Cosmo LS-1866 User manual

OPERATION MANUAL

AIR LEAK TESTER

MODEL LS-1866

No. LS-1866-941B1-H

1 INTRODUCTION

2 GENERAL INFORMATION

AND SPECIFICATIONS

3 LEAK TESTING OVERVIEW

4 FEATURE SUMMARIES

5 INSTALLATION

6 PARTS IDENTIFICATION

AND FUNCTIONS

7 BASIC OPERATIONS

8 COMPENSATION MODE

(MASTER-PRESET)

9 CALIBRATION (CAL) MODE

10 ORIGINAL (ORG) MODE

11 INTERFACE

12 MAINTENANCE AND

TROUBLESHOOTING

13 APPENDIX

TABLE OF CONTENTS 1

TABLE OF CONTENTS

1INTRODUCTION...........................................................................................................................5

1.1 Introduction...............................................................................................................................................5

1.2 Safety Hints ..............................................................................................................................................5

1.3 Notes ........................................................................................................................................................6

2GENERAL INFORMATION AND SPECIFICATIONS....................................................................7

2.1 General Information..................................................................................................................................7

2.2 Features ...................................................................................................................................................7

2.3 Specifications ...........................................................................................................................................9

2.3.1 General Specifications ......................................................................................................................9

2.3.2 Test Pressure Gauge........................................................................................................................9

2.3.3 Timer Setting...................................................................................................................................10

2.3.4 Leak Rate Limit ...............................................................................................................................10

2.3.5 Model Classifications ......................................................................................................................10

3LEAK TESTING OVERVIEW ......................................................................................................11

3.1 Theory of Leak Test................................................................................................................................11

3.1.1Stage Summary ..............................................................................................................................11

3.1.2 Internal pressure changes of the tested part and master...............................................................12

3.2 Leak Rate Theory and Equations...........................................................................................................12

3.3 Estimating the Test Timer.......................................................................................................................14

4FEATURE SUMMARIES.............................................................................................................15

4.1 Master-Preset .........................................................................................................................................15

4.1.1 Theory of Master-Preset .................................................................................................................15

4.1.2 Master-Preset operation .................................................................................................................15

4.1.3 When to execute a Master-Preset process ....................................................................................16

4.2 Leak Calibration (Patented)....................................................................................................................16

4.3 Two-Level Limit Setting and Noise Reduction (NR) Mode.....................................................................17

4.4 Air-Operated Valve Performance and DPS Sensitivity Checks .............................................................17

4.5 Sensor Protection ...................................................................................................................................18

4.5.1 Cleaning pneumatic circuit by Exhaust air blow (DL3) ...................................................................18

4.5.2 External exhaust valve-ready .........................................................................................................18

4.6 CAL ports................................................................................................................................................18

4.7 Clamp Output .........................................................................................................................................19

4.8 Exhaust Interference Prevention ............................................................................................................19

5INSTALLATION ..........................................................................................................................21

5.1 Installing the Unit ..................................................................................................................................21

5.1.1Using Quick Mounting Brackets (standard) ....................................................................................21

5.2 Electrical Connection..............................................................................................................................23

5.3 Pneumatic Connection ...........................................................................................................................24

5.3.1 Connection ports.............................................................................................................................24

5.3.2 Pressure sources ............................................................................................................................24

5.3.3 Notes on source air.........................................................................................................................25

5.4 Connecting Master and Tested part .......................................................................................................25

5.4.1 Notes on designing a sealing fixture...............................................................................................25

5.4.2 Master installation ...........................................................................................................................27

5.4.3 Choosing proper connection to the tested part and the master .....................................................28

5.5 Leak Tester Installation Environment .....................................................................................................29

5.6 Procedure for installation and adjustment ..............................................................................................30

6PARTS IDENTIFICATION AND FUNCTIONS.............................................................................33

6.1 External Appearance ..............................................................................................................................33

