limit to ±10% of the test
pressure reading.
The display is updated at the next start.
7.2.5 Pre-charge setting (P.CHG)

Press SHIFT and CHARGE HOLD.
The following procedure is the same as that for Test pressure adjustment (Section 7.2.3).
NOTE: For a tester equipped with an EP regulator the pre-charge pressure may also be set in the SET
mode. If the value set in the SET mode does not agree with the pressure due to an electrical error,
go to the MEAS mode and use and to make the fine adjustment. Press ENTER to complete
the setting.
7.2.6 Mastering
1) In Manual control mode (MAN)

When Mastering value measurement is enabled, <M> appears below the CH #.
As Mastering compensation aims at monitoring external signals, the display takes precedence over other
processes.
Pressing SHIFT and 6 enables Mastering value measurement. Pressing SHIFT and 6 again disables it.
Also, Mastering value measurement is automatically disabled after completing 1 measurement cycle.
2) In Remote control mode (REM)
When Mastering operation is enabled, <M> appears below the CH #.
As Mastering compensation aims at monitoring external signals, takes precedence over other processes.
See CHAPTER 12: INTERFACE.
7.2.7 Calibration Valve Control (for functional specification J only)

When a pressure standard is connected to the calibration port to check differential pressure sensitivity and
test pressure, or when a Leak Master is connected to the calibration port for an NG judgment check, only the
calibration valve can be operated for testing.
(1) In Manual control mode (MAN)
When the calibration valve is being controlled, <*> appears below the CH number on the upper right of
the screen. Pressing SHIFT 3 enables calibration valve control To disable it, press SHIFT 3 again.
Also, calibration valve control is disabled every time measurement is completed.
(2) In Remote control mode (REM)
When the calibration valve is being controlled, <*> appears below the CH number on the upper right of
the screen. For the use of the control I/O ports, see CHAPTER 12: INTERFACE.
It takes a maximum of 300 ms before valve operation occurs.
7.2.8 K(Ve) check (for functional specification J only)

K(Ve) check is to be performed using a dedicated Leak Master.
(1) In Manual control mode (MAN)
When the K(Ve) check is being conducted, <K> appears below the CH number on the upper right of the
screen. Press SHIFT 5 to enable K(Ve) check. Pressing SHIFT 5 again disables it.
(2) In Remote control mode (REM)
When the calibration valve is being controlled, <K> appears below the CH number on the upper right of
the screen. For the use of the control I/O ports, see CHAPTER 12: INTERFACE.
48 CHAPTER 7: MEASUREMENT (MEAS) MODE OPERATION
7.2.9 To start and stop leak test

Symbol Stage Name Remarks LED Setup screen
DL1 Delay Waits for sealing stabilization COEF. TIME
Fixed to 0.2 seconds; for
PCHK P check
functional specification A2 only CHG
EXT. TIME
(PCHG) Pre-charge Selected
(PEXH) Pre-exhaust Selected
CHG Charge CHG
Equalization Stage for functional
BAL1 Balance delay
specification A2. BAL
COEF. TIME
BAL2 Balance
DET Detection DET
BLW Air blow
(EXH) Exhaust Selected END EXT. TIME
END End COEF. TIME

Pressing START starts measurement, and pressing STOP stops it.
For the use of the control I/O ports, see CHAPTER 12: INTERFACE.
7.2.10 Charge hold

The Work and the Master are pressurized by pressing CHG HOLD. Pressing STOP stops
pressurization and exhausts any pressure inside the tester.
For the use of the control I/O ports, see CHAPTER 12: INTERFACE.
7.2.11 Test pressure confirmation

Pressing 1 and holding it for 3 seconds displays the test pressure of the current channel. The display will
be automatically cleared 30 seconds later, or can be cleared manually by pressing 0 or STOP.
7.2.12 Printout
In Manual control mode (MAN)
When printout is enabled, <P> appears below the CH number on the upper right of the screen. Pressing
PRINT outputs the measured data of each leak test via RS-232C. See Section 12.8: Printer Function.
CHAPTER 8: SET MODE OPERATIONS
8.1 Programming Overview
8.1.1 Data entry

The numeric value or data at the flashing cursor position can be changed using numeric keys.
Pressing SHIFT and 0 clears a numeric value to 0.
Pressing ENTER completes the setting for each item. The entered value is not stored until ENTER is
pressed.
8.1.2 Program limitation
1) Program limitation of leak rate limits and BAL2 and DET timers
When the leak rate limit is programmed in a volumetric flow rate unit, the programmable leak rate limit is
restricted due to its interrelationship with the BAL2 and DET timer settings. If you enter a leak rate limit
value above the programmable range for the current BAL2 and DET timer settings and press ENTER,
the maximum programmable leak rate limit will be automatically entered. If you enter a BAL2 or DET
timer value exceeding the programmable range for the current leak rate limits and press ENTER, the
minimum programmable timer value will be automatically entered.
2) Program limitation for K(Ve) value
When the leak rate limit is displayed in a volumetric flow rate unit, K(Ve) is restricted due to its
interrelationship with the BAL2 and DET timer settings. If you manually enter a K(Ve) value smaller
than the measurable value and press ENTER, the minimum measurable K(Ve) value will be
automatically entered. Also, K(Ve) is restricted due to its interrelationship with the leak limit.
3) Program limitation for large leak rate limits in the DET stage
If you enter a value smaller than Hi into HH, and press ENTER, a value 0.001 Pa larger than Hi will be
automatically set to HH. Also, if you enter a value larger than Lo into LL, and press ENTER, a value
0.001 Pa smaller than Lo will be automatically set to LL. These rules also apply to units other than Pa,
but when a unit other than Pa is used, it is not possible for it to be displayed on the screen even though it
has been selected.
8.1.3 Channel selection

The channel can be changed on the
SET, CALIB or GRAPH screens by Channels can be switched from #0-15
selecting the desired channel and using the numeric keys, the cursor
pressing ENTER. keys, and . Press PAGE
Pressing MEAS returns to the MEAS DOWN/UP to scroll up or down the
mode. pages.
8.1.4 Printout of settings

The settings of only one selected
channel or those of seven
consecutive channels, the numbers
of which comprise a numerical sequence starting from the number of the selected channel, can be output via
RS-232C by performing the following procedure:
(1) Select one of the items on the SET mode screen to go to the desired channel.
(2) Move the cursor from above CH to another item.
(3) Press PRINT twice to output the settings of one selected channel.
(4) Press PRINT SHIFT PRINT consecutively to output the settings of seven consecutive channels, the
numbers of which comprise a numerical sequence starting from the number of the selected channel (see
Section 12.8).
50 CHAPTER 8: SET MODE OPERATIONS
8.2 Description of SET Mode Screen

A) To enter the SET mode
y Turn on the power.
y Enter the password. See Section 6.2.
y Press SET to open the SET mode menu shown below.
B) Menu selection key sequences

y ↓ cursor key: Moves the cursor downward, or moves the cursor to the top if it is at the bottom of
the screen.
y ↑ cursor key: Moves the cursor bar upward, or moves the cursor to the bottom if it is at the top
of the screen.
y Page down key: Changes the screen in descending order from COEFFICIENT, to the TIME screen
to the COM.PORT SETTING screen in the SET mode menu.
NOTE: These keys do not bring up the COPY, INITIALIZE, or SYSTEM SETTING screens. To
enter these screens, use the cursor keys to maneuver, and press ENTER.
NOTE: The contents of INITIALIZE and SYSTEM SETTING cannot be changed.
y Page up key: Changes the screen in ascending order from the COM.PORT SETTING screen to
COEFFICIENT, then to the TIME screen in the SET mode menu.
NOTE: This key does not bring up the COPY, INITIALIZE, or SYSTEM SETTING screens.
y ENTER: Used to complete programming or selection.

y In the SET mode menu screen, you may enter any setting screen by entering the item number
(starting from the top item on the screen) of your desired selection, then press ENTER (the entry of
a numerical value is effective for the items between COEFFICIENT, the TIME screen and the
SWITCH TABLE # 2 screen).
y To clear the counter of the current channel, move the cursor to STATISTICS and press SHIFT 0.
NOTE: Pressing STOP and holding it for 1 second or longer in the SET mode returns to the MEAS
mode.
8.2.1 COEF., TIME (leak coefficient and time) screen
1) Q: Leak rate of Leak Master (for Leak Master model)

2) K(Ve): Equivalent internal volume
Enter an estimated equivalent internal volume before K(Ve) calibration. After K(Ve) calibration is
completed the true K(Ve) value will be stored automatically.
NOTE: There is a programming limitation. See Section 8.1.2.
3) DL1: CHG delay timer
A charge delay is required to allow the sealing to stabilize after clamping. Equalization valve, AV1
(normally open), is activated.
Minimum setting: 000.0 second
Recommended setting: 000.0–000.5 second Varies depending on the sealing condition.
4) CHG: CHG timer
The Work and the Master are pressurized to render a large leak judgment.
On a model equipped with a standard-range DPS, a reading exceeding ±300 Pa at this stage is judged
as No-Go.
Work-side large leak: + NG lamp lights up
Master-side large leak: - NG lamp lights up
Test pressure monitoring:
When the test pressure reading exceeds the upper limit (P.Hi) or falls below the lower limit (P.Lo), the
tester displays the Error #8, “Improper test pressure.”
When P.Hi/Lo is turned off (0), the test pressure is not monitored during this stage.
Recommended setting: Varies depending on the internal volume of the Work, the test pressure and
the Work deformation characteristics.
5) BAL1: Balance delay (Equalization) timer
Isolates the Work and the Master from the pressure source and terminates the supply of air to them.
Waits for a pressure change caused by valve operation.
Recommended setting: Varies depending on the internal volume of the Work, the test pressure and
the part deformation characteristics.
NOTE: The Balance delay stage is required to accurately measure the Mastering compensation value.
The minimum required time varies depending on the test conditions (Min: 0.5–2.0 s).
However if the internal volume of the Work is small, there are cases where the balance delay
stage is not necessary at all.
<For functional specification A2>
Isolates the Work and the Master from the pressure source. The Work and the Master are
pneumatically connected inside the Leak Tester for stabilization.
If the test pressure reading at the end of the BAL1 stage is lower than the set P.Lo, the tester aborts the
test immediately and displays the error message, “BAL TP decayed.”

Test pressure monitoring:
When P.Lo = 000.0 ⎝ Displays Error #17, “P.Lo (Hi) value is 0 (Zero).” at the end of the leak test.
When P.Hi/Lo = 0 (OFF) ⎝ Whether P.Hi/Lo is ON or OFF, the test pressure is constantly monitored
according to the value set to P.Lo.
6) BAL2: Balance timer
Isolates the Work from the Master for stabilization and detects medium leaks.
Used as an auto-zero delay before the DET stage.
Recommended setting: 001.0–003.0 second
NOTE: Do not set the timer too long. Excessively long timer settings cause sensor saturation.
7) DET: DET timer
Detects small leaks and displays the leak rate on the LCD preceded by an auto-zero. Drift
compensation is carried out while this feature is enabled.
Recommended setting: 001.0–010.0 second Varies depending on the test conditions.
8) BLW: Air blow timer
Opens the fill and exhaust valves to clean the pneumatic circuit in the Leak Tester.
Leak judgment takes place at the beginning of this stage and the judgment signal is transmitted through
the control I/O port.
DPS and air operated valve checks take place.
Recommended setting: 000.3 second minimum
High pressure (H15): 000.0 second (mandatory)
NOTE: After receiving a stop signal at any stage the tester aborts the test immediately and jumps to
the BLW stage.
9) END: End timer
Outputs data through the serial interface port (COM1).
The fill valve closes, while the exhaust valve remains open.
High pressure (H15): 000.3 second minimum
8.2.2 EXTENSION TIME screen
1) EXH: Exhaust timer

Pressure exhausts from the Work and the Master. This stage can be used for adjusting the timing from
the exhaust to unclamp (End signal output) stages.
Minimum timer setting: 000.0 second
Recommended setting: Varies depending on the test conditions.
2) MB1: BAL1 (Balance delay or Equalization) timer for Mastering
BAL1 stage for Mastering balance
NOTE: Equalization for functional specification A2.
3) MB2: BAL2 (Balance) timer for Mastering
BAL2 stage for Mastering.
4) PCHK: P check timer <For functional specification A2>
Performs a P sensor auto-zero while the Work and the Master are pressurized.
Checks the performance of the air operated valves, AV1, AV2 and AV3, and also checks whether the P
sensor offset is within the allowable range.
Timer setting: Fixed at 000.2 second.
5) PCHG: Pre-charge timer
Used for pressurizing the Work and the Master by Q-CHG (Quick charging). Set to 000.0 second
unless Q-CHG is used.
6) PEXH: Pre-exhaust timer
Exhausts a preliminarily charged pressure.
The purpose of this action is to remove the noise caused by Work deformation.
8.2.3 UNIT, LIMIT (unit and limit) screen
1) LEAK: Leak rate unit

Leak rate unit Leak rate unit
Code Code
(Differential pressure unit) (Flow rate unit)
"0" Pa “5” mL/s
"1" kPa “6” mL/min
"2" mmH2O “7” in3/min
"3" inH2O “8” in3/d
"4" mmHg “9” L/min
NOTE: Use a differential pressure unit for K(Ve) calibration.

