Translation of the original instructions

Author: Bernd Schwan Version: 2.1

 Operating instructions
Test adapter Leak test

Imprint
© Copyright 2023 Komax Testing Germany GmbH. All rights reserved.

Manufacturer and contact person

Komax Testing Germany GmbH
Strengelrott 4
32457 Porta Westfalica
+ 49 571 7958 0
[email protected]

Internet
Visit our website:
komaxgroup.com

Contacts
In case of question, please contact our
After Sales Service.
+49 571 7958 300
[email protected]

Thank you for purchasing a product from Komax Testing Germany.

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Test adapter Leak test

General document information:

Document name
EN_Test adapter_Leak test_V2.1.docx

History:
Date Name Version Type Comments
2/23/2022 BSN 2.0 Creation Summary of various leak test documents:
▪ Leak test manuals
▪ IntelliMod qualified leak test manuals
▪ „How to perform the Leak Test“
1/17/2023 BSN 2.1 Change Komax Design
Add “Verification of pressure switch SMC”
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--- --- ---
--- --- ---
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Contents

1. NOTES ABOUT THIS DOCUMENTATION ........................................................................................................ 6

1.1 About this manual ................................................................................................................................ 6
1.2 Photos, figures and screenshots ....................................................................................................... 6
1.3 Copyright .............................................................................................................................................. 6
1.4 Document presentation ....................................................................................................................... 7
1.5 Illustrations ........................................................................................................................................... 7

2. IMPORTANT STATEMENT ........................................................................................................................... 7

2.1 Qualification of personnel ................................................................................................................... 7
2.2 Warranty ............................................................................................................................................... 8

3. SAFETY INFORMATION.............................................................................................................................. 8
3.1 General.................................................................................................................................................. 8
3.2 Test adapter.......................................................................................................................................... 9

4. GENERAL DESCRIPTION.......................................................................................................................... 10
4.1 Leak test units .................................................................................................................................... 10
4.1.1 Standard ................................................................................................................................................... 10
4.1.2 Assembly incl. pressure switch ................................................................................................................ 11
4.2 Type of seals ...................................................................................................................................... 11
4.3 Leakage test ....................................................................................................................................... 12

5. OVERPRESSURE LEAK TEST ................................................................................................................... 13

5.1 Leak test unit, overpressure, 24 V DC .............................................................................................. 13
5.1.1 Setting – Preparation ................................................................................................................................ 14
5.1.2 Setting – Air volume ................................................................................................................................. 15
5.1.3 Setting – Compressed air ......................................................................................................................... 16
5.2 Leak test unit, overpressure, 24 V DC, incl. pressure switch ........................................................ 17
5.2.1 Preparation ............................................................................................................................................... 17
5.2.2 Setting…… ............................................................................................................................................... 18
5.2.3 Verifiation ................................................................................................................................................. 20

6. VACUUM LEAK TEST............................................................................................................................... 21

6.1 Leak test unit, vacuum, 24 V DC, incl. pressure switch ................................................................. 21
6.1.1 Setting – Preparation ................................................................................................................................ 21
6.1.2 Setting…… ............................................................................................................................................... 22
6.1.3 Verification................................................................................................................................................ 24

7. QUALIFIED LEAK TEST (WITH INTELLIMOD UNIT) ....................................................................................... 25

7.1 Function .............................................................................................................................................. 26
7.2 Ports and buttons .............................................................................................................................. 26
7.3 Test mode ........................................................................................................................................... 27
7.3.1 Additional Information ............................................................................................................................... 28
7.3.2 Status LEDs ............................................................................................................................................. 28
7.3.2.1 Successful result (OK).................................................................................................................................... 28
7.3.2.2 Faulty result (NOK)......................................................................................................................................... 29
7.3.2.3 Faulty result (NOK) – Filled pressure cannot reach the value ....................................................................... 29
7.3.2.4 Faulty result (NOK) – Filled pressure too high ............................................................................................... 29
7.4 Configuration...................................................................................................................................... 30
7.4.1 Calculation of the pressure sensor ........................................................................................................... 30
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7.4.2 Pressure sensor table .............................................................................................................................. 30

7.4.3 Installation / Changing the pressure sensor ............................................................................................. 31
7.4.4 Programming, with the Mode and Step buttons ....................................................................................... 31
7.4.4.1 Switching on and checking the set function ................................................................................................... 31
7.4.4.2 Select a function ............................................................................................................................................. 31
7.4.4.3 Configuration mode ........................................................................................................................................ 33
7.4.4.3.1 Starting the configuration mode ............................................................................................................................33
7.4.4.3.2 Setting the start pressure ......................................................................................................................................33
7.4.4.3.3 Setting the max. pressure loss ..............................................................................................................................34
7.4.4.3.4 Setting the hold time..............................................................................................................................................35
7.4.4.3.5 Saving ....................................................................................................................................................................35
7.4.5 Programming with the IntelliMod Programmer ......................................................................................... 36
7.4.5.1 Optional: Firmware Update ............................................................................................................................ 37
7.4.5.2 Menu ‘Function mode’ .................................................................................................................................... 38
7.4.5.3 Setup the selected function ............................................................................................................................ 39
7.4.5.4 Transfer data .................................................................................................................................................. 40