6.1.1Indicators ........................................................................................................................................34

6.1.2 Keyboard.........................................................................................................................................35

6.1.3 Characters Appearing on the Digital Indicator ..............................................................................36

6.1.4 Leak Test Stages ............................................................................................................................37

6.2 Settings and LED Indications .................................................................................................................38

7BASIC OPERATIONS.................................................................................................................39

7.1 Turning on Power ...................................................................................................................................39

7.2 Setting a Test Pressure ..........................................................................................................................39

7.3 Test Pressure Gauge Upper and Lower Limit Setting............................................................................39

2 TABLE OF CONTENTS

7.4 Names of Test Pressure Gauge Components (Low · Medium / Vacuum Pressure) ............................ 40

7.4.1 Output Mode .................................................................................................................................. 40

7.4.2 Setting test pressure limits............................................................................................................. 41

7.4.3 Locking the key of the test pressure gauge ................................................................................... 42

7.4.4 Zero reset of the test pressure gauge............................................................................................ 42

7.4.5 Test pressure gauge error display ................................................................................................. 42

7.5 Names of Test Pressure Gauge Components (High Pressure) ............................................................ 43

7.5.1 Output Mode .................................................................................................................................. 43

7.5.2 Setting test pressure limits............................................................................................................. 44

7.5.3 Locking the key of the test pressure gauge ................................................................................... 45

7.5.4 Zero reset of the test pressure gauge............................................................................................ 45

7.5.5 Test pressure gauge error display ................................................................................................. 45

7.6 Unlocking the Keyboard ........................................................................................................................ 46

7.7Switching Remote to/from Manual......................................................................................................... 46

7.8 Start and Stop........................................................................................................................................ 46

7.9 Switching Channels ............................................................................................................................... 46

7.10 Switching Modes ................................................................................................................................... 47

7.11 Measurement Mode............................................................................................................................... 47

7.11.1 Viewing Differential pressure sensor (DPS) offset......................................................................... 47

7.11.2 Viewing raw output of detected differential pressure ..................................................................... 48

7.12 Timer Settings........................................................................................................................................ 48

7.12.1 Viewing........................................................................................................................................... 48

7.12.2 Entry............................................................................................................................................... 48

7.13 Limit Setting ........................................................................................................................................... 49

7.13.1 Viewing........................................................................................................................................... 49

7.13.2 Entry............................................................................................................................................... 49

7.13.3 Limit setting with NR (Noise Reduction) is activated ..................................................................... 49

7.13.4 Two-level limit setting..................................................................................................................... 49

7.14 Unit selection ......................................................................................................................................... 50

7.15 Charge Hold........................................................................................................................................... 50

8COMPENSATION MODE (MASTER-PRESET).......................................................................... 51

8.1 Sampling Master-Preset value .............................................................................................................. 51

8.1.1 Preparation..................................................................................................................................... 51

8.1.2 Sampling by manual operation ...................................................................................................... 52

8.1.3 Sampling externally through control I/O port ................................................................................. 53

8.2 Error message during Master-Preset sampling..................................................................................... 53

9CALIBRATION (CAL) MODE ..................................................................................................... 55

9.1 Leak Calibration..................................................................................................................................... 55

9.1.1 Preparation..................................................................................................................................... 55

9.1.2 Sampling drift value ....................................................................................................................... 55

9.1.3 Leak calibration using a Leak Master ............................................................................................ 56

9.1.4 Leak calibration using a volumetric-variable Leak Calibrator ........................................................ 56

9.1.5 Go/No Go judgement during leak calibration................................................................................. 57

9.2 DPS Offset Calibration .......................................................................................................................... 57

9.3 DPS Span Inspection ............................................................................................................................ 58

9.3.1 Connecting a Pressure Calibrator.................................................................................................. 58

9.3.2 Changing gain coefficients............................................................................................................. 58

9.4 No-Leak Test ......................................................................................................................................... 59