2) P: Test pressure unit K(Ve): K(Ve) unit
Code Pressure unit Code Pressure unit Code K(Ve) unit
"0" kPa "5" mbar "0" mL
"1" MPa "6" mmHg "1" L
"2" PSI "7" cmHg "2" in3
"3" Kg/cm2 "8" inHg "3" ft3
"4" bar
3) BAL Hi: WORK-side leak rate limit for the BAL2 stage (for medium leak)
4) BAL Lo: Master-side leak rate limit for the BAL2 stage (for medium leak)
Two leak limit levels can be set for the DET stage. A relatively large leak limit is HH (LL for Master-side),
and a relatively small leak limit is Hi (Lo for the Master-side).
5) DET HH: Work-side large leak rate limit for the DET stage. This limit should be smaller than BAL Hi.
NOTE: If you enter a value for HH that is smaller than Hi and press ENTER, a value 0.001 Pa larger
than Hi will automatically be set to HH .
6) DET Hi: Work-side small leak rate limit for the DET stage
7) DET Lo: Master-side small leak rate limit for the DET stage
8) DET LL: Master-side large leak rate limit for the DET stage
NOTE: If you enter a value that is larger than Lo into LL and press ENTER, a value 0.001 Pa smaller
than Lo will automatically be set to LL.
9) P.Hi, P.Lo:
Upper limit (P.Hi) and a lower limit (P.Lo) for the test pressure. When the test pressure exceeds P.Hi at
the CHG and BAL1 stages, the test process immediately proceeds to the BLW stage, and Error #8,
“Improper Test Pressure” is output. When the test pressure falls below P.Lo, the test process proceeds
to the BLW stage immediately after the CHG stage, and the same error message appears..
NOTE: Be sure to program these limits because they are used as limits for large leak detection during
the BAL1 stage. When P.Lo is set to 000.000, even if the test pressure is 0, the tester does
not make a large leak judgment but displays Error #17, “P. Lo (Hi) value is 0 (Zero)” at the
end of a leak test.
10) P.Hi/P.Lo:
Turns ON/OFF the test pressure monitoring (0 = OFF, 1 = ON)
When it is OFF, test pressure cannot be checked in the CHG stage, and the large leak judgment function
does not work. It is recommended to keep it on.
8.2.4 COMPENSATION screen
NOTE: See CHAPTER 9: COMPENSATION for details.
8.2.5 P-TYPE, SEQ screen
1) PNEUMATIC CIRCUIT:
y Select: Test pressure selection
0: Apply test pressure from circuit A. 1: Unused
y Inlet A: test pressure polarity
0: Positive test pressure 1: Vacuum test pressure
y Q.CHG: Quick charge model use only
0: OFF 1: ON
2) E.PRESS: Sets the pressure to be applied to the electropneumatic regulator model.

y P.CHG: Preliminary charging setting
y CHG: Test pressure setting
NOTE: Some difference may arise between the set pressure and the actual pressure reading, caused
by an electrical error. In that case, reprogram the pressure by incorporating the difference
(i.e., by adding the difference to the originally set pressure value or subtracting the difference
from the originally set pressure value). Also the pressure can be adjusted in the MEAS mode
with the Master and Work-side stop valves closed. Press CHARGE HOLD, use and for
fine adjustment, or use 0-9 to adjust the sensor’s full scale values in increments of 10%, and
press ENTER to complete the setting.
P.CHG can be adjusted in the same way by pressing SHIFT and CHARGE HOLD first.
3) PRE.SEQ LOOP#: Number of iterations for pre-charge and pre-exhaust
Pre-charge iterates for the programmed number of iterations before the CHG stage.
Pre-charge and pre-exhaust (PEXH) are disabled by setting 0 or 1 to this item. Iteration is enabled by
setting 2 or a larger value to this item.
4) NR LOOP#: Number of iterations for the Noise Reduction (NR) mode
The NR mode is disabled by setting the number of iterations to 0 or 1. The NR mode is enabled by
setting the number of iterations to 2 or a larger value.
The DET stage iterates for the set number of iterations (to a maximum of 20 times).
Only first-phase leak test data is compensated for.
If the measurement value meets one of the following conditions:
Hi NG Limit < Measurement value < HH NG limit; or
Lo NG limit > Measurement value > LL NG limit
the leak test proceeds in the following sequence, and the judgment is made in the last DET stage.
Example of leak test sequence in NR mode (NR LOOP# = 7)

DL1 Delay Waits for sealing stabilization COEF. TIME
PCHK P check Fixed to 0.2 second
CHG
(PCHG) Pre-charge Selected EXT. TIME
(PEXH) Pre-exhaust Selected
CHG Charge CHG
Balance delay
BAL1
(Equalization *1) Normal Leak test process BAL
BAL2 Balance
DET (1) Detection (1) DET
DET (2) Detection (2) 2nd NR detection DET
COEF. TIME
DET (3) Detection (3) 3rd NR detection DET
DET (4) Detection (4) 4th NR detection DET
BLW Air blow
(EXH) Exhaust Selected END EXT. TIME
END End COEF. TIME
*1: For functional specification A2 only.
8.2.6 MASTERING (Mastering factors) screen
NOTE: See Section 9.3.3 for details.
8.2.7 STATISTICS (Statistical counter) screen
1) TOTAL: Counts the total # of tests performed.

2) GOOD: Counts the conforming Works.
3) Hi NG: Counts Work-side No-Go counter (including HH No-Go)
4) Lo NG: Counts Master-side No-Go counter (including LL No-Go)
NOTE: The maximum value of all the counters is 99999999.
Press SHIFT and 0 to reset. An arbitrary value can be entered to the counter using the
numeric keys.
5) HSI Scale: Full scale of an analog bar graph showing UP (HSI)
Full-scale value displayed in the DET stage. Set between 0 and 1000 Pa.
In the CHG and BAL stages, the DPS on the basic model has the HSI full scale fixed at 1000 Pa.
8.2.8 SWITCH TABLE #1 (Memory switch #1) screen
(Manufacturer setting)
1) DET JUDGE METHOD

Judgment method in DET stage
If a large leak is detected in the BAL1 or BAL2 stage, the tester proceeds to BLW and aborts the test.
0: End of DET stage Judgment is made at the end of the DET stage.
1: Instant Abortion Instantaneous judgment. Tester aborts test, and judgment is made when the
leak rate exceeds the leak rate limit.
NOTE: Select 0 when using a flow rate unit for the leak rate limit, and/or the NR feature is enabled.
2) CALIBRATION METHOD
Select the number of leak calibration phases.
0: 3 phases
1: 1 phase
3) P SENSOR AUTO ZERO
0: Inactive
1: Active
4) AIR VALVE CHECK
0: Inactive
1: Active
5) STOP SIG. CONTACT
Stop signal contact
0: Normally open (A contact)
1: Normally closed (B contact)
6) PILOT PRESS SWITCH
When the CHG stage ends, Error #15, “Air Valve Inactive. C5,” appears.
Pilot pressure check
0: Not monitored
1: Monitored
8.2.9 SWITCH TABLE #2 (Memory switch #2) screen
Manufacturer setting
1) STOP VALVE SWITCH

Checks whether the Work-side stop valve is open or closed:
This function is enabled when the optional specification of W is selected..
0: Not Monitored
1: Monitored
NOTE: When the stop valve option is selected, the value must be 1: Monitored. When it is not, it
must be 0: Not monitored.
2) EXHAUST INTERFERENCE Minimum timer settings when exhaust
Exhaust interference prevention interference is used:
See Section 3.9. y High pressure (H15)
Manufacturer setting: 0. BLW=0.0 s EXH=0.0 s END=0.3 s
0: Inactive (EXH = 0.3 s to extend alarm)
1: Active y Others
BLW=0.0 s EXH=0.0 s END=0.3 s
NOTE: The tester does not exhaust while a start
signal is present.
3) START COND. AFTER NG
Start conditions preceded by NG judgment
0: START SIG. only Does not require a STOP signal
1: STOP before START Requires a STOP signal
4) K(Ve) CHECK LIMIT
K check limit
Manufacturer setting: 1.
0: + - 5% 3: + - 20%
1: + - 10% 4: + - 25%
2: + - 15% 5: + - 30%
5) BLOW CHECK DPS LIMIT
An Error#15, “Air Valve Inactive. C4” occurs when the DPS output falls in one of the following
differential pressure ranges during the BLOW stage
Manufacturer setting: 3
Setting this to 0 turns off the Blow check.
0: OFF 3: + - 50Pa
1: + - 10Pa 4: + - 100Pa
2: + - 20Pa
8.2.10 COM. PORT SETTING (Serial communications port setting) screen

Manufacturer setting
1) COM. PORT SETTING
0: 9600 Baud D8 S1
1: 19200 Baud D8 S1
5: 9600 Baud D8 S1 C
6: 19200 Baud D8 S1 C
*C: CTS control available
2) COM. SET (FORMAT)
0: T format
1: ID format
2: I format
6: Printer format
NOTE: See Section 12.7 for details.
8.2.11 COPY SETTING (Channel copy) screen
Copies the contents of the source channel to the

destination channel.
1) Copy to a specified channel

Enter the desired source CH# to SOURCE.
Move the cursor to DESTINATION, enter the desired destination CH# and press ENTER and hold it for 3
seconds or longer to copy the contents from the source to the destination.
2) Copy to all channels at once
Enter 00 for both SOURCE and DESTINATION and press ENTER and hold it for 3 seconds or longer to
copy the contents of Channel 00 to all the other channels.
8.2.12 INITIALIZE (Initialization setting) screen

Manufacturer’s timer settings
Standard A2 specification
PCHK 0.2 0.2
CHG 10.0 10.0
BAL1 0.5 3.0
BAL2 5.0 2.0
DET 10.0 10.0
BLW 0.5 0.5
END 0.5 0.5
MB1 0.5 0.5
MB2 0.5 0.5
This is used to change all the settings to the manufacturer settings.

Yes: Move cursor to Yes and press ENTER and hold it for 3 seconds or longer to execute initialization.
NOTE: All the programmed settings will be cleared, and the timer settings will return to the manufacturer’s
settings as shown in the table above.
No: To cancel initialization, move the cursor to No and press ENTER and hold it until the screen returns to
SET MENU.
8.2.13 SYSTEM SETTING (System settings) screen

Example
1) LEAK CALIBRATOR:
0: Not equipped
1: Leak Master
2: Leak Master with Valve
3: Reserved
4: Reserved
5: Reserved
6: Reserved
7: Reserved
8: No selection (LC)
NOTE: Although the manufacturer’s setting is 1: Leak Master, if you wish to use volumetric-variable
Leak Calibrator 8, please contact a Cosmo representative.
CHAPTER 9: COMPENSATION
9.1 Compensation method and settings

Select a compensation method on the COMPENSATION screen in the SET mode.
Compensation method
Setup item Mastering and Mastering Auto-Drift Constant None
Auto-Drift only only
9.3, 9.4
Sections to see 9.8 9.7 9.8
9.5, 9.9
TYPE
2 1 0
Type of (MSTRG) (DRIFT) (OFF)
compensation
LOOP#
Number of 2–20 (5)* ------
iterations
D.COMP Automatically Automatically Automatically Manually

entered entered entered entered
Drift comp. value (M.COMP)
SAMPL#
01–20 (5)* 0 01–20 (5)* 0
Number of samples
Entered automatically after the Mastering process.
M.COMP (When the Mastering value is manually entered,
Mastering value that value is used as an initial compensation
value.)
Manually Ignores the
(50–80%)* of entered entered
C.LIMIT (50–80%)* of the
C.Hi the leak rate values
leak rate limit
Sampling limit -
range
C.Lo 000.000 000.000
M.Hi denotes Mastering data. Enter a value larger than the

Enter a value equal to compensation value.
M.LIMIT M.Hi
(120–150%)* of the value
Mastering captured from the first loop.
limit
M.Lo 000.000 000.000
Do not transmit.
Mastering signal Transmit
NOTE: Comp. value will be deleted
if signal is transmitted.
NOTE: Values in ( )* are recommended values for typical applications.

64 CHAPTER 9: COMPENSATION
9.2 Compensation Screen

The Compensation screen is displayed by the following key operation:
SET
Click to enter the SET mode
Click 3 times or press 4
ENTER
Clicking ENTER completes selection
0 - 9 Enter the desired number for compensation type.
ENTER
Clicking ENTER completes selection
Type of Compensation
0: OFF
No compensation
1: DRIFT
Auto-Drift compensation
2: MSTRG
Mastering compensation
9.3 Mastering Setup Operation
9.3.1 Mastering setup
1) Select 2, Mastering compensation, for TYPE.

2) LOOP#: Number of iterations (0–20)
0: Executes one Mastering process cycle and clears the
Mastering value to 0.0.
1: Executes one Mastering process cycle and takes in the
result as a Mastering value. Be sure to use a non-leaking
Work.
Typical setting: 05
3) SAMPL#: Number of samples for Auto-Drift compensation (0 to 20)
0: The drift compensation value is not updated.
1: Not applicable since compensation is performed using only the data from the previous leak test.
Typical setting: 05
4) D.COMP: Drift compensation value
A drift compensation value used for the next leak test cycle. Pressing SHIFT 0 clears it. This value is
automatically entered when using Mastering or Automatic compensation.
5) M.COMP: Mastering value
This value is automatically entered upon completion of the Mastering process, and displayed on the
MEAS screen.
Execute the Mastering process after any changes have been made to the number of iterations (LOOP#)
count or to the type. These values are not stored until after ENTER is pressed for each item.
6) C.LIMIT: Compensation limit (Sampling range)
C.Hi: Upper side Sampling range (Compensation upper limit is Mastering value + C.Hi).
C.Lo: Lower side sampling range (Compensation lower limit is Mastering value + C.Lo).
7) M.LIMIT: Mastering limits
Limits for Mastering compensation
M.Hi: Mastering upper limit
M.Lo: Mastering lower limit
Typically, a value 1.2 to 1.5 times the value from the first Mastering loop is entered for M.Hi, and 000.000
for M.Lo.
NOTE: Changes to the settings are not saved unless ENTER is pressed.
9.3.2 Starting Mastering process

The mastering process is started by entering an external start signal preceded by a Mastering signal. In the
Manual mode, press SHIFT, 6 and START to start the process.
Mastering sequence example (Mastering iterations: 3)

DL1 Delay Waits for sealing stabilization COEF.TIME
*1
PCHK P check Fixed to 0.2 seconds
CHG
PCHG Pre-charge Selected EXT.TIME
PEXH Pre-exhaust Selected
CHG Charge Loop #1 leak test CHG
BAL1 Balance delay (Equalization *1)
BAL COEF.TIME
BAL2 Balance
DET(1) Detection 1 DET
Balance delay for Mastering Loop #2 leak test
MB1(1)
(Equalization *1) 1 BAL EXT.TIME
MB2(1) Mastering Balance 1
DET(2) Detection 2 DET COEF.TIME
Balance delay for Mastering Loop #3 leak test
MB1(2)
(Equalization *1) (2) BAL EXT.TIME
MB2(2) Mastering Balance 2
DET(3) Detection 3 DET
COEF.TIME
BLW Air blow
EXH Exhaust Selected END EXT.TIME
END End COEF.TIME
*1: For functional specification A2 only.
MEAS screen during Mastering
MSTRG: Mastering compensation mode

LOOP#: Number of Mastering iterations
C.VAL: Current compensation value
M.CMP: Mastering value
a2: DPS raw output after auto-zero (uncompensated)
S#: Number of samples for compensation
9.3.3 Setting Mastering factors
1) Mastering request signal

While the Mastering process is executed by an external command, the tester may transmit Mastering
request signals to the external control.
The conditions under which the Mastering request signal is transmitted and the leak test measurement
conditions can be programmed on the Mastering factor screen.
Setting example
Setting description of the example

A mastering request signal is transmitted:
y On Monday, at the beginning of the first shift, every
5 minutes for 5 times. (Other days of the week, the
signal is transmitted once when the power is turned
on.)
y After a 10 minute waiting period.
y If measured leak rate exceeds the compensation
limit continuously for 5 times.
2) DAY: Days of the week.

