Short user guide LD 500

SALES OFFICE SOUTH SALES OFFICE NORTH

Zindelsteiner Straße 15 Gewerbehof 14
D-78052 VS-Tannheim D-24955 Harrislee
GERMANY Germany
Tel.: +49 (0) 7705 978 99-0 Tel.: +49 (0) 461 807 105-0
Fax: +49 (0) 7705 978 99-20 Fax: +49 (0) 461 807 105-15
[email protected]

LD 500_SHORT BAL_V2.03 EN Page 1 of 20

1. Safety instructions

About this document

• Read this document carefully and familiarise yourself with the product before
use. Pay particular attention to the safety instructions and warnings to prevent
personal injury and product damage.
• Keep this document close at hand so you can refer to it if necessary.
• Pass the document on to future users of the product.

Ensuring safety

• Only use the product in an appropriate manner and for its intended purpose and
within the parameters specified in the technical data. Do not use force.
• Never use the device to measure on or in the vicinity of live parts!
o Maintain an adequate safety distance when performing leak detection
operations on electrical systems to avoid dangerous electric shocks!
• Avoid any direct contact with hot or rotating parts.
• Always switch on the device first before putting on the headset! At high signal
levels (headset bar chart in the red zone), the volume level may also be similarly
high.
• Never point the integrated laser directly at the eyes! Strictly avoid directly ex-
posing the eyes of humans and animals!
• Laser module: corresponds to DIN EN 60825-1: 2015-07 Class 2 (< 1 mW)
• Observe the prescribed storage and operating temperatures.
• Improper handling or use of force leads to loss of warranty.
• Any form of tampering with the device that does not conform with its desig-
nated use and is not described in the procedures will forfeit any warranty and
exclude liability.
• The device is exclusively designed for the intended use as described here.

Protecting the environment

• Dispose of defective/empty batteries in accordance with the relevant legal provi-

sions.
• At the end of its useful life, dispose of the product at the separate collection
point specified for electrical and electronic equipment (observe local regulations)
or return the product to CS Instruments GmbH & Co. KG for disposal.
CS Instruments GmbH & Co. KG offers no guarantee in relation to the suitability for any other purpose
and accepts no liability for any printing errors in this operation manual. The same applies to conse-
quential damage in connection with the delivery, capacity or use of this device.

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2. Intended use
The LD 500 is a leak detector for quick and reliable leak detection in/on compressed air systems.
The LD500 leak detector evaluates the ultrasonic waves generated by the leakage based on distance
and pressure.

It is solely designed and constructed for the intended use described here and may only be used for this
purpose.

The user must verify that the device is suitable for the intended use. The technical data listed in this
datasheet are binding.

Improper handling or operation outside the technical specifications is not permitted. Claims of any
kind for damages arising from improper use are excluded.

3. Technical data LD500

Dimensions hand-held 263 x 96 x 280 mm (with preamp module and acoustic trum-
housing pet)
0.55 kg with preamp module and acoustic trumpet,
Weight
complete set in case approx. 3.0 kg
Operating frequency 40 kHz (+/-2 kHz)
Power supply Internal 7.4 V lithium-ion battery
Operating time > 9 h (continuous operation)
Operating temperature -5 °C to +40 °C
Charging ext. battery charger (included in scope of delivery)
Charging time max.4 h
Storage temperature -20 °C to +50 °C
Wavelength 645 – 660 nm, output power < 1 mW
Laser
(laser class 2)
3.5 mm stereo jack for headset,
Connections Power supply socket for connecting an external charger
USB connection
Colour screen 3.5" touch panel TFT transmissive
Interface USB for data export/import, SW update, etc.
Data logger 8 GB memory card storage (micro SD class 4)

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4. The LD 500

Acoustic trumpet
Unlock button for preamp
module
Camera

Preamp module
3.5" TFT colour display
with touch panel
USB connection

Foil keypad (4 buttons) Plug-in connection for

power supply (battery
On/Off button charger socket)
Save button

Volume (+/-)

5. Preparing the device

The device must be configured before starting the leakage scan. The user can access the menu by
clicking the "Home" button.