9.5 No-Leak Test Under Atmospheric Pressure.......................................................................................... 59

0ORIGINAL (ORG) MODE ........................................................................................................... 61

10.1 ROM Version Information (P-1) ............................................................................................................. 61

10.2 Memory Switch Settings (P-2) ............................................................................................................... 61

10.2.1 How to move to memory switch to be set ...................................................................................... 61

10.2.2 How to change settings.................................................................................................................. 61

10.2.3 Memory Switch Table .................................................................................................................... 62

10.3 Initialization (P-3) ................................................................................................................................... 65

10.3.1 Manufacturer’s settings.................................................................................................................. 65

10.4 Channel Copy (P-4)............................................................................................................................... 65

10.5 Noise Reduction (NR) (P-5)................................................................................................................... 66

10.6 Serial Number Setting ........................................................................................................................... 66

1INTERFACE ............................................................................................................................... 67

11.1 Control I/O Port...................................................................................................................................... 67

TABLE OF CONTENTS 3

11.2 Channel Selection ..................................................................................................................................70

11.3 Stage Number Output.............................................................................................................................70

11.4 External Signal Timing Charts................................................................................................................71

11.5 Serial Communications Interface ...........................................................................................................72

11.5.1 Interface specifications ...................................................................................................................72

11.5.2 Output formats ................................................................................................................................77

11.5.3 Data format .....................................................................................................................................78

11.5.4 Checksum .......................................................................................................................................80

2MAINTENANCE AND TROUBLESHOOTING ............................................................................81

12.1 Daily Items to Check and Maintain.........................................................................................................81

12.2 Monthly Items to Check and Maintain ....................................................................................................81

12.3 Annual or Semiannual Inspection Items.................................................................................................81

12.4 Error Messages ......................................................................................................................................82

12.4.1 Errors and Treatment......................................................................................................................82

12.4.2 E-3: Excessive Differential Pressure Sensor Zero-point Shift......................................................82

12.4.3 E-4 Improper test pressure ..........................................................................................................83

12.4.4 E-5: Air-operated Valve Inactive ..................................................................................................83

12.4.5 E-9 Pressurization valve error......................................................................................................83

12.5 Leak Test Troubleshooting.....................................................................................................................84

12.5.1 When No-Go judgements occur consecutively...............................................................................84

12.6 Locating Leaks in Places Other Than the Leak Tester ..........................................................................85

3APPENDIX ..................................................................................................................................87

13.1 EXTERNAL APPEARANCE...................................................................................................................87

13.2 PNEUMATIC CIRCUIT...........................................................................................................................88

13.2.1 INTELLIGENT I AIR CIRCUIT LS-1866 .........................................................................................88

13.3 Pressure Unit Conversion Table ............................................................................................................89

13.4 Flow Unit Conversion Table ...................................................................................................................89

13.5 CE Marking.............................................................................................................................................89

13.6 Information to Users (FCC Rules) ..........................................................................................................90

1 INTRODUCTION 5

INTRODUCTION

Thank you very much for purchasing COSMO’s LS-1866 Air Leak Tester. This operation manual provides

information about the LS-1866 Air Leak Tester, including its functionality, operating instructions, and precautions

in handling. Before using the product, read this manual carefully to assure proper handling. After reading, keep

the manual in a safe place for reference.

Instructions to abide by for using the product safely without risking physical injury to the user and other persons,

and property damage are given below.

[Explanations of the signs]

Signs

Explanation

WARNING Failure to take or avoid a specific action could result in death or serious physical harm to

the user.

CAUTION Failure to take or avoid a specified action could result in small physical harm to the user

or property damage.

[Explanation of the symbols]

Δ This symbol denotes a warning to alert the user. A specific description of the warning follows.

(Example: Electrical shock hazard)

a) Ground the unit before plugging it into a power source.

