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9 CALIBRATION (CAL) MODE

9.3.1 Connecting a Pressure Calibrator

This section provides the procedure of the DPS span inspection using the Pressure Calibrator.

<Operation>

1) Turn on the power of the Pressure Calibrator about 10 minutes before calibration for a warm-up.
2) Unplug the sealing plugs from both the WORK CAL. PORT and the MS PORT-side LEAK CAL. ports on

the front panel of the tester.

(The LEAK CAL port is M10 ×1.5. A fitting, M10-Rc/1/4, is available upon request.)

3) Disconnect the 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.

4) Close the both the WORK and the MASTER-side stop valves.
5) Connect WORK port of the pressure calibrator to WORK CAL. PORT, and MASTER port of the

pressure calibrator to MS PORT.

6) While

oFS

is displayed on the leak rate indicator, pressing the START key switches the display to

SPn

Valves are actuated and the BAL stage is followed by the DET stage, with the output of the DPS being

displayed at the completion of auto-zeroing.

7) Close the shutoff valve of the pressure calibrator and generate a pressure (±100 Pa, ±950 Pa) by

turning the knob of the pressure calibrator. Verify if the reading of the tester and that of the pressure

calibrator are the same.

8) Press the STOP key to enter an atmospheric state. Press again to return to Measurement mode.

9.3.2 Changing gain coefficients

1) If there is only a slight difference between a reading and the reference value, the DPS span can be

adjusted with the key operation. Displayed DPS readings are multiplied by a gain coefficient in all

modes. Range of the Gain coefficients is between 0.9 and 1.1.

Reading = DPS × Gain coefficient

2) While a span is displayed during the DET stage, the gain coefficient can be changed. Introduce

differential pressure of +950 Pa to the tester with Pressure calibrator, and press

▲

UP or DOWN

▼

key

to equalize the displayed values of the tester and Pressure calibrator during the DET stage. Repeat

the same procedure for -950 Pa.

3) If the gain coefficient is changed, the reading blinks. Pressing the ENTER key stores the gain

coefficient in the memory. Pressing the STOP key cancels the change.

4) Verify the gain coefficient.

The gain coefficient can be viewed by pressing the

◄

LEFT and RIGHT

►

keys simultaneously for 1

second or longer.

Be sure to let the air in the tester exhaust completely, or the

calibrator may be damaged because of over pressurization.

CAUTION

DPS span calibration is performed by the Cosmo’s representatives.

One’s who has been specially trained by Cosmo could also perform it. In

such case Cosmo does not guarantee the value after the calibration.

CAUTION

DPS calibration is required if the reading of the DPS output

gets out of the allowable range.

NOTE

Summary of Contents for LS-1866

Page 1: ...ERAL 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 ...

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Page 3: ...ecks 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 5 5 INSTALLATION 21 5 1 Installing the Unit 21 5 1 1 Using 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 ...

Page 4: ... activated 49 7 13 4 Two level limit setting 49 7 14 Unit selection 50 7 15 Charge Hold 50 8 8 COMPENSATION 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 9 9 CALIBRATION CAL MODE 55 9 1 Leak Calibration 55 9 1 1 Preparation ...

Page 5: ...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 1 13 3 APPENDIX...

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Page 7: ...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 hazard...

Page 8: ... 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...

Page 9: ...on 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 Equi...

Page 10: ...upply 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...

Page 11: ...trol I O port Current sink Open collector Outputs DB 37P Male connector Communications functions Serial communication port can be switched to printer format Operating temperature 5 to 40 C Storage temperature 20 to 70 C Ambient humidity 80 RH or less no dew condensation Weight M L V 6 3 kg H10 H15 8 1kg Standard components Pressure regulator Oil mist separator except Vacuum pressure type Air filte...

Page 12: ...g point 2 HIH and LL limit settings for DET stage Set to somewhere between 10 and 90 of the HI and LO limits of the DET stage 3 Judgment accuracy Matches with leak rate readings 2 3 5 Model Classifications LS 1866 A B C A Pneumatic Circuit A1 Intelligent I Pneumatic Circuit AS01 Small volume Intelligent I Pneumatic Circuit Recommended test condition Part volume small 50 mL or smaller and leak stan...