Setting the language

Home → Settings → Device Settings → Set Language →
English

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 Checking the current firmware and firmware updates
Regularly check the CS INSTRUMENTS homepage for a new firmware version. We are continuously
developing the product so you can use the device with the most up-to-date software version including
all available functions.
1. Check firmware status on the homepage and download it from the following URL:
https://www.cs-instruments.com/downloads/software/firmware-leak-detectors
2. Check firmware in LD500
Path: Home→ Settings → About LD500 → Software Version
3. If the firmware is out of date, download the new version from the CS Instruments homepage
4. Unpack the ZIP file
5. Copy the DEV0004 folder to a USB stick

The folder structure must be as follows:

6. Connect the USB stick to the LD500 and connect the power supply
7. Perform system update with:

Path: Home → Settings → Device Settings → System

Update

8. Click on the "Check USB Stick for new Software updates" box
9. Available update is shown
10. Execute the "force all" function to perform the update
11. Restart the device and update the channels

The device is now up-to-date

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 Configuration of LD500
Home → Configuration 
In the configuration settings, the unit system can be se-
lected and the required parameters entered to calculate
the leakage costs per year.
➔Select ISO or US unit system
➔ To define the costs, call up the text field "Costs/1000
Nm³"
➔ Enter working hours per year (compressed air system
is operated actively)

There are 2 variants available to define the costs:

• Standard mode: Cost per 1,000 volume units. The
costs and the currency can be entered directly. Standard
value: €19 / 1,000 m³ or €0.58 / 1,000 cf.
• Expert mode: The electricity costs/kWh as well as the
specific output of the system can be defined here in de-
tail.

The specific output refers to the efficiency of the com-

pressor system. For example, how much electrical en-
ergy (kWh) is required to produce 1 cubic metre of com-
pressed air (m³). Three predefined system values are
created for this, as well as a user-defined input field for
individual entry.

The cost type can also be set in expert mode. The "Electricity costs [70%]" are calculated by the "con-
sumed electrical energy" of the compressed air system, which typically represents 70% of the total
costs. For "Total costs [100%]", the investment and maintenance costs are taken into account, which
are in addition to the electricity costs over the entire service life of the compressors.

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 5.3.1 Setting the LD500 parameters

Entering the parameters is necessary for the calculation

of the leak flow rate.
The following settings must be made.

➔ Sensor type
Change the sensor type according to the application and
ambient conditions, see chapter 6.4.

Home → Configuration → Parameter  Pressure and

distance
Values for the pressure and distance can be freely se-
lected in the two fields with the white coloured back-
ground, provided these are within the valid selection
range.

The pressure can be set variably between 1 – 10 bar.

Different distances from the LD500 to the leakage are defined for the different sensor types to calcu-
late valid leakage loss and costs per year. These distances must be adhered to as accurately as possible,
see chapter 6.4.

5.3.2 Setting the LD500 measurement place

Home → Configuration → Measurement place

The measurement place is stored for each leakage in its
journal data (xml file). This information can be viewed
later in the software leakage report.

The company and building can be recorded upon entering

the building, the place identifies the exact position of the
leakage so it can be easily found again when doing repairs.

➔ LeakTag: will automatically increase by one (1) after

storing a measurement.

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6. Leakage detection
This chapter describes the best use of the device in practice.

Leakage detection procedure

The following procedure should be performed in the company on a periodic basis to consistently keep
the leakage rate to a minimum. The aim should be a sustainable leakage rate of 5 to 10 % as one-time
detection and elimination does not permanently reduce the leakage rate and new leakages will occur
again afterwards.

Tip:

To determine the ideal time, the use of a volume flow sensor (VA500) in the main pipe behind the
tank is recommended. At least one week (Monday to Sunday) is recommended as the measurement
period. If an LD 510 is purchased, the volume flow sensor can be connected to it. During production
stops, the volume flow profile shows the leakage rate. If the threshold value is exceeded, leak detec-
tion can be contracted.
The volume flow measurement can also be used to validate the result of the leak detection and elimi-
nation, as this must reduce the volume flow during stoppages.

1. Leakage detection

5. Leakage remedial action

2. Leakage quantification

4. Leakage report creation

3. Leakage documentation

Possible causes of leakage:

Generally, leakages can be found at the connection elements in the compressed air system.
• Leaking couplings and hose clamps
• Leaking screw and flange compressors
• Porous/defective hoses
• Porous/defective seals of tools and machines
• Faulty steam traps
• Leaking or incorrectly installed dryer, filter and maintenance units
• etc.

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 Surface leakage detection with the LD 500
After start-up, the device shows the leakage detection view. The following figure lists the various
functions and displays.