The unit, if not grounded, would be liable to electrical

shock hazards. Never connect the grounding

conductor to a gas pipe. Grounding the unit to a gas

pipe could result in fires or electrical shock hazards.

b) If the metallic part of the power plug or any

surrounding area is found dusty, wipe off thoroughly

with a dry cloth. Continued use could result in fires or

electrical shock hazards.

c) Never run the unit from source voltages other than

marked rated. Running the unit from a nonstandard

source voltage could result in fires or electrical shock

hazards.

d) If the unit should be dropped or damaged, switch it off

and disconnect the power plug from the receptacle.

Continued use could result in fires or electrical shock

hazards.

e) Do not apply air pressure beyond the pressure rating

of the unit. Excessive pressure input could cause

catastrophic component failure and/or injury.

f) If foreign matter, such as water and oils, should get

inside the instrument, switch it off immediately and

unplug it from the receptacle. Continued use could

result in fires or electrical shock hazards. Use

particular care when installing the unit in an

environment where water or oils are used 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 unit is not customer-serviceable. Customer

servicing could result in fires or electrical shock

hazards.

i) Replace with a fuse of the same rating as the one that

is built in the unit. Use of a nonstandard fuse could

result in fires or electrical shock hazards.

j) Discontinue using the unit when:

• The unit smokes.

• The unit emits abnormal noises.

• The unit developed problems not covered in the

operations manual.

• The unit cannot be operated as indicated in the

operations manual.

To avoid electrical shock hazards or physical harm,

disconnect the power cable and remove the pressure

source from the unit. Continued use could result in

fires or electrical shock hazards.

WARNING

6 1 INTRODUCTION

a) 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.

b) To avoid damage to the power cable, which could

result in fires or electrical shock hazards, observe

these precautions:

• Do not damage, modify or apply undue force to

the power cable.

• Before servicing the unit, disconnect the power

plug from the receptacle.

• Do not handle the power plug with wet hands.

• When disconnecting the power plug, do not pull

the power cable.

c) Ensure correct cabling. Incorrect cabling could result

in damage to the unit and surrounding hardware.

d) Mount the unit in firm position in a frame capable of

fully sustaining its load. Do not install the unit in a

violently vibrating, sloped or any other rickety place. If

installed in these environments, the unit could fall

down or drop, resulting in physical harm.

e) Do not step on top of the unit or place a container filled

with water, oils/soapy water, or other similar objects on

its top. These objects might spill, causing physical

harm, or electrical shock hazard, rust or other

damage.

f) Do not disassemble the unit. If disassembled, the unit

could malfunction, resulting in physical harm or

electrical shock hazards.

g) Do not install or remove the tubing with the product

connected to an air pressure source. It could result in

physical harm.

Wear a safety goggle to protect your eyes.

h) When a leak test is completed, unclamp the tested

part after the unit has completely exhausted. Residual

pressure could result harm.

i) When carrying the unit, hold it by the bottom to keep it

from dropping. If dropped, unit could be damaged or

caused result in breakage or physical harm.

j) When packing the product for shipment, remove its

projections, such as rear panel-mounted filters and

regulators, and wrap it with cushioning material as a

whole to guard against damage during transit.

k) Wipe out the unit lightly with a dry and soft cloth for

maintenance. When the unit is with heavy dirt, dilute

the neutral detergent with water, soak the cloth in the

detergent, squeeze the cloth, and wipe the dirt out.

Organic solvent should not be used.

l) Put on steel-toe boots when transferring the product

for shipping, installation, dismantling. Neglecting it

could result in physical harm by dropping the product.

m) Handle the product according to the instructions in this

operation manual or the protection feature equipped

with the product will be compromised.

a) The information in this document is subject to change without notice for the sake of 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 and the consequences of the tests.

d) To minimize incorrect test results, this unit comes complete with self-check functions to detect certain improper settings

and operations, and internal equipment malfunctions and thus to prevent incorrect judgments from being delivered. The

scope of monitoring by self-checking, however, is limited. Verification of the unit performance and operations using

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 these 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 the user has about using our product.