8. TEST MODE .......................................................................................................................................... 41

9. MAINTENANCE AND CARE ....................................................................................................................... 42

9.1 Tips on spare parts ............................................................................................................................ 42
9.1.1 Maintenance unit/compressed air connections ........................................................................................ 42
9.2 Test adapter........................................................................................................................................ 42
9.2.1 Release button ......................................................................................................................................... 43
9.2.2 Test adapter levels ................................................................................................................................... 43
9.2.3 Replacing contact pins (GKS) .................................................................................................................. 43
9.2.4 Replacing switching contact pins (SKS) ................................................................................................... 44
9.2.5 Spring forces of contact pins/locking contact pins .................................................................................... 44
9.2.6 Operating pressure of the leak test adapter ............................................................................................. 45

10. SOURCES OF ERRORS AND REMEDY ...................................................................................................... 46

11. VERIFICATION OF PRESSURE SWITCH SMC ............................................................................................ 48

11.1 Leak test unit, overpressure, 24 V DC, incl. pressure switch ........................................................ 48
11.1.1 Setting – Preparation ................................................................................................................................ 48
11.1.2 Measuring................................................................................................................................................. 49
11.2 Leak test unit, vacuum, 24 V DC, incl. pressure switch ................................................................. 50
11.2.1 Setting – Preparation ................................................................................................................................ 50
11.2.2 Measuring................................................................................................................................................. 51

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1. Notes about this documentation

1.1 About this manual

This documentation is part of the product. Therefore, please keep the documentation for the entire duration
of use of the product.

Prior to commissioning, the operating manual must be carefully read. Only start work
with the product once you have fully understood the content of this manual!
We strive to ensure that the content of this manual is always up to date. However, please let us know if you
find any discrepancies between the manual and the product. If you have any further questions or
comments, do not hesitate to contact us.

1.2 Photos, figures and screenshots

Illustrations in the form of photos, figures and screenshots should always reflect the current product status.
However, ongoing innovations and improvements may mean that the illustrations in this manual may not
precisely match the product. This does not affect operation, functionality or safety.

1.3 Copyright
© Copyright 2023 – Komax Testing Germany GmbH according to DIN ISO 16016
In case of further developments and other improvements, we reserve the right to make changes to the
technical data and function sequences contained in the descriptions and figures of this manual. This
manual is copyright protected. We reserve all rights regarding the translation, reprint and reproduction of
the manual in whole or in part.
This manual must not be reproduced in whole or in part in any form (photocopy, microfilm or any other
process) or processed or forwarded using electronic systems, including for training purposes, without the
prior written consent of the publisher.
If you have any suggestions you would like to make for improving this operating manual, please contact
Komax Testing Germany GmbH.
All of the product and brand names mentioned in this manual are the property of the respective
manufacturer.
CS WIN® is a registered trademark of Komax Testing Germany GmbH.

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 Operating instructions
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1.4 Document presentation

All safety information in the operating manuals has the same structure.
Safety information consists of:
▪ a pictogram indicating the hazard type.
▪ a signal word indicating the severity of the hazard and/or a note precisely describing the hazard.
Symbol Text Font conversion
Caution Arial Narrow, bold

Specific instructions Arial Narrow, bold

Warning, danger, ... Arial Narrow, bold

Information, Note, ... Arial Narrow, italic

1.5 Illustrations

All images and screenshots use the English language settings.

The information in screenshots is solely there as an example. It may therefore not

necessarily apply to your particular test system/application.

2. Important statement

2.1 Qualification of personnel

Only persons who have been previously trained by qualified experts are allowed to work on the test system.

All maintenance work performed on the test system, may only be carried out by trained
expert personnel. This must be familiar with the current standards and guidelines.
Only trained, expert personnel may carry out any manipulations to the control system.

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Test adapter Leak test

2.2 Warranty
Komax Testing grants a 12-month warranty from the date of delivery.
Wearing parts, as well as damage due to improper handling or caused by the use of incorrect spare parts
and assemblies (third-party manufacturer), are excluded from the warranty.

Changes to the software must be performed exclusively by qualified personnel.

Any changes you implement of your own accord may irreparably damage individual parts or the
entire system.
This shall void the warranty!

3. Safety information
Current standards and directives must be complied with when carrying out work on electrical systems.

Komax Testing Germany GmbH accepts no liability for damage or injuries caused by
improper handing or by modifications to the system.

3.1 General

Pay attention to all safety information on the product.

Switch off the test system and remove the mains connector:
▪ Before opening the test system
▪ Before removing or installing the test adapter
▪ Before conducting repairs or maintenance work
Please pay attention to these instructions, so that no electrical shock
can occur at any time.

If a UPS (uninterruptible power supply) is installed in the

system, then a voltage can be applied to the components even when
the main switch and/or the power plug is disconnected.

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Test adapter Leak test

3.2 Test adapter

Before performing maintenance or repair work on a test adapter,

disconnect all electrical and pneumatic connections between the
adapter and the system.
Never reach into the adapter contour when the test system is switched
on.
▪ Advancing locking cylinders and contact pins can cause severe
injuries.
▪ Contact pins may be damaged.
Version 2, 3 and 4 test adapters feature moving mechanical levels that
can result in serious injury.
When installing test adapters, take care to ensure that cables, lines and
compressed air hoses are not kinked or squashed.
You must wear protective goggles when blowing out test adapter
contours with compressed air.