Executes Mastering at the beginning of the first shift on the selected day of the week.
0: Sunday 1: Monday 2: Tuesday
3: Wednesday 4: Thursday 5: Friday
6: Saturday 7: Everyday 8: Off
INTERVAL: Mastering iteration interval
No. of M: Number of Mastering iterations
3) WAIT TIME: Timer for a break or waiting for Work.

After the set time limit is passed, a Mastering request signal is transmitted.
This function is disabled when the value set to this function is 000.
4) C.LIMIT OVER: Number of times the leak rate exceeds the sampling range
A mastering request signal is transmitted if the leak rate (measured raw data) continuously exceeds the
sampling range for the programmed number of times.
This function is disabled when the value set to this function is 0.
5) Current year, month, date, day of the week and time.
y Setting year, month and date (Leap year is predefined.)
Enter year (last two digits), month and date with the numeric keys and press ENTER.
In the case of the above example, enter 0 6 0 5 2 2 and press ENTER.
y Setting the day of the week (This is not synchronized with dates.)
Move the cursor to the day, use the cursor keys and to set the correct day and press ENTER.
y Setting the time (24-hour system)
Enter the time using the numeric keys and press ENTER.
In the case of the above example, enter 1 4 5 1 1 6 and press ENTER.
9.4 No-Leak Test Using Mastering

The purpose of a No-Leak test is to check for leakage from fixtures and/or tubing, stage timer, leak rate limit
and to prepare for K(Ve) calibration.
9.4.1 Preparation
1) Prepare a good non-leaking Work and a Master.

2) Apply a soapy solution to the fixtures, the tubing, the Work and the Master, and press CHARGE HOLD
to pressurize and thereby confirm leak integrity.
3) Make sure that the stop valves are open.
4) Program the stage timers and leak rate limits for the channel to be used on the COEF. TIME and UNIT
LIMIT screens in the SET mode.
NOTE: If K(Ve) is not entered, use the differential pressure unit (Pa) for the leak rate limit.
5) Set TYPE to Mastering (MSTRG) on the COMPENSATION screen in the SET mode.
6) MB1 and MB2 may be changed on the EXTENSION TIME screen in the SET mode if needed.
9.4.2 Operation
Manual mode Remote mode
MEAS
Enters the MEAS mode. MEAS
Enters the MEAS mode.
Switches to manual. Switches to remote.

REMOTE REMOTE
MANUAL MANUAL
C
SHIFT
then 6 Enables Mastering function.
START
Starts Mastering process. Transmitting CH, MASTERING and START signals to
the tester through control I/O port.
See Section 12.5.2.
Judgment LED turns on, and a judgment signal is transmitted.

Mastering data can be viewed in the Graph mode. Press GRAPH, and select MASTERING DATA.
Go judgment No-Go judgment
Completes the Mastering process. Eliminate the cause and execute

Mastering again.
9.5 Verifying Mastering Data

Data accumulated through the Mastering process can be viewed in the GRAPH mode.
NOTE: After GRAPH has been pressed, previous measurement data are not displayed on the MEAS
screen.
9.5.1 Operation
A) Press GRAPH to open the MASTERING DATA screen.

B) Move the cursor to Sample #, and use and to display each measured data in sequence.
C) Successful Mastering should result in an output graph in which the Mastering data transition
measured data gradually decreases and becomes constant in the
neighborhood of 0.0.
D) When data does not decrease, check the fixture sealing and the
Work for leakage, and modify the number of iterations (LOOP#) or
timer settings (CHG, BAL1).
E) The Y-axis range is determined by the M.COMP and C.Hi values
on the COMPENSATION screen, located in the SET mode. If the
graph range is too narrow, change the values of F.S.HI and/or
F.S.LO using the following keys:
y Press PAGE UP to reduce the full-scale value, and enlarge the graph.
y Press PAGE DOWN to increase the full-scale value, and scale down the graph.
Data stops decreasing and eventually becomes

constant.
Data continues to decline. Increase the number

of iterations.
Data is stable and constant.

CHG and BAL1 timers can be reduced.
Data is drastically changing.

Extend CHG and BAL2 timer settings.
Data does not decrease.

There may be leakage.
9.6 Verifying No-Leak Data

A) After Mastering, verify no-leak data by using several non-leaking Works. Do not use the Auto-Drift
compensation feature for this check.
SAMPL# (Number of samples): Set to 00.
B) If a result exceeds ±999 Pa, Error #9, “DPS output saturated” will be displayed on the LCD panel. In
this case the CHG timer setting may be too short. Extend this timer setting to make sure that detection
results settle within the tolerance.
C) If detection results remain unchanged after the CHG timer setting has been extended, leaks may be
present in the system. For functional specification A2, the BAL1 timer setting must also be extended.
9.7 Auto-Drift Compensation Feature

A) If only Auto-Drift compensation is used, select 1, DRIFT, for
TYPE, on the COMPENSATION screen.
If both Mastering and Auto-Drift compensation are combined,
select 2, MSTRG.
B) SAMPL#: Number of sampled data for compensation value

(C.VAL) calculation.
C) D.COMP: Mean value of COMP.DATA. This value is used as a

compensation value in the next cycle of leak testing (C.VAL on
the MEAS screen). Supply the initial compensation value by numeric key entry.
D) M.COMP:
When 1, DRIFT, is selected for TYPE, set M.COMP to “000.000.”
When 2, MSTRG, is selected for TYPE, a Mastering value is displayed.
E) C.LIMIT: Compensation limit (Sampling range)

Set a range for the data to be sampled for Auto-Drift compensation. The unit of the data is fixed to Pa.
A sampling range is defined as follows:
Compensation upper limit = Mastering value + Upper side sampling range, C.Hi
Compensation lower limit = Mastering value + Lower side sampling range, C.Lo
Example: If your Mastering value is 50 Pa and the upper and lower side sampling ranges are +25 Pa
and -25 Pa
Sampling upper limit = 50 + 25 = 75 Pa

Sampling lower limit = 50 - 25 = 25 Pa
The resulting sampling range is 25 Pa < Measured raw data < 75 Pa
Measured data
Sampling upper limit

C.Hi
Sampling range Mastering value (M.COMP)
C.Lo
Sampling lower limit
Auto-drift compensation MEAS screen
DRIFT: Auto-Drift compensation

C. VAL: Compensation value
a2: DPS raw output after auto-zero
S#: Number of samples for Auto-Drift compensation
Leak rate value: LEAK=a2-C.Val (Pa)
9.8 Constant Compensation

Compensates for the measured value using a constant value.
9.8.1 Operation
A) Select 1, DRIFT, for TYPE on the COMPENSATION screen.
B) Set 00 for S#, number of samples. Alternatively, C.Lo,
compensation lower limit and C.Hi, compensation upper limit,
may be set to 000.000.
C) Enter an arbitrary compensation value for D.COMP.
NOTE: To use a Constant compensation value for Mastering,
select 2, MSTRG, for TYPE and 00 for S# on the
COMPENSATION screen.
9.9 Example of Auto-Drift Compensation using Mastering value

The Mastering value obtained by the Mastering process is used as the initial compensation value for
Auto-drift compensation in a normal leak test. The compensation value for the second test is the mean
value of the Mastering value and the raw data of the first test. If the number of the samples is set to 3, the
running average of the latest 3 measured raw data is taken as a compensation value for the fourth test, so
that the system learns to update the compensation value continuously.
1st test Displayed value = 1st raw data – {Mastering value}

2nd test Displayed value = 2nd raw data – {(1st raw data + Mastering value) / 2}
3rd test Displayed value = 3rd raw data – {(2nd + 1st raw data + Mastering value) / 3}
This section provides an actual example of the Auto-Drift compensation under the following conditions:
Mastering value (M.COMP): 100 Pa
Compensation limits (C.Hi/C.Lo): ±20 Pa
Number of samples for Auto-Drift compensation (SAMPLE#): 3
Leak rate limits (DET Hi/DET Lo): ±15 Pa
Graph 1: Raw data and D. Comp value

160
140
C.Hi 120 Graph 2: Display after compensation

+20 Pa
100
Differential Pressure (Pa)
Hi.NG
C.Lo 80 15
-20 Pa
60
Pressure (Pa)
0
Differential
40
Lo.NG
20 -15
0
1st 2nd 3rd 4th 5th 6th 7th 8th
-30
Measured raw data 110 114 103 116 86 123 138 119 1st 2nd 3rd 4t 5th 6th 7t 8th
D. Comp value 100 105 108 109 111 111 114 114 Display 10 9 -5 7 -25 12 24 5
The displayed values with Auto-Drift compensation will be as follows:

The unit of the values is Pa.
{} = compensation value.
1st test: 10 = 110 – {100}

2nd test: 9 = 114 – {(110 + 100) / 2}
3rd test: -5 = 103 – {(114 + 110 + 100) / 3}
4th test: 7 = 116 – {(103 + 114 + 110) / 3}
5th test: -25 = 86 – {(116 + 103 + 114) / 3}
The measured raw data of this test is not taken as a sample because the displayed value, -25 Pa, is
Lo-No Go.
6th test: 12 = 123 – {(116 + 103 + 114) / 3}
The compensation value for this test is the same as that of the 5th test because the raw data of the
5th test is discarded.
7th test: 24 = 138 – {(123 + 116 + 103) / 3}
The measured raw data of this test is not taken as a sample because the displayed value, 24 Pa, is
Hi-No Go.
8th test: 5 = 119 – {(123 + 116 + 103) / 3}
The compensation value for this test is the same as that of the 7th test because the raw data of the
7th test is discarded.
The Mastering value is also used to set the compensation limit. The system is controlled to conduct proper
compensation by preventing overcompensation by means of setting up both the upper and the lower limits
based on the Mastering value.
CHAPTER 10: K(Ve) CALIBRATION
10.1 K(Ve) Calibration using a Leak Master

NOTE: A Leak Master is not included with the LS-1822A. Select the most appropriate Leak Master for
your test specifications (namely, Work volume and test pressure) referring to the selection graph,
and purchase it separately. See Section 3.1.1.
A) 3-phase method (Manufacturer setting)
Normally, Leak Masters are set for three-cycle leak testing, but single-cycle leak testing can be selected
by changing the memory switch setting. The calibration process consists of 3 cycles of leak testing. In
each cycle, the calibration is started by pressing START or transmitting a START signal through a control
I/O port.
Phase 1 is a break-in, and “Warm-up run” is displayed on the LCD panel. During phase 2, the drift
(compensation) value is sampled under non-leaking conditions, and “Comp. data sampling” is displayed.
Connect a Leak Master to the CAL. Port on the front panel before starting phase 3. The equivalent
internal volume, K(Ve) is calculated by subtracting the measured value at phase 3 from the measured
value at phase 2.
K(Ve) calibration stages (Example: Three phases)
Phase1 DL1 Delay Waits for sealing stabilization COEF.TIME
Fixed at 0.2 s for functional
PCHK P check
specification A2 CHG
EXT.TIME
(PCHG) Preliminary charge Selected
(PEXH) Preliminary exhaust Selected
CHG Charge CHG
Equalization for functional
BAL1 Balance delay
specification A2 BAL
COEF.TIME
BAL2 Balance
DET Detection DET
BLW Air blow
(EXH) Exhaust Selected END EXT.TIME
END End COEF.TIME
PC HK P check
EXT.TIME
CHG Charge CHG
BAL1 Balance delay
COEF.TIME
BAL2 Balance
DET Detection DET
BLW Air blow
(EXH) Exhaust (selected) Selected END EXT.TIME
END End COEF.TIME
PC HK P check
EXT.TIME
CHG Charge CHG
BAL1 Balance delay
COEF.TIME
BAL2 Balance
DET Detection DET
BLW Air blow
(EXH) Exhaust Selected END EXT.TIME
END End COEF.TIME
74 CHAPTER 10: K(Ve) CALIBRATION
Selectable stages: The following stages can be skipped by setting the timers to 0.0:
DL1, PCHG, PEXH, MB1, MB2, EXH, and BLW.
B) 1-phase method: Change the memory switch setting to 1 (no compensation value measurement)
Connect a Leak Master and press START. The stage sequence is the same as in phase 3 of the
three-phase measurement method.
For this measurement, a previously sampled or programmed compensation value (D.COMP) is used.
NOTE: In cases where no compensation value has been programmed, the measured K(Ve) contains a
portion of drift error. See Fig. 6 in Section 3.3.1.
10.1.1 Preparation
1) Set LEAK UNIT to the differential pressure unit, Pa, on the UNIT and LIMIT screens in the SET mode.
2) Connect a Work to the Leak Tester.
3) Execute a Charge Hold to check the test pressure.
4) Execute Mastering to measure a Mastering value and check the leak integrity.
Rotameter
NOTE: To verify the flow rate of the Leak Master, use
Cosmo’s Leak Master Checker (LMC series) or Leak Master
a flowmeter (e.g., rotameter) to measure the Work-side Open to the
leak rate. Leak CAL port atmosphere
NOTE: The size for CAL port connection is M10 x 1.5.