Sensitivity level button

Display block for:

Bar graph display of signal
Signal level in dB | Leakage
level
size | Costs /year

Laser "On" icon

Leak-Tag number

Camera image Date/time and

battery level indicator
(change indicator)

Home menu
Laser "On"/"Off"

High sensitivity Settings

Storing the measurement

Selection of accessories
To simplify leakage detection for the user, several attachments are available for different measuring
conditions.
Note on the distance setting for the quantification function:
The distances to be maintained for quantifying the leakage always refer to the front of the respective
attachment measured to the leakage.

6.4.1 Acoustic trumpet (standard attachment)

The acoustic trumpet bundles incident ultrasonic waves,
thereby extending the range of the device. This behaviour
makes it ideal for medium distances.
The leakage can be heard from large distances, for precise de-
tection, the user must approach the leakage and consistently
follow the "loudest" point. Individual compressed air compo-
nents are then checked for precise detection.
Quantification distance (distance) → 1 – 6 m
Use of acoustic trumpet:
• Average distance to pipe/component 0.2 – 6 m
• Low interfering noise
• Leakage freely accessible
• Use at distances of up to 6 metres if no parabolic mirror available

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 6.4.2 Straightening tube
The straightening tube permits only very few ultrasonic waves
to pass in the direction of the ultrasonic transducer, allowing
leakages to be located very precisely.

For this reason, the use of the straightening tube is

recommended for small distances, for the precise detection of
the corresponding leakage.

Quantification distance: (Distance) → 0.2 m

Use of straightening tube:

• Short distance to pipe/component 0.05 m
• Pipe/component freely accessible
• Pipes and components to be inspected are very close together
• Medium to high noise
• Use when no gooseneck available

6.4.3 Gooseneck
Before the gooseneck can be used, its data – located on the
USB stick shipped with the attachment – must first be im-
ported into the LD500, if it was reordered.
Import:
Home → Export/Import → Import → New tool → Goose-
neck_xxxxxxxx

The gooseneck should be used if the pipes and components to be inspected are physically very close.
In addition, the shape of the gooseneck can be flexibly adapted to easily inspect hard-to-reach pipes
and components.

The sensitivity of the gooseneck has been reduced to dampen noise. This makes it ideal for targeted,
local testing of compressed air components at high noise levels, for example in systems using pneu-
matic cylinders and in compressed air distribution cabinets.
Quantification distance (distance) → 0.05 m

Use of gooseneck:
• Short distance to pipe/component 0.05 m
• Leakage not freely accessible
• Medium to high ultrasonic noise
• Pipes and components to be inspected are very close together

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 6.4.4 Parabolic mirror
Before the parabolic mirror can be used, its data – located on the
supplied USB stick – must be imported into the LD500, if it was reor-
dered.

Import:
Export/Import → New tool → Parabol_xxxxxxxx

The parabolic mirror bundles horizontally incident ultrasound in its

focal point where the ultrasonic transducer is located. On the one
hand, this leads to a considerable amplification of the measured ul-
trasound (high range) and, on the other hand, to a very precise direc-
tional behaviour, since ultrasound that does not incident horizontally
is reflected by the reflector.

The combination of these two characteristics enables the parabolic mirror to precisely locate leaks at
large distances.

Quantification distance (distance) → 3 – 12 m

Use of parabolic mirror:

• Large distance to pipe/components 3 – 15 m
• Interfering noise
• Leakage not freely accessible (behind a fence)
• Near leaks (superimposition)

Change of sensitivity levels

Ultrasound levels can be understood as a "loudness" of the leakage.

With the “Sensitivity" button, the sensitivity of the LD500 can be adjusted to the environment, which
strongly influences the acoustic behaviour of the device and increases or decreases the valid value
range. A reduction in sensitivity reduces the range of the leakage reading but the "responding area",
indicated by the circle in the display, also gets smaller, which considerably simplifies detection.

Sensitivity levels
0 – 60 dB = Highest sensitivity level of the device (use with small leaks and no noise), selection with
the "HiSn" button or the "Sensitivity" button
10 – 70 dB = Leakages and noises get "less noisy", the range is reduced.
20 – 80 dB = Leakages and noises get "less noisy", the range is reduced.
30 – 90 dB = Leakages and noises get "less noisy", the range is reduced.
40 – 100 dB = Most insensitive stage (large leaks, many noises → for heavy-duty application)

By default, the LD500 is set to the auto function and will automatically switch between levels
(10 – 70 dB to 40 – 100 dB).

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The highest sensitivity level 0 – 60 dB of the unit can be set using the "HiSn" button or by manually
changing the sensitivity level using the "Sensitivity" button. This mode should be used for the detection
of small leaks in a quiet environment.