The screw tightening torque for fastening the empty adapter or test
adapter is 1.0 – 1.5 Nm.

Symbol image

Do not use pointed or sharp objects to operate the push-button

surface!

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Test adapter Leak test

4. General description
The wire harness manufacturer must test various connectors of the wire harness for leakage to the vehicle
manufacturer. The leak test of special connectors and tubes is carried out as a pure leak test or in one
operation with the connection test.
The leak test units developed at TSK offer the possibility of testing with positive or negative pressure.
A reference pressure of 6 bar serves as the test medium.
With the customer specifications and the measured values from the leak test unit, the results are evaluated
via the test software (CS WIN nx or cable tester SW).

4.1 Leak test units

4.1.1 Standard
Overpressure, 24 V DC, 1 bar
▪ Variant long, 2x solenoid valve
Art.-No.: 106466
▪ Variant small, 2x solenoid valve
Art.-No.: 106467
▪ Variant long, 1x solenoid valve
Example: 106466, variant long Art.-No.: 108588
▪ Variant small, 1x solenoid valve
Art.-No.: 106880
Overpressure, 24 V DC, 2 bar
▪ Variant long, 2x solenoid valve
Art.-No.: 114322
▪ Variant small, 2x solenoid valve
Art.-No.: 114323
Example: 106467, variant small
Overpressure, 12 V DC, 1 bar
▪ Variant long, 2x solenoid valve
Art.-No.: 106637
▪ Variant small, 2x solenoid valve
Art.-No.: 106638
▪ Variant long, 1x solenoid valve
Art.-No.: 107088
▪ Variant small, 1x solenoid valve
Art.-No.: 107087
Overpressure, 12 V DC, 2 bar
▪ Variant long, 2x solenoid valve
Art.-No.: 114324
▪ Variant small, 2x solenoid valve
Art.-No.: 114325
▪ Variant long, 1x solenoid valve
Art.-No.: 114327
▪ Variant small, 1x solenoid valve
Art.-No.: 114326

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Test adapter Leak test

4.1.2 Assembly incl. pressure switch

Overpressure, 24 V DC
▪ Assembly Overpressure
Art.-No.: 2344671
▪ Pressure switch SMC ZSE30AF01BG
Art.-No.: 110351
Vacuum, 24 V DC
▪ Assembly Vacuum
Art.-No.: 2344672
▪ Pressure switch SMC ZSE30AF01BG
Art.-No.: 110351
▪ Venturi nozzle
Art.-No.: 110352

4.2 Type of seals

Explanation:

▪ Sealer:
Seal on the outside of the housing (sealer).

▪ Seals:
Seals for each individual contact (Seals) in the
housing.

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Test adapter Leak test

4.3 Leakage test

After adaptation of the test item, the leak test is started.
The measured values for the test are determined empirically.
The test chamber of the connector is closed by a sealing cage. Air flows into the connector with a short
delay (filling phase). The pressure sensor checks the pressure build-up in the sealed connector. If air leaks
through the connector, damaged seals or through chambers that are not equipped with individual seals and
sufficient pressure does not build up in the connector, the pressure sensor does not switch. Since the
pressure sensor is electrically evaluated by the tester like the interrogation of a sealer, the tester thus
recognizes the leakage as a fault.
At the end of the test, the level of the test module is returned to the home position.
The connector is unlocked and released.

No compressed air fluctuations may occur in the system during the test!

▪ Aluminum sealing cage

▪ e.g., Pressure air inlet
▪ e.g., Pressure air outlet

▪ Sealing of the aluminum sealing cage

(View: bottom side of the test adapter)

Path of the compressed air.

▪ Sealing cage
▪ Leak test unit

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Test adapter Leak test

5. Overpressure leak test

5.1 Leak test unit, overpressure, 24 V DC

With this test method, the air pressure fed into the cage is no more than 0.25 bar. The leakage test is
determined by triggering a mechanical switch and a sensitive membrane. For this purpose, a leak test unit
consisting of an air throttle valve, air regulator, diaphragm and switch is used.

Example: Art.-No.: 106467

TSK recommends a setting range on the

pressure regulator of 0.08 to 0.25 bar. Experience
has shown that almost all plugs can be checked for
leaks within this range.

▪ Output regulated compressed air

▪ Input pressure switch
(compressed air from sealing cage)

▪ Inlet pressure 6 bar

▪ Pressure regulator
▪ Contacts from compressed air switches

▪ Solenoid value 1
▪ Adjusting screw throttle
▪ Solenoid value 2

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Test adapter Leak test

5.1.1 Setting – Preparation

Adjustments must always be executed with connectors or harnesses from current production!

Pull the tube from the ‘Pressure switch input’.

Example sketches

Connect a certified digital pressure instrument

(from accredited office) via a PE converter and a
Y-connector as follows:
▪  Tube end from Y connector
 Unit ‘Input pressure switch’ .

▪  Tube end from Y connector

 disconnected tube end (that was
previously into the ‘pressure switch input’ unit).

Connect the test adapter pneumatically and

electrically, e.g., to a TSK module tester.
▪ Test points
▪ Power supply
▪ Pneumatic

See document
‘Operating Manual_TSK_Module_Tester’ or
‘[Test system]_Operating Manual’.