Conversion joints M10 x 1.5 (male) - Rc (PT1/8) and M10 x 1.5 (male)-Rc (PT)1/4 are available
upon request.
10.1.2 Key Operation (Three-phase method)

Switches to manual in the MEAS mode.
REMOTE
MANUAL
CALIB.
Enters the Calibration (CALIB.) mode.
ENTER
Selects COEF K(Ve).
0 - 9
Enter a desired channel number (0–15).
ENTER
Complete programming.
0 - 9 Enter the leak rate, Q, of the Leak Master.
ENTER
Complete programming.
START
Phase 1 starts.
“Warm-up run” is displayed during measurement.
START
Phase 2 starts.
“Comp. data sampling” is displayed during measurement.
Connect a Leak Master to the Work-side CAL. port

on the front panel.
START
Phase 3 starts.
Measured equivalent internal volume, K(Ve), will be displayed.
MEAS
Return to the MEAS mode screen after calibration is completed.
10.2 Automatic K(Ve) Calibration <functional specification J>

a) 3-phase method:
Normally, the Leak Tester is set for three-cycle leak testing, but single-cycle leak testing can be selected
by changing the memory switch setting. Three cycles of leak testing are in each measurement
operation. Each of the three cycles is launched by pressing START. The first cycle is dedicated to
running, the second to drift (compensation value) measurement, and the third to operation of the Leak
Master mounted on the CAL port on the front panel. The value of K(Ve) can be calculated by
subtracting the second differential pressure value from the third differential pressure value.
b) 1-phase method (compensation value measurement stage not included):
Connect a Leak Master and press START. The stage sequence is the same as in phase 3 of the
three-phase method measurement. For this measurement, a previously sampled or programmed
compensation value (D.COMP) is used.
10.2.1 Preparation
1) Set LEAK UNIT to the differential pressure unit of Pa on the UNIT and LIMIT screens in the SET mode.
2) Connect a Work to the Leak Tester.
3) Perform a Charge Hold and check the test pressure.
4) Execute Mastering to measure a Mastering value and check for freedom from leakage.
5) Connect the Leak Master to the front-panel CAL. Work port.
10.2.2 Operating procedure (3-phase method)

REMOTE
MANUAL Set the mode to Manual <MAN> on the MEAS screen.
CALIB. Open the calibration (CALIB.) mode.
ENTER Select COEF K(Ve) .
Enter the desired channel number (0–15).

F
0 - 9
ENTER Complete programming.
0 - 9 Enter a Leak Master leak rate (Q).
ENTER Complete programming.
START Phase 1 starts.
“Warm-up run” is displayed during measurement.
“Comp. data sampling” is displayed during measurement.
Measured equivalent internal volume K(Ve)

is displayed.
MEAS Returns to the MEAS mode screen after calibration is completed.

10.3 Manual K(Ve) Calibration Operation Using Leak Calibrator

K(Ve) can be calculated using a leak calibrator (LC series), by which the volume can be changed manually.
To do this, however, the system setting needs to be changed. Users who wish to use a leak calibrator are
recommended to contact the manufacturer.
The 3-phase method is normally used.
10.3.1 Operating procedure
1) Connect a leak calibrator (LC) to the calibration port (CAL Work) on the front panel.
2) In the calibration (CALIB.) mode, select COEF K(Ve) and enter volume change ΔV (mL).
3) In the DET stage of the three-phase process, turn the LC dial to enter the same volume change ΔV as
the input value. When the measurement ends, the value of K(Ve) is displayed and stored in memory.
10.4 Causes of an Error or Inappropriate Measurement in K(Ve) Calibration

Error
Probable Cause Countermeasure
Display
A The pneumatic circuit is leaking. Stop the leak and check by Mastering. * *
Repeatability is not established because of Reprogram the stage timers and verify them by
B insufficient CHG and BAL1 timer durations for executing a Mastering process. * *
stabilization.
The differential pressure exceeds the measurable Shorten the DET and/or BAL2 timer(s).
C range because the DET or BAL2 timer(s) are set *
too long.
The fixture is so unstable that data lacks Adjust the fixture and verify it by executing a
D * *
repeatability. Mastering process.
The programmed Leak Master range, Q, is too Program a calibrator range suitable for the test
E wide. conditions, referring to the Leak Master *
selection graphs. See Section 3.1.1.
The programmed Leak Master range, Q, is too Program a calibrator range suitable for the test
F narrow. conditions, referring to the Leak Master *
selection graphs. See Section 3.1.1.
The test pressure differs from the tester’s Adjust the test pressure and verify it by
G * *
specifications. checking PRESS on the LCD panel.
Insufficient pilot pressure Set the pilot pressure in the specified pressure
H *
range.
The value of measured K(Ve) is improper. Extend the END timer setting.
(The exhaust timer is too short when the Work has Ve is large if the stabilization timer is short. A
I
a large internal volume and a sufficient leak test sufficient exhaust between phases takes the
time is not available.) place of long stabilization.
J The stop valve(s) is closed. Open the stop valve(s). *
The internal volume has changed in the DET timer. Design the fixture structure to minimize
K * *
(The value of K(Ve) increases.) deformation.
Drastic changes have occurred in the DPS offset See Section 13.5 and/or 13.6 for the
L * *
or span. adjustment procedure.
M The DET timer is shorter than 0.6 second. Set the DET timer to 1 second or longer. *
Leak rate limits exceed the allowable range by Perform K(Ve) calibration in a differential
calculation after K(Ve) is measured pressure unit (Pa) instead of in a flow rate unit
N *
(program limitation). (mL/min.), or program smaller leak limits than
the current ones (See Section 8.1.2.).
A large flow rate resistance exists between the Minimize the flow rate resistance.
tester and the Work. (If the flow rate resistance exists in the tested
O *
(i.e., the inner diameter of the tubing is so small part, relocate the Leak Master.)
that the flow rate is limited.)
P The leak rate of the Leak Master has changed. Replace the Leak Master. * *
Error messages that may be displayed during K(Ve) calibration Probable cause
During K(Ve) calibration, no judgment DPS output saturated A, B, C, D, E, G,
signals or error signals are transmitted J, K, L, O, P
through the control I/O port.
K(Ve) out of range A, B, D, F, G, H,
K, L, M, P, P
Leak Limit out of range N

* Probable cause associated with the error message.
CHAPTER 11: GRAPH MODE AND HELP MODE
11.1 Selecting a Graph and Deleting Data

y Selecting graph screens
Press GRAPH to enter the Graph mode for graph selection.
y Deleting all data
Move the cursor to X CONTROL CHART and press SHIFT 0 to
delete all data.
y SAMPLES or MASTERING data
Move the cursor to the graph you wish to delete. Pressing SHIFT 0
deletes the data in the current channel.
y DP CURVE GRAPH
Not available.
NOTE: K(t) DATA is not used for this model, and skipped when you move the cursor on the Graph menu
screen.
11.2 Control Chart (Quality Control Screen)
11.2.1 Bar graph

The 1000 most recent data of all the channels are stored, and they are
displayed separately for each channel. Data in the rightmost position are
the most recent in the bar graph. Up to 72 records can be displayed in a
single image of the bar graph.
11.2.2 Screen description
1) Use , , and to move the cursor.

2) CH: Use the numeric keys or and to change the channel.
3) #0000: Data# of the blinking bar. The blinking bar shifts using and .
The data in the farthest left position can be manually set by entering a 4-digit number
following #.
4) Time indication: Measured time of the current blinking bar data. Month/date/hour/minute/second
5) LEAK: Test result of the blinking bar data.
6) F.S.: Full-scale value of the Y-axis. The full-scale value can be incremented or
decremented with the DOWN PAGE UP.
NOTE: The displayed leak unit is the one currently selected. Although the display unit can be changed,
values measured before the alteration does not reflect that change.
82 CHAPTER 11: GRAPH MODE AND HELP MODE
11.3 Mastering Data Screen
11.3.1 Mastering graphs

The X-axis represents the number of the detection, and the Y-axis
represents the measured differential pressure. The differential pressure
detected in the last DET stage of the Mastering process is at the rightmost
end.
11.3.2 Screen description
1) Sample#: Blinking bar number / Programmed number of iterations.

The blinking bar can be changed using numeric keys or and .
2) Data: The numeric value of the blinking bar. The value can be changed using numeric keys.
3) M.COMP: Mastering value
4) D.COMP: Drift compensation value
5) F.S. HI: Y axis positive side full scale
6) F.S. LO: Y axis negative side full scale
11.4 HELP Mode Operation

Pressing INDEX HELP enters the HELP INDEX mode.
This mode is for verification of control I/O, serial communication and
system information.
11.4.1 I/O MONITOR

This mode is for verification of the input/output of the external signals.
CAUTION: Set the external PLC to Program mode before entering
this mode to avoid possible risk of damaging the machine.
Go to the Manual <MAN> mode before performing the following:
y An external signal will be transmitted when the keyboard is unlocked
using the password, 1, 3, 5, 7.
y An external signal won’t be transmitted when the keyboard is unlocked using the password, 2, 4, 6, 8.
1) [ INPUT ]
KEY [ ] H00000000, L00000000: The bit corresponds to the pressed key and its symbol
INT: The bit of the input signal to the internal terminal block and its symbol
EXT: The bit of the signal received through the control I/O port and its symbol
The two digits on the right side represent the received channel number.
ADC1: Differential pressure sensor voltage value
ADC2: Pressure sensor voltage value
2) [OUT PUT]
EXT: The bit of the signal transmitted through control I/O port and its symbol
LED: The LED that is lit on the front panel (except CPU RUN and KEY UNLOCK)
SV: Actuated solenoid valve number
AO1: Differential pressure sensor analog output to internal terminal (output voltage reading: ±2.5 V
DC)
AO2: Pressure sensor analog output to internal terminal (output voltage reading: ±2.5 V DC)
AO3: Reserved
AO4: Electropneumatic regulator control voltage (output voltage reading: ±0.5 V DC)
3) Verifying EXT, LED and SV output
y Press STOP on the I/O MONITOR screen.
y Press STOP again if [OUTPUT] EXT is not 0000.
y A signal corresponding to each bit is transmitted and displayed. Press to shift to the left 1 bit at
a time, or to shift to the right.
y By pressing START, output signals are automatically transmitted and displayed one by one every
0.5 seconds.
4) Verifying analog output AO 1, 2 and AO 3, 4
y Press STOP on the I/O MONITOR screen.
y Press STOP again if [OUTPUT] EXT is not 0000.
y Entering the numeric key in the table below transmits the corresponding signal.
On the electropneumatic regulator model, the pressure reading will be changed every time a signal
is transmitted.
Numeric key Reading of AO1 and 2 Reading of AO3 and 4

1 -2.50 V +0.50 V
2 -1.87 V +1.00 V
3 -1.25 V +1.50 V
4 -0.624 V +2.00 V
5 0.000 V +2.50 V
6 +0.624 V +3.00 V
7 +1.25 V +3.50 V
8 +1.87 V +4.50 V
9 +2.50 V +4.50 V
0 +0.00 V +5.00 V
84 CHAPTER 11: GRAPH MODE AND HELP MODE
11.4.2 COM. PORT MONITOR (Communications port monitor screen)
11.4.3 SYSTEM VERSION
y BATTERY: Voltage of the supplied battery

NOTE: The symbols on the right side of the voltage value mean the following:
{: 2.9 V or higher
C: 2.6 V or higher
×: less than 2.6 V
y P. ON: Number of times power has been turned on
y HR. METER: Length of time power has been turned on
y START CNT: Number of times test has been started
y [F. W VERSION#]: Firmware version number
CHAPTER 12: INTERFACE
12.1 Control I/O Port

The control I/O port interfaces the tester to an external device such as a PLC with the capabilities to control
and receive the test results remotely. This port allows the tester to be integrated into a fully automated line.
12.2 Specifications
The control I/O port allows all the functions of the LS-1822A to be controlled by an external device.
Connector type:
Leak tester side: DB-37P (XM2C-3712-112 OMRON or equivalent)
Cable side: DB-37S (XM2D-3701 OMRON or equivalent)
12.2.1 Connector pin assignment

(NO: Normally open NC: Normally closed)
PIN # FUNCTION TYPE PIN # FUNCTION TYPE
1 Reserved 20 Reserved
2 START NO, INPUT 21 CH #3 *3 NO, INPUT
3 STOP NO/NC, INPUT 22 CH #2 *3 NO, INPUT
4 CHARGE HOLD NO, INPUT 23 CH #1 *3 NO, INPUT
MASTERING/
5 NO, INPUT 24 CH #0 *3 NO, INPUT
DRIFT CLEAR *1
6 K(Ve) CHECK NO, INPUT 25 Reserved
Calibration valve
7 NO, INPUT 26 Reserved
operation (CAL. VALVE)
10 DC Power input +DC IN 29 Reserved
12 MASTERING REQ. NO, OUTPUT 31 HH-NG NO, OUTPUT
13 Hi-NG NO, OUTPUT 32 Lo-NG NO, OUTPUT
14 GO NO, OUTPUT 33 LL-NG NO, OUTPUT
15 Reserved 34 TIME EXTENSION *2 NO, OUTPUT
16 ERROR NO, OUTPUT 35 END(a) NO, OUTPUT
17 STAGE PORT#1 NO, OUTPUT 36 BUSY NO, OUTPUT
18 STAGE PORT#0 NO, OUTPUT 37 Reserved
19 COM for all outputs
*1 In case 1, DRIFT, is selected for compensation; receiving this signal clears the drift compensation value.
In case 2, MSTRG, is selected for compensation; Mastering becomes effective when this signal is
received, and the previous Mastering value is cleared by the next START.
*2 A TIME EXTENSION signal is transmitted when the test time is extended due to retesting in the NR
mode or when Mastering is performed.
If a CYCLE TIME OVER alert is programmed for an external device, use this signal to disable it.
*3 Enter a binary code. See Section 12.4.
CAUTION: Never short the pins marked “Reserved.” Doing so may cause damage to the tester.
86 CHAPTER 12: INTERFACE
12.2.2 Power supply

An operational power supply is required to activate the control I/O port.
Rated input voltage: 12 to 24 V DC ±10%, 0.2 A max. (external power supplied by the SELV circuit)
12.2.3 Input circuit

y Photocoupler diode input
y Input impedance 3 KΩ
y Input current 10 mA TYP. (24 V DC)
y Connection method
LS-1822A Input Circuit

Typical terminal connections
2 Typical switch
connection
3
8
External power
9 +12 - 24 V
10
+DC IN
20
Typical transistor
21 connection
(Open collector)
22
23
24
25
26
27
12.2.4 Output
y NPN open collector output
y Maximum switching capacity: 100 mA 24 V DC; the total current from Pin #12 to Pin #18 should be 200
mA or less, and that from Pin #31 to Pin #36 should also be 200 mA or
less.
y Residual voltage: 2 V max.
y Connection method
LS-1822A Output Circuit

+DC IN Typical terminal connections
10
11
12 L Typical load
connection
13 External power
+12 - 24 V
14
15
16
17
18 L
19
COM
28
29
30 Typical photocoupler
connection
31
32
33
34
35
36
12.2.5 Typical PLC connection
LS-1822A Input/Output Circuit Typical connections

PC output card
Input group
10
28
External power PC input card
+24 V
19
31
Output group
36
0.2A MAX
12.3 PNP Specifications of the Control I/O Port (available as an option)