6.5.1 Sensitivity level button

0–
60 dB You can manually switch between individual levels with the
Auto
function
10 – "Sensitivity" button or use the auto function to adjust the level.
70 dB
(start)
The order is shown in the chart on the left.

40 – 20 –
100 dB 80 dB

30 –
90 dB

6.5.2 Auto function (default)

The auto function (automatic change of the sensitivity levels) is activated by default. This means that
the measured ultrasound level is used to automatically adjust the optimum measurement range.
Example: Level = 71 dB → Level: 20 – 80 dB

6.5.3 Manual sensitivity adjustment

It is also possible to switch between sensitivity levels. This can be done with the "Sensitivity" button.

It helps the user to reduce interfering noise and detect leakages as easily and quickly as possible. The
user should frequently increase and decrease the sensitivity to scan the target surface for leakages
with the adjusted sensitivity. Decreasing the sensitivity makes the device react to a smaller area but
also reduces the range.

6.5.4 Procedure for leakage detection

Different approaches to leakage detection are
recommended depending on the ambient condi-
tions.

Option 1 – In what direction can the leakage be

heard? This method is used to aim in all directions
and find the loudest point. The loudest point
should then be approached to precisely locate the
leakage. Works well when there is less interference
from noise.

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 Option 2 – Patrol the compressed air network.
Alternatively, in case of increased noise, leakage
detection can be facilitated by the user listening to
the compressed air network "bit by bit".

This means from the compressor room to the end

user. If noise is detected, it is recommended to
manually reduce the sensitivity of the device and
to use the gooseneck for small distances, and the
parabolic mirror for larger distances. The following
also applies to this method in general: The shorter
the distance to the pipe, the easier it is to detect a
leakage.

Option 3 – Leakage detection during production stoppage

Production and manufacturing processes may give rise to ultrasound noises at times. If, for example,
a pneumatic system blows off air at regular intervals, the LD 500 picks up on this.

If leakage detection is severely impeded by these interfering noises, it is recommended to perform

leakage detection according to Option 1 or Option 2, if the pipes are pressurised but the manufacturing
processes have been stopped. These are the quickest and easiest ways to detect leakages.

Other problems that can make measuring more difficult

There may be further problems in leakage detection, these are de-

scribed in the following sub-chapter.

To reduce any problems, we generally recommend to use the correct

attachment, as outlined in chapter 6.4 Selection of accessories, and to
reduce the sensitivity.

Reflections: If leakages can be heard in walls but there are no pipes,

this is a reflected ultrasound of a leakage. In this case, it is recom-
mended to reduce sensitivity (manually switch to a higher range until
it can no longer be heard). Additionally, aim should be taken in a direc-
tion parallel to the reflection surface as this is where the leakage is lo-
cated. The leakage will be noisier than the reflected ultrasound.

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 Superimposition of leaks: If leaks are close to
one another, the emitted ultrasound overlaps.
In this case, it is recommended to seal the leak-
ages using a cloth. This enormously increases
the accuracy of the measurement, especially
for the quantification of the leakage. At the
same time, measurements should be taken in
close proximity to the components.

Reducing sensitivity and, in particular, using a parabolic mirror (for large distances) and a gooseneck
(for smaller distances) can also make detection a lot easier.

Very large leakages: Very large leakages generate a strong ultrasonic field, which can possibly generate
an ultrasonic signal in the entire room. Here again, it is recommended to reduce the sensitivity and
check close to the individual components. The aim is to detect leakages by using the volume level of
the loudest point.

If the leak cannot be accessed, using a parabolic mirror is recommended, as it has very good direction-
ality.

Lamps and motors:

Interfering noise: Electrical buzzing → do not mix up with leakage!

Some systems and machines can also generate ultrasound that is in a similar frequency range, for ex-
ample fluorescent tubes or motors. These generally "sound" different than the typical "hissing" of leak-
ages and should not be mistaken for them.

If ultrasound can be heard and it clearly does not emanate from the compressed air system, the sen-
sitivity of the device should be reduced in order to suppress the ultrasound. If this does not suffice, the
noise must be ignored.

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 Documenting the leakage
If the leakage has been found, the pressure and distance to the leakage adjusted and the leakage de-
scribed, it can be "captured" with the "Save" button.

Afterwards it is possible to check the parameters (pres-

sure and distance) and to precisely define the measure-
ment place with company, building and location. It is also
possible to enter a short error description (max. 32 char-
acters).

The following error descriptions are available, which

make it much easier to eliminate leakages later.
• Leakage element
• Measure
• Spare part
• Repair under pressure possible?

