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LS182 H My Fukuda
LS182 H My Fukuda
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
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
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:
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 7
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
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
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.
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
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 11
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
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
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.
CHAPTER 2: LEAK TESTING OVERVIEW 13
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.
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.
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 15
J1-10 Q
Upper boundary
J1-5
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
40
30 Working region
J1-2
20
J1-1 Center line
10
Lower boundary
For low or vacuum pressure range models, and an internal Work volume of 2000 mL or less
30 Center line
J1-20
20
J1-10
10 Lower boundary
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
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
Front panel
Filter (Ф8.5, t=2.0 Material: PVF) Manifold for
Leak Master
Filter joint connection port
Leak Master
NOTE: A Leak Master contains a filter. Check it periodically and replace as needed.
18 CHAPTER 3: FEATURE SUMMARIES
NOTE: The compensation features normally correct data deviations, but overcompensation must be
avoided.
CHAPTER 3: FEATURE SUMMARIES 19
Drift error
Drift error
+ Measured value (a)
True leak rate
Differential
Pressure
Fig. 6
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.
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).
22 CHAPTER 3: FEATURE SUMMARIES
Work
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.
External
exhaust
valve
Master
LS-1822A
W ork
24 CHAPTER 3: FEATURE SUMMARIES
START 1
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.
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 25
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.
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 base
LS-1822A
Shield GND
F.G.
GND
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.
CHAPTER 4: INSTALLATION 29
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
69
1) Master Chamber specifications
Model: MC-F02A-200C
Internal volume: 109 mL
non-adjustable Rc(PT)1/8
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.
32 CHAPTER 4: INSTALLATION
E
CHAPTER 5: PARTS IDENTIFICATION AND FUNCTIONS 35
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
H
A
I
B
C J
D K
5.3 Keyboard
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
C Mode keys
SET
PS auto-zero, Air-operated valve performance
mode to program
settings
B) Before programming
Operation Note Refer to
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
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.
Operation Note Refer to
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.
CHAPTER 6: COMPREHENSIVE SETUP PROCEDURE 43
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.
Operation Note Refer to
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
1000
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.
7.2.6 Mastering
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 49
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.
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.
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.
CHAPTER 8: SET MODE OPERATIONS 55
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.
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
56 CHAPTER 8: SET MODE OPERATIONS
(Manufacturer setting)
Manufacturer setting
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 63
CHAPTER 9: COMPENSATION
Do not transmit.
Mastering signal Transmit
NOTE: Comp. value will be deleted
if signal is transmitted.
SET
Click to enter the SET mode
ENTER
Clicking ENTER completes selection
ENTER
Clicking ENTER completes selection
Type of Compensation
0: OFF
No compensation
1: DRIFT
Auto-Drift compensation
2: MSTRG
Mastering compensation
CHAPTER 9: COMPENSATION 65
NOTE: Changes to the settings are not saved unless ENTER is pressed.
66 CHAPTER 9: COMPENSATION
9.4.1 Preparation
9.4.2 Operation
Manual mode Remote mode
MEAS
Enters the MEAS mode. MEAS
Enters the MEAS mode.
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.
9.5.1 Operation
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.
CHAPTER 9: COMPENSATION 71
Example: If your Mastering value is 50 Pa and the upper and lower side sampling ranges are +25 Pa
and -25 Pa
Measured data
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
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 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 73
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
CALIB.
Enters the Calibration (CALIB.) mode.
ENTER
Selects COEF K(Ve).
0 - 9
Enter a desired channel number (0–15).
ENTER
Complete programming.
ENTER
Complete programming.
CHAPTER 10: K(Ve) CALIBRATION 75
START
Phase 1 starts.
START
Phase 2 starts.
START
Phase 3 starts.
MEAS
Return to the MEAS mode screen after calibration is completed.
76 CHAPTER 10: K(Ve) CALIBRATION
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.
0 - 9
CHAPTER 10: K(Ve) CALIBRATION 77
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.
CHAPTER 10: K(Ve) CALIBRATION 79
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
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.
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)
CAUTION: Never short the pins marked “Reserved.” Doing so may cause damage to the tester.