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Test adapter Leak test

5.1.2 Setting – Air volume

Using a flat-blade screwdriver, close the throttle
screw completely (clockwise).

Insert the connector into the test adapter contour

until it locks automatically.

Using a flat-blade screwdriver, slowly open the

throttle screw (counterclockwise).

Depending on the volume of the sealing

cage, the customer-specific connector specification
and in the case of a version 4 test adapter (with
levels), filling may take a little longer.

The compressed air must not exceed

0.25 bar, otherwise the membrane or the switch
may be damaged!

When the sealing cage starts to fill with

compressed air, stop opening.

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Test adapter Leak test

5.1.3 Setting – Compressed air

Use the pressure regulator to set the value from
0.18 - 0.22 bar on the pressure instrument.
▪ Increase compressed air
▪ Decrease compressed air

Example: pressure instrument

Remove the connector from the test adapter

contour.

The compressed air may rise slightly at

the pressure instrument display during
adaptation, due to compression.

Repeat these steps until the desired value

is stable.

TSK Experience Values:

Large sealing ports: Small sealing ports:
0.18 – 0.22 bar 0.10 – 0.14 bar

Different setting values are because the switch in the leak test unit switches off after 0.08
seconds.
If there is a damaged seal on the connector with smaller seals and the pressure in the seal cage does
not fall below 0.08 bar despite the air leak, the damaged seal cannot be detected. It is necessary to set a
value as close as possible to the closing force of the valve for small-seal connectors.

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Test adapter Leak test

5.2 Leak test unit, overpressure, 24 V DC, incl. pressure switch

Art.-No.: 2344671
▪ incl.:
Pressure switch SMC ZSE30AF01BG
(Art.-No.: 110351)

▪ Pressure switch input

(compressed air from sealing cage)
▪ Pressure switch
▪ Output regulated compressed air
▪ Throttle
▪ Inlet pressure 6 bar
▪ 5/2-way solenoid valve

5.2.1 Preparation

Adjustments must always be executed with connectors or harnesses from current production!
Pull the tube from the ‘Pressure switch input’.

Example sketches

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Operating instructions
Test adapter Leak test

Connect a certified digital pressure instrument

(from accredited office) via a PE converter and a
Y-connector as follows:
▪  Tube end from Y connector
 Unit ‘Input pressure switch’ .

▪  Tube end from Y connector

 disconnected tube end (that was
previously into the ‘Output regulated
compressed air’ unit).

Connect the test adapter pneumatically and

electrically, e.g., to a TSK module tester or Test
system.
▪ Test points
▪ Power supply
▪ Pneumatic

See document
‘Operating Manual_TSK_Module_Tester’ or
‘[Test system]_Operating Manual’.

5.2.2 Setting……

Set the applied pressure via the sensor as

0.000 follows:

Press and hold until “F 0“ is shown.

0.000 F0

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Operating instructions
Test adapter Leak test

Select with the / buttons until “BAR“ is

shown.
BAR BAR
Then press .

“F_0“ shown on the display.

F0 F1 Select with the / buttons until “F 1“ is

shown.

Then press .

Select with the / buttons until “HYS“ is

shown.
HYS HYS
Then press .

Select with the / buttons until “P_1“is

shown.
P_1 P_1
Then press .

Use the / buttons to set the value to

e.g., “0.080“.
0.080 0.080
min. Overpressure threshold.
From this value the pressure switch turns on.
(TSK standard values from 0.08 - 0.25)

Then press .

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Test adapter Leak test

“H_1“ shown on the display.

H_1 0.000 Use the / buttons to set the value to

e.g., “0.000“.

The pressure switch switches off again

according to the following calculation:
Switch off = “P_1“ - “H_1“ = “0.080“ – “0.000“,
In this example = “0.080“.
(TSK hysteresis default value 0.000).

Press and hold until the settings have been

saved.
0.000
Then the display changes back to the
measuring mode.

5.2.3 Verifiation

The pressure on the display of the sensor

must be identical to that of the certified measuring
device (from an accredited office)
e.g., 0.490 bar.

Accuracy according SMC data sheet:

▪ Display accuracy: ± 2.0 %
▪ Repeatability: ± 0.2 %

Sensor display Measuring device display

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Test adapter Leak test

6. Vacuum leak test

6.1 Leak test unit, vacuum, 24 V DC, incl. pressure switch

In this test method, a vacuum is created in the cage and the leakage reference value is determined based
on the test samples. All values above the specified reference value are considered defects.
The following component is used for the vacuum leakage test.
Art.-No.: 2344672
▪ incl.:
Pressure switch SMC ZSE30AF01BG
(Art.-No.: 110351)
▪ Venturi nozzle
(Art.-No.: 110352)

▪ Pressure switch input

(compressed air from sealing cage)
▪ Pressure switch
▪ 5/2-way solenoid valve
▪ Inlet pressure 6 bar

▪ Output regulated compressed air

▪ Venturi nozzle (negative pressure or vacuum
generator)

6.1.1 Setting – Preparation

Adjustments must always be executed with connectors or harnesses from current production!
Pull the tube from the Venturi nozzle.