Some suggestions are stored by default to make the input

easier for the user.
Entries made by the user are also stored in an internal da-
tabase and can be used again and again.

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 All relevant data of the leakage are shown in the image
and a final check can be done again before saving. All
leakages, including entries made, are saved to the journal
file.

Exporting journal data

Once all leakages have been documented, the data must
then be exported to a USB stick.
Here, the user has the option of selecting the start and
end time of the exported leakages.

Attention: If the «DELETE leakage data» function is acti-

vated, ALL leakages in the memory will be irretrievably
deleted.

Home → Export/Import → Export → Leakage Data → Change Start Time & Change End Time → Export

To continue with the leakage documentation, please go

to section 7.4 Data import.

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7. Using the CS Leak Reporter software
Main functions:
• Administration of companies/buildings/projects/measurements
• Documentation and reporting
•
Dashboard:

Installing the CS Leak Reporter software

The software is executed with the «Setup.exe» application. The file is located on the supplied USB
stick or can be downloaded from the homepage at the following URL: https://www.cs-instru-
ments.com/downloads/software/computer-evaluation-software

Software licensing
Path: Dashboard → Licence

Following installation, you will receive a 30-day trial access. For permanent use of the software, you
need to purchase a licence key and register it along with your personal data. The licence key is printed
on the invoice and the delivery note. Additionally, a digital copy of the licence can be found on the
supplied USB stick and is also printed on the stick.

Note: One licence key allows for software activation on two devices. If the SW is subsequently installed
on another laptop or computer, the licence on the old device must be deactivated. It can then be used
again on the new device.

Saving your personal data and profile

Path: Dashboard → Profile

You can enter your contact details in the profile. These are printed on the cover page of the report.

Data import
Once you have saved the LD500 data on a USB stick, the leakage data must be read. The export func-
tion of the LD500 is described in section 5.8.

LD 500_SHORT BAL_V2.03 EN Page 17 of 20

 Path: Dashboard → Data import → Select XML

The name of the folder corresponds to the serial number

of the LD500 in use.

After selecting the relevant journal file, the following view

will be displayed:
When you click on «Data import», the displayed compa-
nies will be created.
You can also sort by companies, building or a time range.
Only the corresponding leakages will then be displayed and
imported.

If an existing company was selected for «Company» or

«Project», the data is exported to this company and the
selected project.

Data preparation
Path: Dashboard → Companies (eye of the corresponding
company)
The data import from section 7.4 corresponds to a project.
This can then be further processed by clicking on the eye.
Specific information for a company can be added under the
company and this is where the data imports are located as
separate projects.

Selecting projects
Path: Dashboard → Companies→ Project (eye of the corresponding project)

Each «Data import» corresponds to a project. Here, the desired project of the company in question
must now be selected.

The leakage overview for the project will then be

displayed.

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 Leakage overview
This list now contains all imported leakages from the data import. The relevant parameters of each
individual leakage are displayed and can be sorted by header (e.g. Leak tag).

It is also possible to «copy» or «move» leakages to other

projects or «delete» them.

Editing individual leakages

Using the eye, a detail view of each individual leakage can now be opened and then edited.

Path: Dashboard → Companies→ Project →(eye of the

corresponding leakage)

In this menu, you can:

• upload an additional image
• add/change a comment
• define the priority
• add/edit details on leakage elimination
• set the status

Creating reports
Path: Dashboard → Companies→ Project → «PDF» or «XLS»

After editing leakages, an automatic report can be created by pressing the «PDF» or «XLS» buttons in
the leakage overview. The report follows the selection of building or place and the sorting of the rele-
vant column. Sorting can be done by LeakTag, leakage rate, costs per year or status.

The first page of the «PDF report» shows a cover page in-
cluding contact information, project master data and the
results of the leakage scan.

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The following pages list the individual leakages:

Modifying company master data (customer)

Path: Dashboard → Companies→ Master data

In this screen the contact details of the customer, which

will be printed in the report, can be entered.

Modifying project master data

Path: Dashboard → Companies→ Project → Master data

In this screen, the parameters of the project can be

adapted if the configuration of the LD500 was faulty or in-
complete. The entries made there are then used for all
leakages in the project.

Further explanations and details can be found under:

Instruction manual: https://www.cs-instruments.com/downloads/instruction-manuals

LD500: https://www.cs-instruments.com/products/d/leak-detection/leak-tester-ld500-to-detect-
and-calculate-leakages

LD 500_SHORT BAL_V2.03 EN Page 20 of 20