Page 13: ...art resulting from a leak 3 1 1 Stage Summary Stages A Start After clamping and sealing a tested part initiate a start signal B Charge CHG stage Pressurizes the tested part and the master C Balance BAL stage Isolates tested part and master from pressure supply and each other to let the internal pressure stabilize Large leak is detected during this stage as No Go D Detection DET stage Detects small...

Page 14: ...ed on the conversion equation See Section 4 2 a Pressure and Volume Relationship The relationship between pressure and volume is stated in Boyle s law Boyle s law for an ideal gas pressure multiplied by volume is a constant if the temperature is constant In mathematical form PV constant where P is in absolute pressure units A leak is measured by a change in pressure The amount of leakage to atmosp...

Page 15: ... volume of air that leaked out of a part is known this can be converted to a leak rate by knowing for how long t the pressure change ΔP was measured Mathematically this is expressed as follows Where Q Leak rate in volume per time mL min P Pressure drop due to a leak Pa Ve Equivalent internal volume mL T Detection time The LS 1866 uses the above equation for the calculation of the leak rate Note th...

Page 16: ... a large leak limit setting during BAL initiates the DET stage without a large leak being detected in this stage In this case the differential pressure exceeds its LIMIT before the DET timer ends resulting in a DPS output saturation Further when Leak Master differential pressures are sampled to establish an equivalent internal volume leak coefficient too long a BAL timer can produce a differential...

Page 17: ...ter Preset operation is executed by using an actual tested part In this stage D1 is measured in the same measurement time as in a regular leak test Then the STB stage stability time is initiated to equalize the pressure of the tested part and that of the master with each other through CHG until drifts virtually no longer exist when D2 is measured The drift value Master Preset value can be determin...

Page 18: ... its equivalent internal volume The definition of internal equivalent volume Ve is the volume of air of the entire Work side pneumatic circuit at a particular test pressure It also includes a diaphragm deformation factor of the DPS Ve is used as leak coefficient K Ve in the leak rate calculation Once equivalent internal volume is measured the differential pressure detected in the leak test DET sta...

Page 19: ...r r O Op pe er ra at te ed d V Va al lv ve e P Pe er rf fo or rm ma an nc ce e a an nd d D DP PS S S Se en ns si it ti iv vi it ty y C Ch he ec ck ks s Air operated valve malfunction or DPS sensitivity degradation can lead to serious measurement errors In order to prevent such failure the sensor and air operated valve performance is automatically checked at the end of the each test cycle to ensure...

Page 20: ...5 2 External exhaust valve ready Air operated valve are installed between the tested part and the master and the leak tester to effect external exhaust An external exhaust valve unit G3 is separately required The standard leak tester controls the G3 This feature is not available for vacuum pressure leak tester 4 4 6 6 C CA AL L p po or rt ts s The front panel contains inspection ports that connect...

Page 21: ...its cycle while the other s are still in the leak test process This is called Exhaust Interference Exhaust interference can cause jumps in the leak tester readout during the exhaust of one of the other testers both in normal leak test and Mastering processes In order to prevent this all leak testers on the station must be synchronized with one another before exhausting air With this software the l...

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Page 23: ...he tester is to be mounted The mounting brackets A and B are assembled in the bottom of the tester body 2 Mounting base Attach the mounting base where the tester is to be mounted using four M3 screws The mounting base cannot be attached to a rugged surface An outline drawing of the leak tester body is shown below Clamp the mounting base at the screw pitches indicated The leak tester does not come ...

Page 24: ... an LS 1866 fitted with mounting brackets A and B somewhat in front of the intended site of installation Push the LS 1866 backward to force the tip of the mounting bracket B into the square holes in the mounting base Push the LS 1866 until the mounting bracket A touches the mounting base With the hole in the mounting bracket A and the screw hole in the mounting base aligned with each other secure ...

Page 25: ...the I O port connector Electrical Shock Hazard Turn off the main power before connection CAUTION Electrical Shock Hazard operating the leak tester from a nonstandard power source can result in electrical shock hazards or fire CAUTION Use a power line free from a noise source If the power line falls on a path of noise propagation use an insulating transformer or noise cut transformer for their nois...

Page 26: ... the test pressure Up to 1 8 MPa H15 High 1 5 MPa or lower Connect a pressure source sufficiently higher than the test pressure Up to 1 8 MPa V Vacuum 100 kPa or lower Connect a vacuum pump 1 Source pressure regulator Connect a source pressure regulator to the leak tester s oil mist separator directly or with an as short a separation as possible through a sufficiently broad pipeline to prevent sho...