Users of the LS-1822A are given the option of selecting an I/O control port for a PNP-type current control unit
(source current control).
Connector type:
Leak Tester side: DB-37P (XM2C-3712-112 OMRON or equivalent)
Cable side: DB-37S (XM2D-3701 OMRON or equivalent)
12.3.1 Connector pin assignment
(NO: Normally open NC: Normally closed)

PIN # FUNCTION TYPE PIN # FUNCTION TYPE
2 START NO, INPUT 21 CH #3 *3 NO, INPUT
3 STOP NO/NC, INPUT 22 CH #2 *3 NO, INPUT
4 CHARGE HOLD NO, INPUT 23 CH #1 *3 NO, INPUT
MASTERING/
5 NO, INPUT 24 CH #0 *3 NO, INPUT
DRIFT CLEAR *1
6 K(Ve) CHECK NO, INPUT 25 Reserved
Calibration valve
7 NO, INPUT 26 Reserved
operation (CAL. VALVE)
10 DC Power input *4 +DC IN 29 Reserved
12 MASTERING REQ. NO, OUTPUT 31 HH-NG NO, OUTPUT
13 Hi-NG NO, OUTPUT 32 Lo-NG NO, OUTPUT
14 GO NO, OUTPUT 33 LL-NG NO, OUTPUT
15 Reserved 34 TIME EXTENSION *2 NO, OUTPUT
16 ERROR NO, OUTPUT 35 END(a) NO, OUTPUT
17 STAGE PORT#1 NO, OUTPUT 36 BUSY NO, OUTPUT
18 STAGE PORT#0 NO, OUTPUT 37 DC Power output *5
*1 In case 1, DRIFT, is selected for compensation; the drift compensation value is cleared. In case 2,
MSTRG, is selected for compensation; the previous Mastering value is cleared by the next START
(Mastering is launched again).
*2 A TIME EXTENSION signal is transmitted when the test time is extended due to retesting in the NR
mode or when Mastering is performed.
If a CYCLE TIME OVER alert is programmed for an external device, use this signal to disable it.
*3 Enter a binary code.
*4 Since this is a power supply input for an input circuit, it is not connected to an output circuit.
*5 This is a power supply input for a protection output circuit. The polarity of the power source connected
is the opposite of Pin #19. To use a protection circuit, connect it to Pin #10 and Pin #37.
CAUTION : Do not connect anything to the pins marked “Reserved.” Doing so may cause
damage to the tester.
12.3.2 Power supply

An operational power supply is required to activate the optional PNP I/O port:
Rated input voltage: 12 - 24 V DC ±10%, 0.2 A MAX
12.3.3 Input circuit

• Photocoupler diode input: 16 circuits
• Input impedance: 3 kΩ
• Input current: 8 mA TYP. (24 V DC)
• Typical connection
PNP-type input circuit configuration of LS-1822A Typical terminal connection

1
5 Typical switch
connection
6
9 External power
+
10
20
21
22
23
Typical transistor
24 connection
25
26
27
28
19
37
12.3.4 Output circuit

• Photo-MOS relay: 16 circuits
• Load voltage: 5–24 V DC
• Reverse voltage: 5–24 V DC
• Load current: 60 mA MAX
• ON resistance: 40 Ω MAX
• Example connection
PNP-type ititonfiguration of LS-1822A Typical terminal connection

10
Po MOS relay
11 L
IC
12
13
14
Typical load
15
connection
16
OPTION
17
18 External power L
IC
COM 19
+
28
IC
29
30
31
32
Typical
33
photocoupler
34 connection
35
36
IC
37
12.3.5 Typical connection with PLC
PNP-type input circuit configuration of LS-1822A Typical connection

PC output card
1
2
3
4
5
6
7
8
9
10
External power input 28 External power
Photo MOS relay +24V
COM PC input card
19
31
IC
36
IC
37
12.4 Channel Selection

Channel changes are effected by entering a binary code to pins from #21 to #24 with Pin #21 (CH #3) being
the most significant bit (MSB) and Pin #24 being the least significant bit (LSB).
CH CH #3 CH #2 CH #1 CH #0
0 OFF OFF OFF OFF
1 OFF OFF OFF ON
2 OFF OFF ON OFF
-
9 ON OFF OFF ON
10 ON OFF ON OFF
11 ON OFF ON ON
-
14 ON ON ON OFF
15 ON ON ON ON
8 4 2 1 Weight of each bit
Example:
CH #0 ON
CH #1 OFF
CH #2 OFF Æ Channel number = 9
CH #3 ON
NOTE: CH #0 is selected when all channels from CH #3 to CH #0 are either not selected or are turned off.
NOTE: Channel switching takes effect on START or CHARGE HOLD input. See the timing charts in
Section 12.6.
12.5 Stage Number Output

Leak test stages can be identified from combinations of Stage # 0 and Stage #1.
Stage Stage #1 Stage #0 Stage #

WAIT, DL1 OFF OFF “0”
PCHK – CHG OFF ON “1”
BAL1, BAL2 ON OFF “2”
DET ON ON “3”
BLW – END hold hold See NOTE
NOTE: The stage # in which a No-Go judgment is made, or a STOP signal is entered, is held through the
BLW to END stages (no output is generated for a Go judgment). For instance, if a No-Go
judgment is made during BAL2, the stage # in END stage is “2.” This feature makes sorting
defected parts easier.
12.6 Signal Timing Charts
12.6.1 Leak test timing chart
WAIT DL1 PCHK CHG BAL1 BAL2 DET BLW EXH END WAIT
100 ms (MIN.) 300 ms (MIN.)
CH#(*1)
400 ms (MIN.)
START
300 ms (MAX.)
BUSY
"1," "2," or "3" for NG

STAGE# "0" "1" "2" "3" only "0"
END
JUDGE(*2)
ERROR
NOTE: CH # denotes the CH #, K(Ve) CHECK, MASTERING/D. CLR, and CAL. VALVE signals.
NOTE: JUDGE denotes the GO, Hi-NG, Lo-NG, HH-NG, and LL-NG signals.
12.6.2 Mastering timing chart
CH#
300 ms (MIN.)
300 ms (MAX.)
MASTERING
REQUEST
MASTERING
COMMAND
100 ms (MIN.)
START 400 ms (MIN.)
300 ms (MAX.)
BUSY
NOTE: MASTERING REQUEST refers to Pin #12 of the control I/O connector, which transmits
MASTERING REQUEST signal, which is transmitted from the LS-1822A.
NOTE: MASTERING COMMAND refers to Pin #5 of the control I/O connector, which transmits
MASTERING/DRIFT CLEAR signal, which the LS-1822A receives from an external device.
12.6.3 Charge hold timing chart

W AIT/DL1/CHG/BAL1/BAL2/DET CHG BLW EXH END W AIT
100 ms (MIN.) 300 ms (MIN.)
CH#(*3)
(REMOTE)
CHARGE HOLD
(REMOTE)
300 ms (MAX.) 300 ms (MAX.)
STAGE# "0," "1," "2," or "3" "1" "0"
BUSY
END
CHARGE HOLD
(MANUAL)
STOP
(MANUAL)
NOTE: CH # is acceptable in the WAIT stage, but not in any other stage.
12.7 Serial Communication Interface (COM1)

This interface port is an asynchronous half duplex serial interface based on EIA-232. This interface
provides communication with external devices such as computers (NULL-MODEM mode direct connections).
Through this port, the LS-1822A transmits leak test data after every test execution. The Leak Tester does
not accept any commands from the host; it only transmits leak test data.
Test parameters are programmed in the SET mode.
12.7.1 Interface specifications

y Data transmission Half duplex
y Baud rate 9600 or 19200 bps Max (selectable)
y Start bit 1 bit
y Data length 8 bits
y Parity Non-parity
y Stop bit 1 bit
Connector pin assignments (DB-25P)
Pin # Name Function

1 FG Frame ground
2 TxD Transmitted data
3 RxD Receive data
4 RTS Request to send
5 CTS Clear to send
7 GND Signal ground
8 DCD Data carrier detect
20 DTR Data terminal ready
12.7.2 Interface cable wiring example
Interface cable wiring diagram (COM1)
LS-1822A External Device

25 pin 25 pin 9 pin
FG 1 1
SD (TxD) 2 2 3
RD (RxD) 3 3 2
RS (RTS) 4 4 7
CS (CTS) 5 5 8
SG 7 7 5
In case RS (RTS) and CS (CTS) are not used
LS-1822A External Device

25 pin External Device
25 pin 25 pin 9 pin
FG 1 1
SD 2 2 3
(TxD)
RD (RxD) 3 3 2
RS (RTS) 4 4 7
CS (CTS) 5 5 8
SG 7 7 5
12.7.3 Output formats

The LS-1822A supports the four following output formats:
1) T format: Fixed-length output of leak data only
2) ID format: Fixed-length output of leak rate limits, as well as leak data (Manufacturer setting)
3) I format: Fixed-length output of leak rate limits, as well as leak data
4) Printer format: Fixed-length output of the details of judgments, as well as leak data
Memory switch setting

0 T format
1 ID format (CH # is a 2-digit integer)
COM. PORT (FORMAT) 2 I format (CH # is a 1-digit integer)
compatible with LS-1841N
6 Printer format
NOTE: An RS-232C printer can be used.
12.7.4 Data representation

y All output field is coded in ASCII characters.
y A block of output fields begins with the ASCII code “#” (23H) and ends with a carriage return (0DH).
All output fields are separated by spaces (20H).
y A significant figure for the leak rate and test pressure is three digits, and three zeroes fill blanks.
y A significant figure for DET Hi, DET Lo, P.Hi and P.Lo is six digits.
y Overflow data defaults to ±999.999
y The checksum field is in hexadecimal notation and proceeded by the ASCII code “:” (3AH).
y A field with 3-digit integer data is preceded by two zeroes, and does not include a decimal point.
y ΔP and leak rate value may not match due to compensation.
NOTE: Differential pressure reading when an error occurs is ±999.999.
1) T format
# 00_00_J_±LLL.L: GG <CR>
Data field Data type Unit Min. Max. Note

1: Lo NO-GO
2: GO
ASCII code 4: Hi NO-GO
Judgment # J 1 D
(1-digit hexadecimal) 9 :LL NO- GO
C: HH NO-GO
D: Error
Leak rate L Fixed floating point Leak rate unit ±0.000 ±00999
Checksum G 2-digit hexadecimal - 00 FF
2) ID format
#00_00_J_±LLL.LLL_±AAA.AAA_±BBB.BBB_±DDD.DDD_PPP.PPP_EEE.EEE_±FFF.FFF_CC : GG <CR>

1: Lo NO-GO
2: GO
ASCII code 4: Hi NO-GO
Judgment # J - 1 D
C: HH NO-GO
D: Error
Leak rate L Fixed point Leak rate unit -999.999 +999.999

DET Hi A Fixed point Leak rate unit -999.999 +999.999
DET Lo B Fixed point Leak rate unit -999.999 +999.999
ΔP D Floating point Pa -999.999 +999.999
Test pressure P Fixed point Pressure unit -999.999 +999.999
P.Hi E Fixed point Pressure unit -999.999 +999.999
P.Lo F Fixed point Pressure unit -999.999 +999.999
CH # C 2-digit integer - (a) 00 (b) 32
Checksum G 2-digit hexadecimal - 00 FF
3) I format
#00_00_J_±LLL.LLL_±AAA.AAA_±BBB.BBB_±DDD.D_PPP.PPP_EEE.EEE_±FFF.FFF_C : GG <CR>

1: Lo NO-GO
2: GO
One ASCII code 4: Hi NO-GO
Evaluation J - 1 D
C: HH NO-GO
D: Error
Leak rate L Fixed point Leak rate unit -999.999 +999.999

DET Hi A Fixed point Leak rate unit -999.999 +999.999
DET Lo B Fixed point Leak rate unit -999.999 +999.999
UP D Fixed point daPa -999.9 +999.9
Test pressure P Fixed point Pressure unit -999.999 +999.999
P.Hi E Fixed point Pressure unit -999.999 +999.999
P.Lo F Fixed point Pressure unit -999.999 +999.999
CH # C 1 character - 0–9, A – V 32
Check sum G 2-digit hexadecimal - 00 FF
4) P (printer) format
See 12.8 Printer Function.
12.7.5 Checksum
Checksum is two’s complement of the value that adds every ASCII code in the calculation range.
Calculation example: T format

Character number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Transmitted data # 0 0 0 0 2 - 0 0 0 . 4 : 3 2 CR
ASCII HEX 23 30 30 20 30 30 20 32 20 2D 30 30 30 2E 34 3A D
code DEC 35 48 48 32 48 48 32 50 32 45 48 48 48 46 52 58 13
DEC HEX Lower two digits

Note
notation notation HEX notation BIN notation
Calculation Sum 718 2CE CE 11001110 sum of every ASCII code
of Complement -719 D31 31 110001 complement of the sum
data strings Two’s complement -718 D32 32 110010 adds 1 to the complement value
Checksum 32
12.8 Printer Function
12.8.1 Printer specifications (RS-232C serial interface)

Use a printer that can print 80 characters or more in one line, and that can print character fonts. Also, use a
cable whose length is 3 m or shorter.
12.8.2 Printout of leak test data

(1) Print function ON/OFF
Pressing PRINT key in the MEAS mode turns ON and OFF the print function. When the print function
is turned ON, <P> appears on the MEAS mode screen. When lead test operation is performed, leak
test data is always generated.
(2) Leak test data output items
Item Example
DATE 2000/6/16 Day testing ended
TIME 11:14:21 Time testing ended
CH # 0 Channel number for which testing was conducted
TOTAL # 116 The number of Works tested (a default value can be set)
PRESSURE 97.8 kPa Test pressure value
dP[Pa] 5.59 Raw data of differential pressure
COMP[Pa] 5.77 Drift and compensation values
LEAKAGE 0 mL/min Leak rate after compensation
Judgment result of leak test; an error is output when an error
RESULT GOOD
occurs during a leak test.
(3) Printout of judgment results
Result Symbol Judgment or Error Message
GOOD Go
CHG +NG, CHG -NG Differential pressure out of range
BAL1 +NG Test pressure insufficiency detected by PS (P.Lo limit)
Hi NG*, Lo NG* Set limit exceeded in BAL2
Hi NG, Lo NG Set limit exceeded in DET
HH NG, LL NG Set limit exceeded in DET
ADC ?! A/D converter abnormal
ADC OV! A/D out of range due to input of excessive differential pressure
DPS 0! Differential pressure sensor offset abnormal
PS 0! Pressure sensor offset abnormal
DPS OV ! Differential pressure sensor output abnormal
PS OV ! Pressure sensor output abnormal
TP <> ! Test pressure abnormal
V CLS ! Ball valve closed
DPS ?! Differential pressure sensor oscillation stopped abnormally
MCMP<>! Mastering value abnormal
P.Lo=0 P.Lo not set yet
AV ?! Air-operated valve malfunctioning
BAT ?! Battery voltage decreasing
12.8.3 Printout of settings of the SET mode

The settings of one channel or seven consecutive channels can be printed.
SET Enter the SET mode.