CAUTION

2 GENERAL INFORMATION AND SPECIFICATIONS 7

GENERAL INFORMATION AND SPECIFICATIONS

LS-1866 is an air leak tester based on a differential pressure method that tests the air tightness of various

parts and products. Air leak tester allows not only enhancing a detection capability but also an automated

detection process. Ideal for professional and industrial use.

Housing a high-sensitivity, high-pressure differential sensor and air-operated valves free from thermal

effects, the unit is built of intelligent air circuitry that makes on various checks during each run of testing,

including valve action and sensor sensitivity checks, to assure exceptional performance and reliability. Its

Master-Preset feature and noise reduction feature support assures enhanced detectability or shorter test

times. Other user conveniences include compatibility with various kinds of tested parts, direct reading of

leak rates, and easy-to-service CAL ports.

a) Master-Preset compensation feature

• This feature compensates the drift errors caused by the volume difference between the tested part

and the master, adiabatic compression effect and change in ambient temperature.

• Cosmo’s patented Master Chamber that is easy to adjust and maintain can be used as a Master

(Reference) to reduce installation cost.

• Suitable measurement for different part can be achieved by executing Master-Preset process.

b) 2 levels of limit settings and Noise Reduction (NR) mode

• Sorts out NG-judged part by magnitude of leakage.

• In NR mode, DET stage is repeated for the rejected parts fell between the two limits to minimize

false rejection good parts.

c) Leak rate unit (mL/min) can be displayed.

• Differential pressure is converted into leak rate by calibration with Leak Master (LM-1B).

d) High-performance differential pressure sensor and Intelligent I Pneumatic Circuit

• Equipped with a differential pressure sensor that is highly sensitive, proof against high pressure

and low volume. The pneumatic circuit is simple yet full function.

• Equipped with air operated valves with high flow capacity, which is free from thermal effect.

• Includes self-cleaning feature to protect sensor from being contaminated with water and oil inside

the tested part.

• The sensor and the valve performance is automatically checked at the end of the each test cycle to

ensure reliability of leak testing.

e) Multi-channel

• 16 different sets of test parameters can be programmed independently. A channel copy feature

eases multi-channel setting.

f) CAL ports

• CAL ports are easily accessible on the front panel for daily sensitivity check using a Leak Master or

a Leak Calibrator. These ports are also convenient for periodic calibration of the differential

pressure and the pressure gauge.

g) Test pressure and Leak limit setting monitoring

• Test pressure is digitally displayed.

• Upper and lower limits of test pressure can be programmed

• Leak limit setting can always be monitored on the sub-panel

h) Serial communication

• The tester can be connected to computer and/or printer through the serial communication port to

maintain and control the test data.

• Use of a multiplexor enables to connect multiple testers to a single computer.

8 2 GENERAL INFORMATION AND SPECIFICATIONS

i) Quick mounting brackets

• Tester can be removed from the machine easily from the front side by using these brackets.

j) Clamp signal

• This tester can control external solenoid valve to drive air cylinder. Use of this feature allows

building a simple and low cost machine system.

k) Fitness to overseas use

• The power inlet can accept 100 to 240 VAC ±10 % at 50/60 Hz single-phased power supply,

100VA max. The standard power cord supplied with the leak tester is rated for 100 to 120.

Special power cord for 125 to 240 VAC is available upon request.

l) Data storage in flash memory

• There is no need of battery replacement because all the test parameters are stored in flash

memory.

m) Channel copy

• Test parameters of a channel can be copied to the another. This makes multi-channel program

easier.

n) Exhaust interference prevention

• When using several leak testers to measure different cavities on the same part simultaneously, this

prevents jumps in the leak tester readout during the exhaust of one of the other testers.

Table of contents

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