Page 27: ...aks The seal must be designed to prevent leaks from inside the tested part such as other sealed spaces gaps between part and seal and cavities that are not open to atmosphere as well as external leaks Since those internal leaks are hardly visually noticeable it requires extra attention 2 Reducing internal volume of tested part A smaller internal volume allows a shorter test time and gives better s...

Page 28: ...le the part is submerged the tester should always be on charge hold Never exhaust air while the tested part is submerged under water Put an external exhaust valve between the tester and the tested part Refer to 4 5 2 Install leak tester higher level than water surface 8 Using multiple leak testers on a single system To ensure that the all the clamping fixtures do not interfere each other build eac...

Page 29: ...of fast temperature stability which derives excellent pressure stability and repeatability for long term or period Inexpensive Compact and space saving 3 Location of master Install the master where there will be minimal effects due to vibration from motors heat wind from fans air conditioning of heating vents In cases where these situations cannot be avoided use a curtain or screen However it is n...

Page 30: ...ss 0 41 to 1 57 mm Used in the lower test pressure range Test pressures up to 200 kPa N2 tubing group 2 N2 2 Inner diameter 1 60 to 6 40 mm thickness 0 79 to 3 15 mm Used in the higher test pressure range Test pressures up to 3 MPa Tubing grouped by millimeter Manufacturer Nitta Moore Company N2 tubing group 4 N2 4 Inner diameter 2 to 13 mm thickness 1 00 to 1 50 Manufacturer SMC T Series tubing I...

Page 31: ...e fluctuations that could occur in the tested part Therefore partial covering will give better results b Temperature changes in tested parts Do not put the leak test station just after heating cooling welding or washing processes 4 The leak tester works best with the tested part that is ambient temperature If the temperature of the floor and test bench are different and the tested part is taken fr...

Page 32: ... and test conditions 7 9 4 Set a test pressure Use the regulator on the rear of the leak tester and the front panel pressure indicator 7 2 5 Set upper and lower limit test pressures Using the and buttons on the test pressure gauge set an appropriate test pressure range 7 3 c Preliminary setup of test parameters Setting basic test parameters in Measurement mode See 1 Set preliminary stage timers Se...

Page 33: ...quired for running a leak test See 1 The channel copy feature makes it easier to set up multiple channels The channel copy feature makes it easier to set up multiple channels 3 3 10 4 2 Set leak rates in a leak rate unit such as mL min 7 14 3 Set limit values 7 13 4 Set NR mode Set NR mode to deal with high percentages of noise presence as needed 7 13 3 10 5 h Starting leak test Complete the setti...

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Page 35: ... stop valve H Tested part WORK side port Connector Rc1 4 part stop valve I Exhaust port Exhaust silencer Exhausts pressure from the master and the tested part at the end of leak test cycle J Pilot pressure inlet Connector 6mm one touch joint filter regulator Connect an air pressure regulated through a regulator to this port for driving air operated valves K External signal connector 1 Can be used ...

Page 36: ...ndicates a stage when on or blinking F REM LED lamp On when in remote off in manual G COMP LED lamp On when Master Preset compensation is on H KEYBOARD UNLOCK lamp On when the keyboard is unlocked I Leak unit LED lamp Switched between mL min and min as standard kPa available as an option J Leak rate HI limit indicator WORK side limit setting K Channel number indicator L HI NO GO LED lamp Tested pa...

Page 37: ...Used to pressurize or evacuate for vacuum testers the master and tested part continuously See Section 7 15 F MAN REM key Used to switch the leak tester mode to remote or manual See Section 7 7 G CHANNEL UP key Used to increments a value or change the channel See Section 7 9 H CAL COMP key Used to calibrate leak tester calculation of leak coefficient K Ve See Section 8 and Section 9 I UNIT DOWN key...

Page 38: ...36 6 PARTS IDENTIFICATION AND FUNCTIONS 6 1 3 Characters Appearing on the Digital Indicator Character Symbol Character Symbol Character Symbol 0 A L 1 b n 2 C o 3 d P 4 E r 5 F S 6 G t 7 H U 8 i v 9 J y ...