↓ Proceed to the channel whose settings are to be printed.
Press this key and move the cursor from above the current CH
↓
PRINT Press this key to display <P> below the CH # at the upper right corner of the screen.
To outputs one channel, To output the setting of seven channels,

PRINT press this key a second time. SHIFT PRINT press these keys alternately.
This prints out the settings of seven consecutive
channels, the numbers of which comprise a
numerical sequence starting from the number of
the selected channel.
MEAS Printout starts.

Press this key to return to the original screen.
Example printout
-----------------------------------------------------------------------------------------------------------------------------------------------
COEF.,TIME CH=00 CH=01 CH=02 CH=03 CH=04 CH=05 CH=06
dV: +000.000 +000.000 +000.000 +000.000 +000.000 +000.000 +000.000
CAL read: +000.000 +000.000 +000.000 +000.000 +000.000 +000.000 +000.000
dQ: +000.000 +000.000 +000.000 +000.000 +000.000 +000.000 +000.000
P cal: +000.000 +000.000 +000.000 +000.000 +000.000 +000.000 +000.000
Ve: +101.325 +101.325 +101.325 +101.325 +101.325 +101.325 +101.325
DL1: 000.0 000.1 000.2 000.3 000.4 000.5 000.6
CHG: 001.0 001.1 001.2 001.3 001.4 001.5 001.6
BAL1: 001.0 001.1 001.2 001.3 001.4 001.5 001.6
BAL2: 001.0 001.1 001.2 001.3 001.4 001.5 001.6
DET: 001.0 001.1 001.2 001.3 001.4 001.5 001.6
BLW: 000.0 000.1 000.2 000.3 000.4 000.5 000.6
END: 000.1 000.2 000.3 000.4 000.5 000.6 000.7
------------------------------------------------------------------------------------------------------------------------------------------------
EX.TIME CH=00 CH=01 CH=02 CH=03 CH=04 CH=05 CH=06
EXH: 000.0 000.1 000.2 000.3 000.4 000.5 000.6
MB1: 000.0 000.1 000.2 000.3 000.4 000.5 000.6
MB2: 000.5 000.6 000.7 000.8 000.9 001.0 001.1
PCHG: 000.0 000.1 000.2 000.3 000.4 000.5 000.6
PEXH: 000.0 000.1 000.2 000.3 000.4 000.5 000.6
------------------------------------------------------------------------------------------------------------------------------------------------
UNIT, LIMIT CH=00 CH=01 CH=02 CH=03 CH=04 CH=05 CH=06
LEAK: 0 0 0 0 0 0 0
PRESS: 0 0 0 0 0 0 0
12.8.4 Printer interface cable specifications

Recommended printer: Seiko Instruments’ DPU-414 Series
LS-1822A DPU414
25 pin 9 pin
FG 1
SD(TxD) 2 3 RxD
Change the printer settings as follows:
RD(RxD) 3 2 TxD CR function = Carriage return
Baud rate = 9600 (bps)
RS(RTS) 4 7 NC
CS(CTS) 5 8 RTS
SG 7 5 GND
CHAPTER 13: MAINTENANCE AND TROUBLESHOOTING
Periodic inspections help maintain test accuracy and prevent failures. Please perform inspections as
described in this chapter.
13.1 Daily Items to Check and Maintain

Turn on the power of the tester at least 5 minutes before inspection to warm-up.
A) Check the oil mist separators and the filter (Start-up check).
Drain any accumulated water and clean the filter if dirty or dusty.
Check whether there is water or oil around the exhaust port.
NOTE: Water, oil, or other contaminants entering the Leak Tester through the air pressure source
causes the largest majority of breakdowns in the Leak Tester. If contaminants are found in the
oil mist separator, it is strongly recommended to install an air dryer or additional in-line filters.
If water or oil contaminates the Leak Tester, the pneumatic circuit will have to be overhauled to
clean it, and DPS replacement will be required.
B) Check the test pressure. The regulator must be set at the correct pressure (Start-up check).
C) Check all the programmed test parameters (Start-up check).
Confirm they have not been accidentally changed.
D) Check the No-Go judgment performance.
Run a leak test using a Leak Master or a good Work.
13.2 Monthly Items to Check and Maintain

A) Check the oil mist separators and the filter.
B) Check all the programmed test parameters and the test pressure.
C) Conduct a No-Leak test using only the Leak Tester while the Master- and Work-side stop valves are
closed.
D) Check the test PS offset.
13.3 Annual or Semiannual Inspection Items

A) Check the oil mist separator and the filter.
B) Check all the programmed test parameters and the test pressure.
C) Conduct a No-Leak test using only the Leak Tester while the Master- and Work-side stop valves are
closed.
D) Check the DPS offset.
E) Check the DPS span.
F) Check the test PS offset.
G) Check the test PS span.
102 CHAPTER 13: MAINTENANCE AND TROUBLESHOOTING
13.4 DPS and PS Calibration

Press CALIB to enter the CALIBRATION MENU screen in the Calibration mode.
NOTE: Other than DP SENSOR OFFSET and P SENSOR OFFSET

the contents of this menu are key-operable only in the manual
<MAN> mode.
13.4.1 Description of CALIBRATION MENU
1) COEFK(Ve):
Calculates equivalent internal volume, K(Ve). See Chapter 10.
2) DP SENSOR OFFSET:
Differential pressure sensor offset (zero) check is performed. See Section 13.5.
3) DP SENSOR SPAN:
Differential pressure sensor span check is performed. See Section 13.6.
4) P SENSOR OFFSET:
Test pressure sensor offset (zero) check is performed. See Section 13.7.
5) P SENSOR SPAN:
Test pressure sensor span check is performed. See Section 13.8.
6) NO LEAK CHECK
Leak integrity inspection of the tester itself with stop valves closed.
13.5 DPS Offset Calibration

A) Press CALIB to enter the CALIB MENU screen. Select DP SENSOR OFFSET using the cursor keys
and press ENTER on the CALIB. MENU screen.
B) Select a unit using the cursor control keys and press ENTER.
C) Verify that the LCD reading is within the Tolerance.
D) Under the following circumstances, it is possible to reset the LCD reading to zero using the auto-zero
function (“PRG, Zero ADJ Active!”). Proceed as directed:
• “PRG, Zero ADJ Active!” is not appearing at the bottom of the screen (auto-zero is OFF)
Press SHIFT and 0/ZERO keys to reset the reading, then the message “PRG, Zero ADJ Active!”
starts blinking.
• “PRG, Zero ADJ Active!” is blinking at the bottom of the screen (auto-zero is ON)
First press SHIFT and 0/ZERO keys to disable the auto-zero function (“PRG, Zero ADJ Active!”),
then press the same keys to enable that function. The reading is reset to 0, and the message
“PRG, Zero ADJ Active!” starts blinking.
* The manufacturer setting of the auto-zero function is OFF.
NOTE: In case the DPS reading is out of Tolerance, it can be provisionally adjusted by turning the DPS
ZERO potentiometer. If this measure does not solve the problem, the DPS may be contaminated.
Contact a Cosmo representative in such a case.
E) Press MEAS to complete the procedure.
CAUTION: Never touch the SPAN potentiometer. This is intended for use by the manufacturer only.
13.6 DPS Span Inspection and Calibration

For DPS span inspection, Cosmo’s Pressure Calibrator, PC-3000 which is equipped with a highly durable
pressure transducer is recommended. This section outlines the DPS span inspection procedure using the
PC-3000.
CAUTION: Although DPS span calibration is performed by a Cosmo representative, those who have
been specially trained by Cosmo can perform it as well. In such cases, however Cosmo
does not guarantee the calibrated value.
13.6.1 Preparation
1) Turn on the power of the LS-1822A and the PC-3000 about 10 minutes before calibration to warm-up.
2) Remove the sealing plugs from both the Work and the Master-side CAL. ports on the front panel of the
tester.
3) Disconnect the air pressure source and make sure that the air is exhausted completely from the
pneumatic circuit of the tester. Leave the pilot pressure source as it is.
CAUTION: Be sure to let the air in the tester exhaust completely, or the calibrator may be damaged
because of over pressurization.
4) Close both the Work and the Master-side stop valves on the rear panel.
5) Connect the Work port of the PC-3000 to the Work-side CAL. port of the tester. Connect the Master
port of PC-3000 to the Master-side CAL. port of the tester.
The CAL port is M10 × 1.5.

A conversion fitting, M10-Rc/1/4, is available upon request.
CAL.
MASTER WORK
13.6.2 Key operation
1) Press CALIB to enter the CALIB. MENU screen. Select DP

SENSOR SPAN using the cursor keys and press ENTER.
2) Select a unit using the cursor control keys and press ENTER.
3) Press SHIFT and 0 to unlock the auto-zero function first, then press
SHIFT and 0 again to reset the reading to zero.
While auto-zero is being executed, the message “PRG, Zero ADJ
Active!” blinks on the LCD.
4) Close the PC-3000 shutoff valve and introduce differential pressures
by turning the knob of the PC-3000. Verify that the readings of the
tester and the PC-3000 are the same at ±950 Pa and ±100 Pa.
5) If the LCD reading exceeds ±5% of the reading ±1 Pa (Tolerance),
span calibration needs to be carried out in the maintenance mode by
the manufacturer or qualified personnel.
6) Press CALIB and MEAS to complete the procedure.
13.7 PS Offset Calibration

A) Press CALIB to enter the CALIB. MENU screen. Select P SENSOR
OFFSET using the cursor keys and press ENTER.
B) Select a unit using the cursor control keys and press ENTER.
C) Verify that the LCD reading is within the Tolerance.
D) If the LCD reading is within the Tolerance, but not 0.0, the reading can
be reset to 0.0.
Press SHIFT and 0 to unlock the auto-zero function first, then press
E) Press MEAS to complete the procedure.
NOTE: If the LCD reading of the PS is out of Tolerance, contact a
Cosmo representative.
13.8 PS Span Inspection

For PS span inspection, the use of Cosmo’s Digital Manometer, DM-3501, or DP gauge DP330, as a
reference unit is recommended.
CAUTION: Although PS span calibration is performed by a Cosmo representative, those who have
been specially trained by Cosmo can perform it as well. In such cases, however, Cosmo
does not guarantee the calibrated value.
13.8.1 Preparation
1) Connect the reference unit to the Work or the Master-side CAL. port.
2) Close both the Work and the Master-side stop valves on the rear of the tester.
3) Connect a pressure source to the tester, and suppress the pressure to 0.
1) Press CALIB to enter the CALIB. MENU screen. Select P SENSOR

SPAN using the cursor keys and press ENTER.
2) Select a unit using the cursor control keys and press ENTER.
3) Press SHIFT and 0 to unlock the auto-zero function first, then press
4) Adjust pressure until the reading of the reference unit agrees with the
test pressure. Verify that the LCD reading is same as that of the reference unit at this point.
5) If the LCD reading is out of Tolerance (over ±5%), span calibration needs to be carried out by the
manufacturer or qualified personnel.
6) Press CALIB and MEAS to complete the procedure.
13.9 No-Leak Check of LS-1822A Itself

A) Close both the Work and the Master-side stop valves on the rear panel.
B) Check whether the test pressure is appropriate.
C) Press CALIB to enter the CALIB MENU screen. Select the NO
LEAK CHECK using the cursor control keys and press ENTER.
D) Press START to start a leak test.
E) The leak test timer settings are fixed as follows:
CHG=10 s
BAL1=3 s
BAL2=2 s
DET=10 s
The Leak Tester judges that the tester is in a non-leaking condition if the measurement result is within
the range of ±10 Pa. If the measurement result is not within this range, there may be a leak or an
electrical circuit fault inside the tester. Contact a Cosmo representative in such a case.
F) Press CALIB and MEAS to complete the procedure.
G) Open the Work and the Master-side stop valves.
13.10 NG Check Using a Leak Master

No-Go judgment can be checked using a Leak Master in either the Remote (REM) or Manual (MAN) mode.
13.10.1 Preparation
This check requires a Leak Master whose leak rate is 1.5 to 2 times larger than your leak rate limit. The
leak rate of the Leak Master for K(Ve) calibration is too large for this check.
Connect an appropriate Leak Master to the Work-side CAL. port on the front panel of the tester.