Example sketches

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Operating instructions
Test adapter Leak test

Connect a certified digital pressure instrument

(from accredited office) via a PE converter and a
Y-connector as follows:
▪  Tube end from Y connector
 Unit ‘Input pressure switch’ .

▪  Tube end from Y connector

 disconnected tube end (that was
previously into the Venturi nozzle).

Connect the test adapter pneumatically and

electrically, e.g., to a TSK module tester or Test
system.
▪ Test points
▪ Power supply
▪ Pneumatic

See document
‘Operating Manual_TSK_Module_Tester’ or
‘[Test system]_Operating Manual’.

6.1.2 Setting……

Set the applied pressure via the sensor as

0.000 follows:

Press and hold until “F 0“ is shown.

0.000 F0

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Test adapter Leak test

Select with the / buttons until “BAR“ is

shown.
BAR BAR
Then press .

“F_0“ shown on the display.

F0 F1 Select with the / buttons until “F 1“ is

shown.

Then press .

Select with the / buttons until “HYS“ is

shown.
HYS HYS
Then press .

Select with the / buttons until “1_N“is

shown.
I_N I_N
Then press .

Use the / buttons to set the value to

e.g., “-.540“.
-.540
Determine the vacuum:
1. Insert the connector into the test adapter
contour.
2. Read the current vacuum value e.g.,
-0.600 bar.
3. Adjustment threshold = vacuum value - 10%
-0.600 - 10 % = -0.540

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Test adapter Leak test

“H_1“ shown on the display.

H_1 0.000 Use the / buttons to set the value to

e.g., “0.000“.

The pressure switch switches off again

according to the following calculation:
Switch off = “P_1“ - “H_1“ = “-.540“ – “0.000“,
In this example = “-.540“.
(TSK hysteresis default value 0.000).

Press and hold until the settings have been

saved.
0.000
Then the display changes back to the
measuring mode.

6.1.3 Verification

The pressure on the display of the sensor

must be identical to that of the certified measuring
device (from an accredited office)
e.g., - 0.180 bar.

Accuracy according SMC data sheet:

▪ Display accuracy: ± 2.0 %
▪ Repeatability: ± 0.2 %

Sensor display Measuring device display

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7. Qualified leak test (with IntelliMod unit)

The IntelliMod unit is used to evaluate and control assemblies that are integrated within test adapters. The
measurement is evaluated within the test adapter so that the higher-level test software (e.g., CS WIN nx,
cable tester SW) only must accept and show the test result.
The qualified leak test unit consists of the following components:
▪ IntelliMod leak test board
(Art.-No.: 2331502)
▪ Latest pressure sensors:
▪ 5 psi / 0,35 bar (Art.-No.: 247114)
▪ 15 psi / 1 bar (Art.-No.: 247502)
▪ 30 psi / 2 bar (Art.-No.: 247503)
▪ 100 psi / 7 bar (Art.-No.: 247504)
▪ Older pressure sensors:
▪ 7 psi / 0,5 bar (Art.-No.: 109918)
▪ 15 psi / 1 bar (Art.-No.: 109919)
▪ 30 psi / 2 bar (Art.-No.: 109920)
▪ 75 psi / 5 bar (Art.-No.: 109921)

▪ IntelliMod board
(Art.-No.: 241292)

The pressure sensor on the IntelliMod leak

test board can be used for both vacuum and
overpressure applications.

In the case of a tube test, the second test

adapter is connected to the IntelliMod board via a
4-pin connector (see TSK wiring diagram).

TSK recommends to always use the latest

firmware, min. version 2.8.

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Test adapter Leak test

7.1 Function
The IntelliMod test adapter and IntelliMod leak test board will be a test unit that controls and evaluates a
qualified leak test. The leak test fills the pressure chamber to a programmable start pressure, closes the
vent valve, and verifies the holding pressure over a programmable duration. The holding pressure can be
adjusted relative to the start pressure. Via the leak test board 2 valves are connected to control the
ventilation of the test adapter and 2 inputs to detect correct adaptation. The test result is transferred to the
test software (e.g., CS WIN nx, cable tester SW) via 2 simulated switches (optocouplers) using the test
point cards.

7.2 Ports and buttons

IntelliMod board:
▪ X1: Control LEDs status
Pin 1 LED 1 +
Pin 2 LED 1 -
Pin 3 LED 2 +
Pin 4 LED 2 -
▪ X4: Connection to SV1 (IntelliMod leak test
board)
▪ LED1-8 Status LEDs
▪ X5: Test point interface
Pin 1 / 2 Test end
Pin 3 / 4 Test OK
Pin 5 / 6 Presence
Pin 7-16 n.c.
▪ S2: button ‘Mode’
▪ X2: Module voltage
Pin 1 LED 5V
Pin 2 TP LED
Pin 3 GND
Pin 4 +24 V DC
▪ S1: button ‘Step’
IntelliMod leak test board:
▪ SV1: Connection to X4 (IntelliMod board)
▪ Pressure switch
▪ Connection vacuum
▪ Connection overpressure
▪ X1:
Pin-1 (-) Test adapter 1
Pin-2 (+) Test adapter 1
Pin-3 (-) Test adapter 2
Pin-4 (+) Test adapter 2
▪ X2:
Pin-1 (-) Ventil Filling
Pin-2 (+) Ventil Filling
Pin-3 (-) Ventil Chamber
Pin-4 (+) Ventil Chamber