Page 39: ... the differential pressure sensor output has shifted by 1000 Pa or more Balance BAL Balancing leak judgement The auto zero function is executed for leak judgement in BAL stage The leak rate is displayed on the leak rate indicator in the selected unit for judgement Balancing limit settings for the master and tested part are displayed on the limit setting indicators HI and LO in the selected unit De...

Page 40: ...NO GO LED blinking together with the stage guidance display to distinguish between a work setting and a tested part setting Stage names and guidance Stage name Guidance display Leak rate indicator Judgement LEDs LO NO GO HI NO GO Time settings Charging delay dL1 Charging CHG Balancing delay dL2 Balancing bAL Detection dEt End delay bL3 End End Stabilization Stb Alarm settings BAL HI WORK side bAL ...

Page 41: ...rst 7 7 3 3 T Te es st t P Pr re es ss su ur re e G Ga au ug ge e U Up pp pe er r a an nd d L Lo ow we er r L Li im mi it t S Se et tt ti in ng g The pressure gauge indicates the error and the tester transmits the error signal when the test pressure exceeds the programmed upper and lower limit limits Setting the limits eases test pressure management The smallest settable test pressure limits each ...

Page 42: ...N C Mode selection key RUN MODE This is the pressure detection state MENU SETTING MODE PRO MODE not use it D Unit display E LED display Display of pressure value output mode setting value F Sub display G Setting value UP key H Setting value DOWN key 7 4 1 Output Mode EASY mode Hysteresis mode Window comparator mode can be set However this tester uses Window comparator mode Window comparator mode S...

Page 43: ...imits The initial setting of the pressure gauge allows programming the common upper and lower limits for all the channels 1 Setting procedure 2 Pressure limit set mode Upper lower limit set in RUN mode Display the setting condition value in Sub display ...

Page 44: ...power OFF and check the load Pressure is applied during zero point adjustment Applied pressure at the pressure port should be brought to atmospheric pressure and zero point adjustment should be done again External input is carried out outside the rated pressure range Applied pressure range should be brought within the rated pressure range Communication error Disconnection faulty connection etc Che...

Page 45: ...tus of pressure setting mode selected indication unit and error code B Operation indicator Display operation condition of the pressure gauge C UP key Alters the mode or increases ON OFF set value D DOWN key Alters the mode or decreases ON OFF set value E S key Press this key to change to mode and set a value 7 5 1 Output Mode Window comparator mode Switch output can be turned ON or OFF within a pr...

Page 46: ...ng procedure b Pressure limit set mode Pressing key once increments the value by one digit Keep pressing it increments the value continuously Pressing the key once decrements the value by one digit Keep pressing it decrements the value continuously There are 5 different pages within Initial Set mode Press SET key to switch pages The manufacturer s setting in each page is the following Never alter ...

Page 47: ... is applied In 1 sec the mode will reset to the measurement mode 1 digit of the zero clear range changes with individual product differences Perform zero clear operation again after restoring the applied pressure to an atmospheric pressure condition zero reset again Pressurizing error HHH Pressure exceeding the high limit of the set pressure range is applied Reset applied pressure to a level withi...

Page 48: ...evice through the control I O port The MAN LED turns on b In manual The leak tester can be controlled by the keyboard The MAN LED turns off 7 7 8 8 S St ta ar rt t a an nd d S St to op p a Start When in manual pressing the START key starts a leak test When in remote transmitting START signal through control I O port starts a leak test b Stop Pressing the STOP key during leak test operation clears ...

Page 49: ...s Start and stop of leak test and charge hold are allowed in manual mode Start and stop of leak test charge hold and Master Preset value automatic measurement are allowed 7 11 1 Viewing Differential pressure sensor DPS offset Press the STOP key for 1 second or longer while tester is in Measurement mode and the raw output of DPS is displayed on the leak rate indicator as long as the STOP key is pre...

Page 50: ...G dL2 bAL dEt DL3 End Press the LEFT key to move backwards 5 When the Master Preset feature is on each time you press the RIGHT key the display will change in the following sequence dl1 CHG dL2 bAL dEt STB DL3 End Press the LEFT key to move backwards 7 12 2 Entry A timer setting will be displayed on both HI and LO leak limit indicators If the keyboard is unlocked the least significant digit of the...