Start the leak test in the Remote or Manual mode.
The NG check is complete when the HI NO GO LED turns on, and a judgment signal is transmitted.
13.11 Locating Leaks by Means Other than the Leak Tester

13.11.1 Bubble test
Connect the Work to the tester and apply a diluted soap solution to the fixture between the stop valves of the
tester and the Work and the Master.
Press CHARGE HOLD to pressurize the Work to locate possible leaks.
NOTE: For a vacuum type tester, be sure to disconnect the piping from the Work and the Master ports and
supply a regulated micro-pressure to the piping and fixture to execute a bubble test.
13.11.2 Interchanging the Work and the reference Master part

In cases where a Work has been judged as a false part but its leak cannot be located even using the bubble
test, do another leak test after switching the Master and the Work to pinpoint the leakage.
In such a case, if the polarity of the leak rate changes to negative, the leakage should be in neither the Leak
Tester nor the tubing, but in the Work or sealing section.
NOTE: Return the piping to its original position after the check has been completed.
13.12 Built-in Battery Discharge

y This Leak Tester is equipped with a built-in battery to back up the calendar timer and its settings. When
the tester is left with its power turned off for more than 1 month, the battery may have become
discharged, and Error #18, “RTC Battery Discharge” is displayed when the power is turned on.
y When this error message is displayed, leave the unit with its power on continuously for at least 120
hours (5 days). The battery charge may recover if the battery was not completely discharged. Verify
the test parameters, and if any of them have been changed, program them again. After the battery is
recharged, pressing STOP to reset the error, which again allows the execution of leak tests.
y Battery voltage can be viewed on the SYSTEM, VERSION# screen in the HELP/INDEX mode.
See Section 11.4.3.
y If errors occur frequently, contact a Cosmo representative to have the battery replaced.
13.13 Error Display

If an error occurs when the power is turned on or during K(Ve) calibration, a leak test, or a Mastering process,
an error message appears on the LCD, an LED indicator blinks and an error signal is transmitted through the
control I/O port.
Errors indicated only by LED’s blinking

y ROM check and RAM check
If the ROM or the RAM is defective, the Hi NO GO
and LO NO GO LED light up. No operations are
possible.
Contact a Cosmo representative.
13.13.1 Error messages and countermeasures

(1) ERROR No.1
Exceeding M COMP Limit! Mastering Error
Timing of judgment After the last Mastering operation is completed
Judgment criteria The value of the leak data value of the first sample taken minus that of the last sample taken exceeds the Mastering limit.
Cause Countermeasure
Wrong setting for Mastering Increase the Mastering limit (set a value that is larger than the value of Loop 1 to M.COMP LIMIT).
Insufficient stabilization period for Extend the stabilization period for pressurization (CHG timer and BAL1 timer settings).
pressurization
Output Signal Timing Chart
PIN
FUNCTION TYPE WAIT DL1 PCHK PCHG PEXH CHG BAL1 BAL2 DET BLW EXH END WAIT
#
12 MASTERING REQ. NO
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
34 TIME EXTENSION NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(2) ERROR No.2

A/D Converter Malfunction! A/D Converter Malfunctioning
Timing of judgment Immediately
Judgment criteria The A/D converter is malfunctioning.
A/D converter is malfunctioning Request the manufacturer to replace the A/D converter.
PIN
FUNCTION TYPE WAIT
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(3) ERROR No.3

DP Sensor Malfunction! Differential Pressure Sensor Malfunctioning (oscillation stopped)
Judgment criteria The differential pressure sensor stopped oscillating.
Interrupted power supply to the sensor, broken
electronic circuit, or disconnected cable
PIN
FUNCTION TYPE WAIT
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(4) ERROR No.4

Stop Valve closed Stop Valve Closed
Timing of judgment PCHK time up (if a stop valve is closed while it is operating, the time up of the ongoing stage.)
Judgment criteria A stop valve is closed.
Closed stop valve Open the Work and Master stop valves and lower the cover plate.
Output Signal Timing Chart Time up
PIN
FUNCTION TYPE WAIT DL1 PCHK BLW EXH END WAIT
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(5) ERROR No.5

DPS Offset Exceeding Limit Differential Pressure Sensor Offset Improper
Timing of judgment When the power is turned on
Judgment criteria The differential pressure offset value is over ±30% of the differential pressure sensor range.
When the power is turned on, the pressure
Adjust the differential pressure sensor offset value in the CALIB. mode.
sensor offset value is out of range
PIN
FUNCTION TYPE WAIT
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(6) ERROR No.6

PS Offset Exceeding Limit Test Pressure Sensor Offset Improper
Timing of judgment When the power is turned on
Judgment criteria The test pressure sensor offset value is over ±2 % of the test sensor range.
When the power is turned on, the test
Adjust the test pressure sensor offset value in the CALIB. mode.
pressure sensor offset value is out of range
PIN
FUNCTION TYPE WAIT
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(7) ERROR No.8

Improper test pressure Test Pressure Improper
Timing of judgment During the pressurization (CHG) stage, the test pressure exceeded the upper limit (Immediately).
Judgment criteria Test pressure upper limit setting: P.Hi
Improper setting of test pressure limit Check test pressure limit settings.
Insufficient duration of pressurization Extend the duration of pressurization.
Test pressure sensor defective Contact a Cosmo representative.
Immediately
PIN
FUNCTION TYPE WAIT DL1 PCHK PCHG PEXH CHG BLW EXH END WAIT
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
Timing of judgment Time up of the pressurization (CHG) stage; when the test pressure is below the lower limit
Judgment criteria Test pressure lower limit setting: P.Lo
Output Signal Timing Chart Time up
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(8) ERROR No.9

DPS output saturation Differential Pressure Sensor Output Saturation BAL2 Hi
Timing of judgment Time up of the balance (BAL2) stage
Judgment criteria Differential pressure sensor output saturation
Large leak is occurring A large leak may be occurring in the measurement system.
Insufficient stabilization period for
Extend the pressurization and equalization durations.
pressurization
Improper adjustment of differential pressure
Adjust differential pressure sensor offset value.
sensor offset value
PIN
FUNCTION TYPE WAIT DL1 PCHK PCHG PEXH CHG BAL1 BAL2 BLW EXH END WAIT
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
DPS output saturation Differential Pressure Sensor Output Saturation BAL2 Lo
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
DPS output saturation Differential Pressure Sensor Output Saturation DET Hi
Timing of judgment Time up of the detection (DET) stage
Insufficient stabilization period for
Extend the pressurization and equalization durations.
pressurization
Improper adjustment of differential pressure
Adjust differential pressure sensor offset value.
sensor offset value
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
DPS output saturation Differential Pressure Sensor Output Saturation DET Lo

PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(9) ERROR No.10

PS output saturation Test Pressure Sensor Output Saturation
Timing of judgment Time up of the pressurization (CHG) stage
Judgment criteria Test pressure sensor output saturation
Test pressure improper Check the test pressure.
Test pressure sensor offset value adjustment
Adjust the test pressure sensor offset value.
improper
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(10) ERROR No.11

K(Ve) out of range K(Ve) Out of Range
Timing of judgment When executing COEF.K(Ve), time up occurred during the last detection (DET) stage.
Judgment criteria The measured K(Ve) value is greater than 100L.
Calibrator setting improper Check the calibrator setting.
Output Signal Timing Chart Last detection
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(11) ERROR No.12

Leak Limit out of range Leak Limit Out of Range
Timing of judgment When executing COEF.K(Ve), time up occurred during the last detection (DET) stage.
Judgment criteria The leak limit is out of the differential pressure range calculated based on the measured K(Ve) value.
Change the unit of leak rate to that of the differential pressure and execute COEF.K(Ve).
Wrong settings
Check the leak limit setting.
Output Signal Timing Chart Last detection
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(12) ERROR No.15

Air Valve Inactive Air-operated Valve Malfunctioning C1
Operation of air-operated valves AV2 and AV3, is checked
Timing of judgment PCHK time up
Judgment criteria The test pressure sensor auto-zero value is over ±1% of the test pressure sensor value range.
Air-operated valve Check the pilot pressure.
malfunctioning Solenoid valve and air-operated valve malfunctioning; contact a Cosmo representative.
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved

Operation of air-operated valves AV2 and AV3, is checked
Judgment criteria When time up occurs during the pressurization (CHG) stage, the value of (test pressure – auto-zero value) is less than
1% of the test pressure sensor value range.
Check the pilot pressure.
Air-operated valve inactive
Solenoid valve and air-operated valve malfunctioning; contact a Cosmo representative.
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved

Operation of air-operated valves (AV1, AV2, and AV3), presence of differential pressure sensor
malfunctioning, and leak sensitivity are checked
Timing of judgment Time up of the air-blow (BLW) stage
Judgment criteria The differential pressure generated by air blow is below the set value.
Insufficient air-blow duration Extend the air-blow duration, or reduce the value set to BLOW CHECK DPS LIMIT
Air-operated valve
Solenoid valve, air-operated valve, and differential pressure sensor malfunctioning; contact a Cosmo
malfunctioning
representative.
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved

Timing of judgment Time up of the balance (BAL2) stage
Judgment criteria: The pressure switch (PSW) for the pilot pressure does not turn ON.
Under high-pressure specifications (H15 and H20),
Pressure switch and solenoid valve malfunctioning; contact a Cosmo
equalization valve AV2 is malfunctioning during the BAL2 stage
representative.
Under the external pressure detection mechanism (C circuit),
Pressure switch and solenoid valve malfunctioning; contact a Cosmo
balance valve AV1 is malfunctioning during the BAL2 stage
representative.
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(13) ERROR No.17

P.Lo(Hi)value is 0 (Zero) Test Pressure Limit Set to 0 (Zero)
Timing of judgment Time up of the detection (DET) stage
Judgment criteria Test pressure limit set to zero
Test pressure limit set to zero The test pressure limit, P.Lo (P.Hi for vacuum), is set to 000.000; enter a proper value.
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(14) ERROR No.18

RTC Battery Discharge Battery Voltage Drop
Judgment criteria The internal battery voltage is decreasing.
If the internal battery completely runs out, the calendar timer function will be disabled. Do not turn off the
Battery voltage drop
power; contact a Cosmo representative.
PIN
FUNCTION TYPE WAIT
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(15) ERROR
BAL TP decayed Equalization and Test Pressure Improper
Timing of judgment Time up of the balance delay (BAL1) stage
Judgment criteria Test pressure lower limit
Air-operated valve AV3 is Check the pilot pressure contact.
malfunctioning Solenoid valve and air-operated valve malfunctioning; contact a Cosmo representative.
PIN
FUNCTION TYPE WAIT DL1 PCHK PCHG PEXH CHG BAL1 BLW EXH END WAIT
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
(16) CHG +NG Pressurization Large Leak

A large leak is occurring A large leak may be occurring in the measurement system.
Insufficient pressurization duration Extend the pressurization duration.
PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
CHG -NG Pressurization Large Leak

PIN
#
31 HH-NG NO
13 Hi-NG NO
14 GO NO
32 Lo-NG NO
33 LL-NG NO
15 Reserved
16 ERROR NO
35 END(a) NO
17 STAGE PORT#1 NO
18 STAGE PORT#0 NO
36 BUSY NO
37 Maker Reserved
13.13.2 Error messages and associated countermeasures

Code Message Probable cause and countermeasures
1 Exceeding The Mastering value has exceeded M. COMP limits.
M.COMP Limit Extend the CHG and the BAL1 timers. The leak rate during Loop #1 will
be smaller, which allows the resetting of a smaller Mastering value.
2 A/D Converter Contact a Cosmo representative to have the A/D converter replaced with
Malfunction! a new one.
3 DP SENSOR The DPS power supply or electric circuit may be malfunctioning, or a
Malfunction! cable may be disconnected.
5 DPS Offset The DPS offset is out of Tolerance when the power is turned on.
Exceeding Limit Adjust the DPS offset in the CALIB mode. See Section 13.5.
6 PS Offset The PS offset is out of Tolerance when the power is turned on.
Exceeding Limit Adjust the PS offset in the CALIB mode. See Section 13.7.
8 Improper The test pressure exceeds the programmed test pressure limits at the end
Test Pressure of the CHG stage due to inappropriate P.Lo (P.Hi for vacuum) settings, or
to PS malfunction.
9 DPS The DPS output during the BAL1, BAL2 and DET stages is out of the
Output saturation allowable range.
Check the DPS offset. See Section 13.5.
10 PS output The PS output during leak testing is out of the allowable range.
saturated Check the PS offset and the test pressure setting. See Section 13.7.
11 K(Ve) out of range The measured K(Ve) exceeds 100L.
Check the leak rate of the Leak Master.
12 Leak Limit out of Leak rate limits exceed the allowable range that is calculated based on
range the measured K(Ve) (program limitation).
Perform calibration after changing the unit to a pressure unit. See
Section 8.1.2. Or set lower leak limits.
15 Air Valve Inactive C1 The equalization valve AV2, exhaust valve AV3, and/or solenoid valves for
pilot pressure are/is malfunctioning.
Air Valve Inactive C2 Fill valve AV1 and/or the solenoid valve for pilot pressure are/is inactive,
or the test pressure may be insufficient.
Verify the test pressure and contact a Cosmo representative if necessary.
Air Valve Inactive C4 The DPS sensitivity may have been lowered. Check the sensitivity.
If the test pressure is low, the BLW timer setting may be too short.
Verify the BLW timer setting and contact a Cosmo representative if
necessary.
Air Valve Inactive C5 For H15, equalization valve AV2, is inactive during the BAL2 stage.
For the Y or C circuit, balance valve AV1, is inactive during the BAL2
stage.
Apply the appropriate pilot pressure (except for the H15 circuit and the C
circuit).
Verify pilot pressure and contact a Cosmo representative if necessary.
17 P.Lo(Hi) Value is 0 Test pressure limit, P.Lo (P.Hi for vacuum), is set to 000.000. See
(zero) Section 8.2.3 (9).
18 RTC Battery discharge The built-in battery has been completely discharged. See Section 13.12.
NOTE: Error codes 4, 7, 13, 14 and 16 are currently not used.
13.14 When NG Judgment Occurs Frequently

Error/NG
Probable cause Suggested countermeasures
judgment
Leakage from the Work Check for leaks using the bubble test.
(continuous failures due to
blowhole leaks)
Leakage from sealing due to
machining defects
Originating Differential pressure due to See the Mastering graph and change the
in the Work deformation or internal seal timer settings or the test pressure setting
volume changes if necessary.
Use the Pre-charge and Pre-exhaust
stages. See Section 8.2.2.
Differential pressure due to Keep the Work temperature the as same
temperature changes as the ambient temperature.
Leakage due to worn-out sealing After checking the sealing rubber for
rubber wear or contamination with foreign
matter, execute a leak test using a good
non-leaking Work.
Clean and/or replace the sealing rubber

if necessary.
Originating
in the Leakage from tubing, coupler Execute a bubble test. See Section
Hi NO-GO
sealing and/or valve 13.11.1.
occurs
fixture or
frequently. Differential pressure due to a Implement the exhaust interference
tubing
change in sealing fixture volume prevention feature to avoid effects from
caused by a change in clamp other testers if any.
pressure.
Review the sealing fixture and rubber
designs.
Differential pressure due to a Discharge water by air blow.
change in the temperature of the Control water temperature.
fixture after a water-dunk test
Internal leakage Execute a No-Leak check.
See Section 13.9.
DPS malfunction due to
contamination by water, oil,
Originating
shavings or other foreign matter.
in the tester
Timer settings, test pressure Execute a No-leak test using a known
and/or K(Ve) may be non-leaking part.
inappropriate. See Section 9.4.
The Work used for Mastering See the Mastering graph and change the
sampling may be inappropriate timer setting or number of iteration
Originating because of leaks, deformation, or (Loop#) if necessary.
in temperature effects.
Mastering
The type of Work used for Use an appropriate Work.
Mastering may be wrong.
Error/NG
Probable cause Suggested countermeasures
judgment
Verify the P.Hi/Lo settings and change them
Improper P.Hi/Lo settings
Hi NO-GO if necessary.
occurs, and
After checking the sealing rubber for wear
leak test is
A large leak may have occurred or contamination with foreign matter,
aborted
(always monitored by PS). replace the sealing rubber if necessary, and
when BAL1
execute a leak test with a non-leaking Work.
stage
completes. Check the source pressure and the
Improper test pressure
regulator setting.
No-Go The Work may be leaking. Retry Mastering using another part.
occurs
during leak
test with Avoid conducting the Mastering process on
Mastering parts in irregular condition, such as ones
Temperature change in the Work
comp. that have just been subjected to a
water-dunk test.
The Master may be leaking. Replace the Master with another Work.
Lo NO-GO
occurs Replace the Master with Cosmo’s Master
frequently. Poor Master temperature stability Chamber, which has good temperature
stability.
Appendix
APPENDIX A1:
195
331.5 Max.(150)
FUSE AC100~ 240V POWER