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Test adapter Leak test

7.3 Test mode

The test is performed in following subsequent steps:
▪ Wait for adaptation:
Both adaptation inputs must be closed to start the test. This is the signal that the connection has been
inserted into the adaptation module.
▪ Fill pressure chamber:
The valves “Fill” and – in case of vacuum test – “Inlet” is opened so that air flows into the pressure
chamber, increasing / decreasing the pressure. When reaching the “start pressure”, the valves are
closed. During this phase the green state Led on the adaptation module’s upper side blinks.
▪ Hold pressure:
The electronics supervises the pressure during this period. If the pressure falls below the pre-defined
hold pressure value, the test ends with an error. During this phase both state LEDs on the adaptation
module’s upper side blink.
▪ Test Ready:
After test the result is reported through the simulated switches to the connected test point card. If both
signals are set, the test was ok. The state LEDs are set according to the test result: green for OK, red
for NOK.
▪ Venting (de-aerate):
Finally the inlet valve is activated again to release the pressure air from the adaptation chamber. The
test results (front and test point output) are kept until the connector is released

The following graph shows a typical

pressure curve during the test phases:

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Test adapter Leak test

7.3.1 Additional Information

▪ If the pressure during the phase “Fill chamber” does not reach the “start pressure” within 5 seconds,
the test breaks, displaying an error condition (front red LED on). The same happens if the pressure is
reached too fast (less than 0.5 seconds). No test point switch is activated in these cases.
In both cases, the throttle valve must be readjusted; the optimum filling time is between 1 and 3
seconds.
▪ During the phases “fill chamber” and “hold pressure” the actual measured pressure is displayed by the
IntelliMod LEDs in relative values of the sensor’s range. This is a good help for regulation of the throttle
valve (see above).
▪ If the connector is released during test, the test is stopped immediately without output of a test result.
▪ The test only starts if both adaptation switches (tube) are activated. If only one switch is used, the
second contact must be bridged permanently.
▪ In the vacuum variant, the chamber valve is also opened during filling, as the Venturi nozzle is guided
to the chamber via this valve.
▪ In the case of the hose test (2 ends), the venturi valve is located on the second adaptation module. In
the case of a hose test with 3 ends, a second measuring unit is also evaluated. This must report back
at least half the nominal final pressure when the final pressure is reached.

7.3.2 Status LEDs

You can visually follow the status of the test procedure and the test result using the green and red LEDs on
the test adapter top plate.

The LEDs can be installed on any leak test adapter. In most cases, they are only installed on
'tube' or 'single tube' test adapters, e.g.:

Test adapter Test adapter Test adapter

Tube-2 Tube-1 Tube-3
incl. status LEDs

7.3.2.1 Successful result (OK)

Filling: Hold / Capture: Venting: OK result:
Red LED flashes. Red and green LED Filled pressure is Green LED lights
flash at the same time. released. continuously.

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7.3.2.2 Faulty result (NOK)

Filling: Hold / Capture: Venting: NOK result:
Red LED flashes. Red and green LED Filled pressure is Red LED lights continuously.
flash at the same time. released.

There is a leak in the system. Make sure the test item is correct and recheck the connection
points.

7.3.2.3 Faulty result (NOK) – Filled pressure cannot reach the value
Filling: Venting: NOK result:
Red LED flashes. Filled pressure is Red LED lights continuously.
released.

The pressure value cannot be reached, check the settings of the regulator.

7.3.2.4 Faulty result (NOK) – Filled pressure too high

Filling: Venting: NOK result:
Red LED lights Filled pressure is Red LED lights continuously.
continuously. released.

The incoming air is too high, use the air shut-off valve to vent the valve.

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7.4 Configuration

7.4.1 Calculation of the pressure sensor

Option Leak Test: IntelliMod (Overpressure)
Start pressure: 2.100 bar Example of a customer specification:
Max. pressure loss: 0.300 bar
Hold time: 6s
The calculation is made using the information from
the customer specification and the table below.

To realize the test pressure according to customer

specification (2.1 bar), there are two possibilities:
1. Pressure sensor type 2.1 bar,
i.e., the range value must be 100%.
2. Pressure sensor type 7.0 bar,
i.e., the range value must be 30%.

7.4.2 Pressure sensor table

Latest pressure sensors, Art.-No.: 247114 --- 247502 247503 --- 247504
Older pressure sensors, Art.-No.: --- 109918 109919 109920 109921 ---
PSI bar PSI bar PSI bar PSI bar PSI bar PSI bar
LEDs Range 5 0.35 7 0.5 15 1.05 30 2.1 75 5 100 7
1 2 3 4 5 6 7 8 Step %
◼ ◼ ◼ ◼ ◼ ◼ ◼ 1 30 1,50 0,10 2,10 0,15 4,50 0,31 9,00 0,63 22,50 1,50 30,00 2,10

◼ ◼ ◼ ◼ ◼ ◼ 2 35 1,75 0,12 2,45 0,18 5,25 0,37 10,50 0,73 26,25 1,75 35,00 2,40

◼ ◼ ◼ ◼ ◼ ◼ ◼ 3 40 2,00 0,14 2,80 0,20 6,00 0,42 12,00 0,84 30,00 2,00 40,00 2,80