Page 51: ...t to left Pressing it for 1 second or longer reverses the polarity 3 After setting has been changed the LEFT and RIGHT keys become inoperable until the ENTER key is pressed Press the ENTER key to complete the setting or press the STOP key to cancel it after that tester returns to Measurement mode 7 13 3 Limit setting with NR Noise Reduction is activated When HI and LO leak limits are set those lim...

Page 52: ...s the master and tested part continuously The purpose of charge hold is to find the location of leak For example when using a pressure type tester this could be done by applying a sop solution to pipe fittings or other possible leak paths in the pneumatic circuit Charge hold can be controlled also by an external device through the control I O port a Charge Hold in Manual Press the CHG HOLD key to ...

Page 53: ...he keyboard Press RIGHT and UP simultaneously for 1 second or longer 5 Turn the Master Preset compensation ON Press the CAL COMP key PrE then P d will be displayed on the leak rate indicator The Master Preset value will be displayed on the HI limit indicator and the COMP LED blinks at the same time Press the ENTER key PrE will be displayed on the leak rate indicator and oFF or on will be displayed...

Page 54: ...isplayed on HI leak limit indicator during the BAL and DET stages 5 When the DET 2 stage times out the limit setting indicator HI displays the Master Preset value Press the LEFT key for longer than 1 second to display the differential pressure of DET 1 on the leak rate indicator or press the RIGHT key for longer than 1 second to display the differential pressure of DET 2 on the leak rate indicator...

Page 55: ...k judgement when the measured differential pressure exceeds 1000 Pa or 300 Pa depending on memory switch setting during DL2 1 DET 1 and DET2 2 stages The tester makes NG judgement when the measured differential pressure exceeds HI or LO limit b The Master Preset value is not stored when NG is made c The AD overflow value is 2048 Pa or higher d The following errors may be detected P sensor offset e...

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Page 57: ...k Master is used for the Leak Calibration volumetric variable Leak Calibrator can be used as well See Section 4 2 9 1 1 Preparation 1 Connect a master and a known non leaking part 2 Prepare a Leak Master or a Leak Calibrator See Section 9 1 4 3 Unlock the keyboard 4 Press the MAN REM key to enter manual mode 5 Set the test pressure and a test pressure upper and lower limits 6 Set stage timers and ...

Page 58: ...measured drift value can be viewed on the leak rate indicator by pressing the RIGHT key for 1 second or longer 9 Press the STOP key to change the unit to mL min and return to Measurement mode 9 1 4 Leak calibration using a volumetric variable Leak Calibrator Obtain an equivalent internal volume using a Leak Calibrator LC Series Convert the measured volume change into a volumetric leak rate in mL m...

Page 59: ...ted 9 Press the STOP key to change the leak unit to mL min and return to Measurement mode 9 1 5 Go No Go judgement during leak calibration 1 Tester makes large leak judgement if the leak rate exceeds 1000 Pa or 300 Pa as selected with a memory switch during DL2 stage Tester also makes No Go judgement if the leak rate exceeds 1000 Pa during the BAL stage or the compensated leak rate exceeds 1000 Pa...

Page 60: ... pressure calibrator are the same 8 Press the STOP key to enter an atmospheric state Press again to return to Measurement mode 9 3 2 Changing gain coefficients 1 If there is only a slight difference between a reading and the reference value the DPS span can be adjusted with the key operation Displayed DPS readings are multiplied by a gain coefficient in all modes Range of the Gain coefficients is ...

Page 61: ...ges tester is no leak condition if the reading is within a range of 10 Pa 9 9 5 5 N No o L Le ea ak k T Te es st t U Un nd de er r A At tm mo os sp ph he er ri ic c P Pr re es ss su ur re e When the No Leak test result exceeds 10 Pa the cause of tester malfunction is pneumatic fault or electrical fault To find out the possible cause perform another No Leak test without applying air pressure under ...

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Page 63: ...n with memory switches 10 2 1 How to move to memory switch to be set 1 In the Original mode press LEFT or RIGHT key several times until P 2 is displayed on the leak rate indicator and displays SEt on the LO leak limit indicator 2 Pressing the ENTER key once displays a memory switch number 00 to XX on the LO leak limit indicator and 1 on the HI leak limit indicator 1 blinks if the keyboard is unloc...