FG T2.5A-250V 50/60Hz*100VA*MAX.1ph
CPU RUN PRESSURE PILOT

CH SOURCE PRESSURE
E/P
G REGULATOR
BAL
DET
EN EXHAUST
D
KEYBOAR
DUNLOC
K
LO GO Hi
NO GO NO GO
OPERATION PORT
CONTROL? I/O
297.2
AIR LEAK TESTER
LS-1822A
D E F
7 8 9
A B C
4 5 6 WORK EXHAUST MASTER

-
COM1
SPAN +
CAL. UP
SHIFT PAGE
MASTER WORK 1 2 3 DOWN
EXTERNAL APPEARANCE
ZERO
REMOTECHARGE
ENTER GRAPH MEAS
0 MANUAL HOLD
INDEX
PRINT CALIB SET STOP START
HELP
COSMO INSTRUMENTS
CO.,LTD.
MADE IN JAPAN
150 260 35.5

119
120 Appendix
APPENDIX A2: PNEUMATIC CIRCUIT

NOTE: The circuit diagrams may differ from the actual circuit.
(a) Standard (Intelligent I pneumatic circuit) Medium pressure M and Low pressure L
OPTION R
V1 P.S
SV4-2
F2 V2
MASTER
AV1 AV3
V1
F1
S1
PRESSURE DP
EXHAUST
SOURCE S
O O
F3 V3
WORK
CAL.
AV4
MASTER
WORK SV2 O
SV8
400kPa SV4-1
F4
G G3 PILOT
PILOT
PRESSURE PRESSURE PORT
OPTION J
DL1 PCHG PEXH CHG BAL1 BAL2 DET BLOW END T.NO
+ -
6 5
SV2 6 7
SV3 9 8
SV4 9 10
SV5 12 11
12 13
SV7 15 14
*SV8 15 16
* SV8 operates during K(Ve) check and calibration
(b) Optional (Intelligent II pneumatic circuit) Medium pressure M and Low pressure L
OPTION R
V1
F2 V2
MASTER
AV1 AV2 P.S AV3
V1
F1
S1
SOURCE O O O
F3 V3
WORK
CAL.
AV4
MASTER
WORK SV2 O
SV8 SV3
SV4
400kPa
F4 G
G3 PILOT
PILOT
OPTION J
DL1 PCHK PCHG PEXH CHG BAL1 BAL2 DET BLOW END T.NO
+ -
6 5
SV2 6 7
SV3 9 8
SV4 9 10
SV5 12 11
12 13
SV7 15 14
*SV8 15 16
(c)
Appendix 121
Small volume pneumatic circuit (Circuit A), A01 (Intelligent I pneumatic circuit) Medium pressure M and
Low pressure L
OPTION R
V1 P.
SV4-2 S
F2 V2
MASTER
AV1 AV3
V1
F1
S1
PRESSURE DP
EXHAUST
SOURCE S
O O
F3 V3
WORK
CAL.
AV4
MASTER
WORK SV2 O
SV8
400kPa SV4-1
F4
G G3 PILOT
PILOT
OPTION J
DL1 PCHG PEXH CHG DL2 BAL2 DET BLOW END T.NO
+ -
6 5
SV2 6 7
SV3 9 8
SV4 9 10
SV5 12 11
12 13
SV7 15 14
*SV8 15 16
(d) External pressure capsule pneumatic circuit, C Medium pressure M and Low pressure L
OPTION R
TEST PRESSURE
V1 OUTLET
F2 V2
P.S
SV1 MASTER
AV1
V1
F1
PRESSURE DPS
SOURCE O
F3 V3
WORK
CAL.
MASTER
S1
WORK
EXHAUST
SV3
400kPa PS1
F4
G
PILOT
PRESSURE
DL1 PCHG PEXH CHG BAL1 BAL2 DET BLOW END +T.NO
-
SV1 6 5
SV2 6 7
SV3 9 8
SV4 9 10
SV5 12 11
12 13
SV7 15 14
15 16
122 Appendix
(e) Standard (Intelligent I pneumatic circuit) Vacuum pressure V
OPTION R
V1 P.
SV4-2 S
F2 V2
MASTER
AV3 AV1
V1
F1
VACUUM DP
SOURCE O S
O
F3 V3
WORK
CAL.
AV4
MASTER
WORK O
SV4-1
SV8
SV2
400kPa
F4 G
PILOT
PRESSURE
OPTION J
DL1 PCHG PEXH CHG BAL1 BAL2 DET BLOW END T.NO
+ -
6 5
SV2 6 7
SV3 9 8
SV4 9 10
SV5 12 11
12 13
SV7 15 14
*SV8 15 16
(f) High pressure (Intelligent I pneumatic circuit) (H15, H20)
F2 V2
P.S MASTER
AV1-1 AV2 AV3
V1
F1
S1
SOURCE O O
AV1-2
F3 V3
WORK
CAL.
MASTER
WORK SV1 SV2
400kPa SV4
F4
G G3 PILOT
PILOT
DL1 PCHG PEXH CHG BAL1 BAL2 DET BLOW END +T.NO
-
SV1 6 5
SV2 6 7
SV3 9 8
SV4 9 10
SV5 12 11
12 13
SV7 15 14
*SV8 15 16
Appendix 123
APPENDIX A3: PRESSURE UNIT CONVERSION TABLE

1kg/cm2 → 0.980665 14.2233 735.55914 28.959 393.7 10000 98.0665 0.0980665 980.665 0.96784
1.0197162 ← 1 bar → 14.50373 750.06158 29.529962 401.46227 10197.162 100 0.1 1000 0.9869221
0.0703072 0.0689478 ← 1 psi→ 51.715083 2.0360254 27.679934 703.07172 6.8947783 0.0068948 68.947783 0.0680461
0.0013595 0.0013332 0.0193367 ← 1 mmHg → 0.0393701 0.5352391 13.5951 0.1333224 0.0001333 1.3332239 0.0013158
0.0345316 0.0338639 0.491153 25.400018 ← 1 inHg → 13.595083 345.31579 3.3863911 0.0033864 33.863911 0.033421
0.00254 0.0024909 0.0361273 1.8683239 0.073556 ← 1 inH2O → 25.400051 0.2490894 0.0002491 2.4908941 0.0024583
0.0001 9.807E-05 0.0014223 0.0735559 0.0028959 0.03937 ← 1 mmH2O → 0.0098067 9.807E-06 0.0980665 9.678E-05
0.0101972 0.01 0.1450373 7.5006158 0.2952996 4.0146227 101.97162 ← 1 kPa → 0.001 10 0.0098692
10.197162 10 145.0373 7500.6158 295.29962 4014.6227 101971.62 1000 ← 1 MPa → 10000 9.8692214
0.0010197 0.001 0.0145037 0.7500616 0.02953 0.4014623 10.197162 0.1 0.0001 ← 1 hPa → 0.0009869
1.0332286 1.0132512 14.695921 760.00076 29.921268 406.78211 10332.286 101.32512 0.1013251 1013.2512 ← 1 atm
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
MmHg,
kg/cm2 bar psi inHg inH2O mmH2O kPa MPa hPa atm
Torr
NOTE: E-05 stands for 10-5 (negative fifth power).
APPENDIX A4: CE MARKING

A CE mark is affixed to products compliant with CE marking.
Only the main body of the LS-1822A complies with CE marking. Whether or not the supplied power cable
complies with CE marking depends on its voltage specifications:
(1) 100–125 V: not compliant
(2) 220–250 V: compliant
Especially in EU countries, use a power cable that is compliant with the country’s laws and regulations.
NOTE: Measurements might deviate due to jamming. When the effects of jamming are negated,
measurements will be normal again (IEC-61000-4-3).
We issue the EC Declaration of Conformity, which certifies that this product is compliant with CE marking.
Contact us if it is required.
APPENDIX A5: NOTICE TO USERS (FCC Rules)

Do not modify or remodel this product.
This product has been tested pursuant to Part 15 of FCC and has been proven to comply with the limits for a
Class A digital device, presuming that it is being marketed for use in a commercial, industrial or business
environment. This product emits radio frequency energy, so it can adversely affect radio communications if
it is not used or installed in accordance with the Operation Manual. When this product is used in a
residential area, it can have adverse effects, and users are responsible for the measures they take to nullify
such effects.
124 Appendix
APPENDIX A6: TEST PARAMETER BLOTTER

CH CH CH
Q(ΔV) Leak rate (volume change)

K(Ve) Equivalent internal volume
DL1 Delay
CHG Pressurization
BAL1 Balance delay (equalization)
BAL2 Balance
DET Detection
BLW Air blow
END Completion
EXH Exhaust
MB1 Balance delay or equalization for Mastering
MB2 Balance for Mastering
PCHK Auto-zero delay
PCHG Preliminarily pressurization
PEXH Preliminarily exhaust
TYPE Type of compensation

LOOP# Number of iterations
SAMPL# Number of samples
D.COMP Drift compensation value
C.Hi Upper side sampling range
C.LIMIT
C.Lo Lower side sampling range
M.Hi Mastering upper limit
M.LIMIT
M.Lo Mastering lower limit
LEAK Leak rate unit

PRESS Test pressure unit
K(Ve) Equivalent internal volume unit
BAL Hi Work-side leak rate limit for BAL2 stage
BAL Lo Master-side leak rate limit for BAL2 stage
DET HH Work-side HH leak rate limit for DET stage
DET Hi Work-side Hi leak rate limit for DET stage
DET LL Master-side Lo leak rate limit for DET stage
DET Lo Master-side LL leak rate limit for DET stage
P.Hi Test pressure upper limit
P.Lo Test pressure lower limit
P.Hi/Lo P.Hi/Lo monitoring ON/OFF
Select Test pressure selection

Inlet A A-side polarity +/-
Inlet B B-side polarity +/-
Q.CHG Quick-charge
PCHG Pre-charge
E.PRESS
CHG Test pressure
PRE SEQ .LOOP# Number of iterations for pre-charge
NR LOOP Number of iterations for NR detection
DAY Days of the week to execute Mastering

I NTERVAL Interval of Mastering operations
No.of M. Number of iterations of Mastering cycles
WAIT TIME Wait time
C.LIMIT OVER Number of times exceeding drift compensation limit
COSMO INSTRUMENTS CO., LTD.
2974-23 ISHIKAWA
HACHIOJI, TOKYO 192-0032 JAPAN
PHONE: +81-(0)42-642-1357 FAX: +81-(0)42-646-2439
COSMO LOCATIONS WORLD WIDE

INTERNATIONAL SALES PHONE: +81-(0)42-642-1357
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GUANGZHOU, CHINA FAX: +86-(0)20-6120-5932
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DIAFRIEND CORPORATION PHONE: +886-(0)2-27121050
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SALES OFFICES IN JAPAN
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FAX: +81-(0)42-586-3166
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FAX: +81-(0)48-836-3939
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FAX: +81-(0)6-6395-2634
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FAX: +81-(0)82-264-5358
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FAX: +81-(0)53-438-5716
TOHOKU(SENDAI) SALES OFFICE PHONE: +81-(0)22-246-8701
FAX: +81-(0)22-246-8966

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OPERATION MANUAL

AIR LEAK TESTER

COSMO INSTRUMENTS CO., LTD.

4.5 Connecting Master and Work.............................................................................................................. 29

12.5 Stage Number Output ......................................................................................................................... 93

[Explanations of the symbols used]

CHAPTER 1: GENERAL INFORMATION AND SPECIFICATIONS

J) An RS-232C interface serial communication port is equipped as standard.

1.3 General Specifications

Guaranteed accuracy range Standard: ±1000 Pa

Leak rate display 3 digits (floating point), Sampling rate: 10 times/s

1.4 Model Classifications

Low L 10 to 100 kPa PS: 100 kPa

NOTE: PS: Pressure sensor range

CHAPTER 2: LEAK TESTING OVERVIEW

2.1 Theory of Leak Testing

2.1.1 Stage Summary

Basic Type Pneumatic Circuit (Medium pressure)

Work and the Master. Pressure change

Leak rate is calculated using the following equation:

Leak rate reading

2.2 Leak Rate Conversion

2.2.1 Pressure and Volume Relationship

Leakage (ΔVL ) = Ve × ΔP / Patm

2.2.2 Equivalent internal volume

1) Equation for calculating equivalent internal volume

Tester internal volume, Vt, of pneumatic circuit (including CAL port)

2.2.3 Calculation of a Leak Rate

2.3 Estimating the Test Time

2.3.1 Setting Charge (CHG) and Balance Delay (BAL1) timers

2.3.2 Limitation on the BAL2 timer setting

2.3.3 Setting the DET timer

General guidelines for the charge and balance timer settings

0s 10s 20s 30s 40s 50s

CHAPTER 3: FEATURE SUMMARIES

3.1 K(Ve) Calibration

3.1.1 Selecting a Leak Master

1) Sizes of standard Leak Masters

Leak rate at 100 kPa

2) Leak Master selection graphs

Sizes of Leak Masters

J1-2 Working region

J1-1 c b Center line

J1-5 50 Upper boundary

700 600 500 400 300 200 100 0 500 1000

Low and Vacuum 70 Upper boundary

100 90 80 70 60 50 40 30 20 10 0 1000 2000

Low and Vacuum 100 Upper boundary

5) Composition of Leak Master

O-ring (S12) O-ring (S12)

3.2 Compensation Features

Mastering Method Feature Summary Compensation

3.3 Mastering Compensation

3.3.1 Theory of Mastering

Drift error + True leak rate

True leak rate

Mastering value (a-b)

CHG DET 1 DET 2 DET (n) True leak rate (b)

3.3.2 When to execute a Mastering process

4) When No-Go judgments occur consecutively

3.3.3 Annotation for use of Mastering compensation feature

3.4 Auto-Drift Compensation (U.S. PAT. #4670847)

3.5 Noise Reduction (NR) Mode