◼ ◼ ◼ ◼ ◼ ◼ 4 45 2,25 0,16 3,15 0,23 6,75 0,47 13,50 0,94 33,75 2,25 45,00 3,10

◼ ◼ ◼ ◼ ◼ ◼ ◼ 5 50 2,50 0,17 3,50 0,25 7,50 0,52 15,00 1,05 37,5 2,50 50,00 3,50

◼ ◼ ◼ ◼ ◼ ◼ 6 55 2,75 0,19 3,85 0,28 8,25 0,58 16,50 1,15 41,25 2,75 55,00 3,80

◼ ◼ ◼ ◼ ◼ ◼ ◼ 7 60 3,00 0,21 4,20 0,30 9,00 0,63 18,00 1,26 45,00 3,00 60,00 4,20

◼ ◼ ◼ ◼ ◼ ◼ 8 65 3,25 0,23 4,55 0,33 9,75 0,68 19,50 1,36 48,75 3,25 65,00 4,50

◼ ◼ ◼ ◼ ◼ ◼ ◼ 9 70 3,50 0,24 4,90 0,35 10,5 0,73 21,00 1,47 52,5 3,50 70,00 4,90

◼ ◼ ◼ ◼ ◼ ◼ 10 75 3,75 0,26 5,25 0,38 11,25 0,79 22,50 1,57 56,25 3,75 75,00 5,20

◼ ◼ ◼ ◼ ◼ ◼ ◼ 11 80 4,00 0,28 5,60 0,40 12,00 0,84 24,00 1,68 60,00 4,00 80,00 5,60

◼ ◼ ◼ ◼ ◼ ◼ 12 85 4,25 0,30 5,95 0,43 12,75 0,89 25,50 1,78 63,75 4,25 85,00 5,90

◼ ◼ ◼ ◼ ◼ ◼ ◼ 13 90 4,5 0,31 6,30 0,45 13,50 0,94 27,00 1,89 67,50 4,50 90,00 6,30

◼ ◼ ◼ ◼ ◼ ◼ 14 95 4,75 0,33 6,65 0,48 14,25 1,00 28,50 1,99 71,25 4,75 95,00 6,60

◼ ◼ ◼ ◼ ◼ ◼ ◼ 15 100 5,00 0,35 7,00 0,50 15,00 1,05 30,0 2,10 75,00 5,00 100 7,00

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7.4.3 Installation / Changing the pressure sensor

Install the calculated pressure sensor on the
socket of the IntelliMod leak test board.

Example of calculation:
▪ Customer specification: 2.1 bar
▪ Pressure sensor type: 7 bar
(Art.-No.: 247504)
▪ Range: 30 % (for 2.1 bar)

When inserting the pressure sensor,

make sure that the polarity is correct and the
contacts are not bent!

7.4.4 Programming, with the Mode and Step buttons

7.4.4.1 Switching on and checking the set function
Connect the IntelliMod board to a 24 V DC power
supply (see page 26).

Afterwards, the currently set function is

displayed by shortly switching on an LED e.g.,
‘LED 3 = qualified leak test overpressure’.

7.4.4.2 Select a function

If the required function is not active, then you must
proceed as follows:

Disconnect the IntelliMod board from the power

supply.

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Reconnect the IntelliMod board to a power supply.

The currently set function is displayed.

Then all LEDs from 1-8 are switched on and off

one after the other.

After the last LED (8) is switched off, the “Mode”

button must be pressed immediately and hold for 3
seconds.

Press the ‘Step’ button repeatedly until the

required function is selected,
e.g., ‘LED 3 = qualified leak test overpressure’.

Possible function settings options:

LED 1: Color test (with Keyence color sensor)
LED 2: Qualified Leak test vacuum
LED 3: Qualified Leak test Overpressure
LED 4: Qualified Leak test tube Overpressure
LED 5: << not be used >>
LED 6: Qualified Leak test tube Overpressure
with 3 ends (2x leak test boards)
LED 7: Qualified Leak test Stand-alone
test system
LED 8: Qualified Leak test tube Overpressure
with 4 ends (digital sensors)

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7.4.4.3 Configuration mode

7.4.4.3.1 Starting the configuration mode
Press the ‘Mode’ button to start the configuration
mode.

The activation of the configuration mode is

confirmed by all 8 LEDs flashing once.

7.4.4.3.2 Setting the start pressure

The current ‘set start pressure’ is

displayed.
Press the ‘Step’ button repeatedly until the
required setting is selected e.g., Step 1 = LED 1.

Example of calculation:
▪ Customer specification: 2.1 bar
▪ Pressure sensor type: 7 bar
▪ Range: 30 % (for 2.1 bar)
 Step 1, according to table (see page 30)

If you use other pressure sensor types

which are not in the table (see page 30), you can
calculate them as follows:
 pressure sensor (range) * (0,25 + (0,05 *
Step))

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7.4.4.3.3 Setting the max. pressure loss

Then press the ‘Mode’ button to set the ‘max.
pressure loss’.