Page 64: ...it in the DL2 stage 12 0 CHG stage display 3 1 13 0 1 14 0 The judgement signal is transmitted at END stage 2 1 The judgement signal is transmitted at DL3 stage 15 0 RESERVED 1 RESERVED 16 0 Pilot pressure is monitored Set to 1 for other than the pressure switch built in unit 3 1 Pilot pressure is not monitored 17 0 Test pressure is not monitored with upper and lower limits 1 Test pressure is moni...

Page 65: ...ory switch Busy signal control I O port pin 36 10 09 08 0 0 0 RESERVED 0 0 1 RESERVED 0 1 0 Standby signal 1 0 1 1 Activation of the tester is synchronized with the external limit switch 1 0 0 Held when No Go judgement and error 2 1 0 1 DET stroke signal 3 1 1 0 Activated only in the DL1 stage 1 1 1 Activated from DL1 through END 1 Activated from DL1 through END 2 Hold the Busy signal when NG judg...

Page 66: ...0Pa 13 1sec 500Pa 14 1sec 1000Pa 21 5sec 100Pa 22 5sec 300Pa 23 5sec 500Pa 24 5sec 1000Pa 31 10sec 100Pa 32 10sec 300Pa 33 10sec 500Pa 34 10sec 1000Pa Pressurization valve failure detection Verifies DPS offset during a pre determined waiting time upon completion of the leak test If DPS offset exceeds its limit error message E 9 is displayed by regarding the status of AV1 pressurization valve as no...

Page 67: ...ster Preset compensation OFF Detection DET 10 0 s Equivalent internal volume Ve 0 000 End delay DL3 0 5 s Master Preset value 0 Pa End END 0 5 s HH and LL ratio settings 10 Stabilization STB 10 0 s 1 10 0 4 4 C Ch ha an nn ne el l C Co op py y P P 4 4 Settings of a channel can be copied to another Operation 1 In the Original mode press LEFT or RIGHT key several times until P 4 is displayed on the ...

Page 68: ...imits HH NG LL NG Press the ENTER key for 1 second or longer rto will be displayed on the LO leak limit indicator and 10 will be displayed on the HI leak limit indicator The displayed value for the NR limits is the ratio of HI and LO limits to be added If the displayed value is 10 the NR limits are HI and LO limits plus 10 Example If HI is 100 and LO is 50 HH is 110 and LL is 55 4 Values can be se...

Page 69: ...Lo NG 3 NO OUTPUT 14 Good NO OUTPUT 33 MASTER NG LL NG 3 NO OUTPUT 15 Reserved 34 Time extension 2 NO OUTPUT 16 ERROR NO OUTPUT 35 END a NO OUTPUT 17 STAGE 1 NO OUTPUT 36 BUSY NO OUTPUT 18 STAGE 0 NO OUTPUT 37 Reserved 19 COM for all outputs 1 Master Preset value sampling 2 Timer extension signal is transmitted at the Noise Reduction process execution or the Master Preset value sampling 3 NG judge...

Page 70: ...e Output Open collector output Load current 100 mA at 24 VDC Load when the sum of pins 12 to 18 is 200 mA or less and the sum of pins 31 to 36 is 200 mA or less ON voltage 2 VDC max Connection method f Protection of Output Load When using the output induction load such as relay monitor etc please arrange the diode for protection ...

Page 71: ...11 INTERFACE 69 g Typical PLC connection NPN h Typical connection with PLC PNP ...

Page 72: ...F ON ON ON ON 1 11 1 3 3 S St ta ag ge e N Nu um mb be er r O Ou ut tp pu ut t Leak test stages can be identified from combinations of stage 0 and stage 1 Stage Stage 1 Stage 0 Stage number Halted DL1 OFF OFF 0 CHG OFF ON 1 BAL ON OFF 2 DET ON ON 3 DL3 to end 1 1 1 1 In the DL3 to END stages the stage number of each stage in which a judgement is rendered or a stop signal is entered is held In the ...

Page 73: ... START signals can be turned OFF while BUSY signal turns ON when the BUSY signal selection is the standard manufacturer setting 2 No HH NG and LL NG signal will be transmitted unless the leak rate in DET stage exceeds the HH or LL limit b Leak test stop c Charge hold No judgement signal will be transmitted if a stop signal is received NOTE ...