86 CHAPTER 12: INTERFACE
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
CHAPTER 12: INTERFACE 87
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
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
88 CHAPTER 12: INTERFACE
Input group
10
28
External power PC input card
+24 V
19
31
Output group
36
0.2A MAX
CHAPTER 12: INTERFACE 89
Connector type:
Leak Tester side: DB-37P (XM2C-3712-112 OMRON or equivalent)
Cable side: DB-37S (XM2D-3701 OMRON or equivalent)
CAUTION : Do not connect anything to the pins marked “Reserved.” Doing so may cause
damage to the tester.
90 CHAPTER 12: INTERFACE
5 Typical switch
connection
6
9 External power
+
10
20
21
22
23
Typical transistor
24 connection
25
26
27
28
19
37
CHAPTER 12: INTERFACE 91
28
IC
29
30
31
32
Typical
33
photocoupler
34 connection
35
36
IC
37
92 CHAPTER 12: INTERFACE
10
External power input 28 External power
Photo MOS relay +24V
COM PC input card
19
31
IC
36
IC
37
CHAPTER 12: INTERFACE 93
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.
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.
94 CHAPTER 12: INTERFACE
WAIT DL1 PCHK CHG BAL1 BAL2 DET BLW EXH END WAIT
CH#(*1)
400 ms (MIN.)
START
300 ms (MAX.)
BUSY
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.
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.
CHAPTER 12: INTERFACE 95
CH#(*3)
(REMOTE)
CHARGE HOLD
(REMOTE)
300 ms (MAX.) 300 ms (MAX.)
BUSY
END
CHARGE HOLD
(MANUAL)
STOP
(MANUAL)
NOTE: CH # is acceptable in the WAIT stage, but not in any other stage.
SD (TxD) 2 2 3
RD (RxD) 3 3 2
RS (RTS) 4 4 7
CS (CTS) 5 5 8
SG 7 7 5
RS (RTS) 4 4 7
CS (CTS) 5 5 8
SG 7 7 5
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>
3) I format
#00_00_J_±LLL.LLL_±AAA.AAA_±BBB.BBB_±DDD.D_PPP.PPP_EEE.EEE_±FFF.FFF_C : GG <CR>
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.
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
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 101
Periodic inspections help maintain test accuracy and prevent failures. Please perform inspections as
described in this chapter.
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.
13.6.1 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.
CAL.
MASTER WORK
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.
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.
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
FUNCTION TYPE WAIT DL1 PCHK PCHG PEXH CHG 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
19 COM for all outputs
110 CHAPTER 13: MAINTENANCE AND TROUBLESHOOTING
(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
Cause Countermeasure
Large leak is occurring A large leak may be occurring in the measurement system.
Air-operated valve AV3 is Check the pilot pressure contact.
malfunctioning Solenoid valve and air-operated valve malfunctioning; contact a Cosmo representative.
Output Signal Timing Chart
PIN
FUNCTION TYPE WAIT DL1 PCHK PCHG PEXH CHG BAL1 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
19 COM for all outputs
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)
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
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
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
PRESSURE DPS EXHAUST
SOURCE O O O
F3 V3
WORK
CAL.
AV4
MASTER
WORK SV2 O
SV8 SV3
SV4
400kPa
F4 G
G3 PILOT
PILOT
PRESSURE PRESSURE PORT
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
* SV8 operates during K(Ve) check and calibration
(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
PRESSURE PRESSURE PORT
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
* SV8 operates during K(Ve) check and calibration
(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
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
* SV8 operates during K(Ve) check and calibration
F2 V2
P.S MASTER
AV1-1 AV2 AV3
V1
F1
S1
PRESSURE DPS EXHAUST
SOURCE O O
AV1-2
F3 V3
WORK
CAL.
MASTER
400kPa SV4
F4
G G3 PILOT
PILOT
PRESSURE PRESSURE PORT
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
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
EXH Exhaust
MB1 Balance delay or equalization for Mastering
MB2 Balance for Mastering
PCHK Auto-zero delay
PCHG Preliminarily pressurization
PEXH Preliminarily exhaust