Page 74: ...ce specifications Voltage specifications EIA232 compliant Communications mode Half duplex Baud rate 9600 19 200 bps Start bit 1bit Data length 8bit Parity non parity Stop bit 1bit Delimiter CR Control line Hardware RTS CTS Output format T format and I format P format A block of output fields begins with ASCII code 23H and ends with a carriage return 0DH All output fields are separated by spaces 20...

Page 75: ...transmission is suspended while this signal is off Connected to the RS terminal of the remote equipment or the tester 1 Interface cable wiring diagram COM1 In case RS RTS and CS CTS are not used 2 Command list Control command Command Function STT CR START STP CR STOP CHS CR Charge Hold EDS CR Dumping test data at the beginning of END stage Default EDR CR Not dumping test data at the beginning of E...

Page 76: ...ison DT1_Lo 0999 000 to 0999 000 Leak rate unit WDHI 0123 000 CR DET_Hi limit Multi comparison DT2_Hi 0999 000 to 0999 000 Leak rate unit WDLO 0123 000 CR DET_Lo limit Multi comparison DT2_LO 0999 000 to 0999 000 Leak rate unit WDL1 0123 000 CR DL1 Charge delay timer 0000 100 to 0999 900 s WCHG 0123 000 CR CHG Charge timer Multi comparison CG1 0000 000 to 0999 900 1 s WDL2 0123 000 CR DL2 Balance ...

Page 77: ...nd GG CR Data field Symbol Data type Unit Min Max Remarks Identification No S 2 digit integer 00 99 Channel C 2 digit integer 00 15 Command ASCII code Checksum G 2 digit integer 00 FF Data from to is summed up and its two s complement is taken 3 Writing commands Following commands are effective only during rest stage in measurement mode for remote operation Transmitted data ACK or error response W...

Page 78: ...teger 00 99 Channel C 2 digit integer 00 15 Command ASCII code Data V Fixed point 0000 000 9999 000 Checksum G 2 digit integer 00 FF Data from to is summed up and its two s complement is taken Example Writing command WDET_0000 500 programs DET timer 0 5s Limit ratio can be set every 10 from 10 to 90 of the leak rate limits Hi and Lo limits The tester transmits error if other numbers are received N...

Page 79: ... T format SS_00_J_ VV VV GG CR Data field Symbol Data type Unit Min Max Remarks Identification No Symbol 2 digit integer 00 99 Judge field J ASCII code 1 digit hexadecimal 0 D 0 No test data 1 Lo NG 2 GOOD 4 Hi NG 9 LL NG C HH NG D ERROR Data V 4 digit floating point Leak rate unit 0 000 0999 Checksum G 2 digit integer 00 FF Data from to is summed up and its two s complement is taken Transmitted d...

Page 80: ...ak tester transmits leak test data after every test execution SS_00_J_ LLL L GG CR Data field Symbol Data type Unit Min Max Remarks Identification No S 2 digit integer 00 99 Judgement J ASCII code 1 digit hexadecimal 1 D 0 No test data 1 Lo NG 2 GOOD 4 Hi NG 9 LL NG C HH NG D ERROR Leak L Floating point Leak rate unit 0 000 0999 Checksum G 2 digit integer 00 FF Data from to is summed up and its tw...

Page 81: ... set to the memory switch setting P 2 23 the output of the setting is 23 2 WAIT DSP LIMIT CH 0 TOTAL COUNT TOTAL 0000 GOOD 0000 HH NG 0000 Hi NG 0000 LL NG 0000 Lo NG 0000 CH 0 UNIT LIMIT LEAK U Pa BAL Hi 650 BAL Lo 250 DET HH 72 0 DET Hi 060 DET Lo 020 DET LL 24 0 NR 02 CH 0 COEF TIMER K Ve 003 960L COMP OFF 000 Pa DL1 0000 5s CHG 0005 0s DL2 0001 0s BAL 0003 0s DET 0003 0s STB 0005 0s DL3 0000 5...

Page 82: ... data 0 0 0 0 2 0 0 0 4 3 2 CR ASCII Code HEX 23 30 30 20 30 30 20 32 20 2D 30 30 30 2E 34 3A D DEC 35 48 48 32 48 48 32 50 32 45 48 48 48 46 52 58 13 DEC notation HEX notation Lower two digits Note HEX notation BIN notation Calculation of Data strings Sum 718 2CE CE 11001110 Sum of the every ASCII code Complement 719 D31 31 110001 Complement of the sum Two s complement 718 D32 32 110010 Adds 1 to...

Page 83: ...nt ta ai in n a Check the oil mist separators and filter b Check for the presence or absence or water oils and dust in the pneumatic circuit c Items to Check and Maintain d No Leak test with the MASTER and WORK side stop valves closed See Section 9 4 e Check the test pressure f Leak calibration See Section 9 1 1 12 2 3 3 A An nn nu ua al l o or r S Se em mi ia an nn nu ua al l I In ns sp pe ec ct ...

Page 84: ...test pressure or reset the test pressure limits See Seccion12 4 3 Detected at the end of CHG stage 5 E 5 Air operated valve Inactive Verify that the pilot pressure is regulated at least 400 kPa See Section 12 4 4 Detected in CHG or DL3 stage 6 E 6 A D Converter error Exchange of CPU board 7 E 7 DPS output saturated Check the DPS offset No Go judgement will be made ERROR signal won t be transmitted...

Page 85: ...del will require longer DL3 timer than usual Extend the DL3 timer by 1 to 2 seconds In case of Micro low pressure model may require optional orifice 4 Air operated valves and solenoid valves If contaminants are found in the air operated valves cleaning or replacement is required 5 DPS sensitivity Check the DPS sensitivity using a Leak Master and DPS span 12 4 5 E 9 Pressurization valve error In ca...

Page 86: ...ster Internal leak or contamination of DPS Perform No Leak test with the stop valves closed Improper test timer Execute Master Preset sampling with non leaking part and check if the value is within the limit If it is extend timers Improper equivalent internal volume Perform leak calibration with a Leak Master calibrated to specific leak rate Master Preset Compensation Improper tested part leak def...

Page 87: ... MASTER side and WORK side This helps find out whether the leak is from the MASTER side or WORK side tubing or fixture If the polarity of the leak rate changes when tubing and fixtures of the MASTER and the WORK are switched a leak is more likely to locate in the tested part or fixture seal Do this check with the Master Preset feature disabled Be sure to replace the tubing in original position whe...

Page 88: ......

Page 89: ...13 APPENDIX 87 1 13 3 APPENDIX 1 13 3 1 1 E EX XT TE ER RN NA AL L A AP PP PE EA AR RA AN NC CE E ...

Page 90: ...3 2 2 P PN NE EU UM MA AT TI IC C C CI IR RC CU UI IT T 13 2 1 INTELLIGENT I AIR CIRCUIT LS 1866 a Pneumatic circuit diagram low pressure model L medium pressure model M b Pneumatic circuit diagram vacuum pressure model V ...

Page 91: ... 4014623 10 197162 0 1 0 0001 1hPa 0 0009869 1 0332286 1 0132512 14 695921 760 00076 29 921268 406 78211 10332 286 101 32512 0 1013251 1013 2512 1atm kg cm2 bar psi mmHg Torr inHg inH2O mmH2O kPa MPa hPa atm 1 13 3 4 4 F Fl lo ow w U Un ni it t C Co on nv ve er rs si io on n T Ta ab bl le e 1mL s 60 0 06 0 00019 101 3 0 1013 0 0167 1mL min 0 001 0 01138 1 689 0 001689 16 667 1000 1L min 11 37990 1...

Page 92: ...ursuant to part 15 of the FCC Rules Those limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the operation manual may cause harmful interference to radio communications Operation of this equip...

Page 93: ...7766 Thailand Cosmowave Technology Co Ltd Bangkok Thailand Phone 66 0 2 736 1667 Fax 66 0 2 736 1669 Indonesia Pt Cosmowave Bekasi Indonesia Phone 62 0 21 89328750 Vietnam Cosmowave Vietnam Co Ltd Hanoi Vietnam Phone 84 0 24 37876085 Fax 84 0 24 37876084 India Cosmo Instruments India Pvt Ltd Gurgaon Office Head Office Phone 91 0 124 421 0946 Fax 91 0 124 411 5926 South Zone Regional Office Bangalo...

Page 94: ... The specifications are subject to change without notice http www cosmo k co jp COSMO INSTRUMENTS CO LTD 2974 23 Ishikawa Hachioji Tokyo 192 0032 Japan Phone 81 0 42 642 1357 Fax 81 0 42 646 2439 ...

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Cosmo LS-1866, Operation Manual

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