LEDs Step Pressure loss (%)

1 2 3 4 5 6 7 8 The current ‘max. pressure loss’ is
◼ ◼ ◼ ◼ ◼ ◼ ◼ 1 2 displayed.
◼ ◼ ◼ ◼ ◼ ◼ 2 4

◼ ◼ ◼ ◼ ◼ ◼ ◼ 3 6
% = max. pressure loss * 100 / start pressure
◼ ◼ ◼ ◼ ◼ ◼ 4 8

◼ ◼ ◼ ◼ ◼ ◼ ◼ 5 10

◼ ◼ ◼ ◼ ◼ ◼ 6 12
Example of calculation:
◼ ◼ ◼ ◼ ◼ ◼ ◼ 7 14 According to customer specification:
◼ ◼ ◼ ◼ ◼ ◼ 8 16 ▪ Start pressure: 2.1 bar
◼ ◼ ◼ ◼ ◼ ◼ ◼ 9 18 ▪ Max. pressure loss: 0.3
◼ ◼ ◼ ◼ ◼ ◼ 10 20

◼ ◼ ◼ ◼ ◼ ◼ ◼ 11 22
 0.3 *100 = 30
◼ ◼ ◼ ◼ ◼ ◼ 12 24
30 / 2.1 = 14.28 (= Step 7)
◼ ◼ ◼ ◼ ◼ ◼ ◼ 13 26

◼ ◼ ◼ ◼ ◼ ◼ 14 28

◼ ◼ ◼ ◼ ◼ ◼ ◼ 15 30

Press the ‘Step’ key repeatedly until the required

setting is selected e.g., Step 7 = LED 4.

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7.4.4.3.4 Setting the hold time

Then press the ‘Mode’ button to set the ‘hold time’.

LEDs 1…8 Step Hold time (s)

1 2 3 4 5 6 7 8 The current ‘hold time’ is displayed.
◼ ◼ ◼ ◼ ◼ ◼ ◼ 1 2

◼ ◼ ◼ ◼ ◼ ◼ 2 4
According to customer specification should be 6
◼ ◼ ◼ ◼ ◼ ◼ ◼ 3 6
seconds.
◼ ◼ ◼ ◼ ◼ ◼ 4 8

◼ ◼ ◼ ◼ ◼ ◼ ◼ 5 10

◼ ◼ ◼ ◼ ◼ ◼ 6 12
 6 seconds (= Step 3)
◼ ◼ ◼ ◼ ◼ ◼ ◼ 7 14

◼ ◼ ◼ ◼ ◼ ◼ 8 16

◼ ◼ ◼ ◼ ◼ ◼ ◼ 9 18

◼ ◼ ◼ ◼ ◼ ◼ 10 20

◼ ◼ ◼ ◼ ◼ ◼ ◼ 11 22

◼ ◼ ◼ ◼ ◼ ◼ 12 24

◼ ◼ ◼ ◼ ◼ ◼ ◼ 13 26

◼ ◼ ◼ ◼ ◼ ◼ 14 28

◼ ◼ ◼ ◼ ◼ ◼ ◼ 15 30

Press the ‘Step’ key repeatedly until the required

setting is selected e.g., Step 3 = LED 2.

7.4.4.3.5 Saving
Press the ‘Mode’ button again to save the settings
to the IntelliMod board.

The LEDs light up once from 1 to 8 to

indicate test readiness.

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7.4.5 Programming with the IntelliMod Programmer

The setting of the IntelliMod unit (incl. IntelliMod leak test board) is done by the firmware which has to be
loaded via the IntelliMod programmer.

See documentation ‘IntelliMod Programmer_Operating manual’.

Connect the IntelliMod programmer to the

IntelliMod board with the programming cable.

Pay attention to the correct polarity!!

Never disconnect the IntelliMod

programmer from the IntelliMod board during
the update/setup process.

During data transfer the LEDs on the

IntelliMod board light up.

Switch on the IntelliMod Programmer.

The start screen with the TSK logo appears. Press

any button to enter the menu.

On…Off

Explanation of the menus:

Choose action: Start detect
Start detect Detection and setup of the connected IntelliMod
board.
Repair settings
Program device Repair settings
Restoration of the parameters of the connected
Info IntelliMod board.
Program device
Update the firmware version of the connected
IntelliMod board.
Info
Display of the current firmware version.

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Choose action: Select the ‘Start detect’ menu with /

Start detect buttons.
Repair settings
Program device
Then press .
Info

Start detect device… In the first step, the IntelliMod programmer detects
IntelliMod detected! whether an IntelliMod board is connected correctly.

Press key…

If the plug has been inserted

incorrectly, a warning appears.

Press any button to continue e.g., .

7.4.5.1 Optional: Firmware Update

Check If the firmware version is outdated, the IntelliMod
firmware version: programmer first asks for an update.

V2.8 detected ->

Improved standard The programmer saves the parameters
from the IntelliMod board and restores them
firmware
after the update.
No parameters are lost.
Press key… It is possible to change parameters without
updating to new firmware. We recommend
updating old IntelliMod versions!
crc:0xfe2b

Press any button to continue e.g., .

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Update The firmware update is started.

firmware version:

Progress 80% Example: Firmware Update.

Restore EEPROM An information message appears after the update.

[Information]
[Information] Press any button to continue e.g., .
[Information]

Update
Complete !

Press key …

7.4.5.2 Menu ‘Function mode’

First set the function mode of the connected IntelliMod board:

Explanation of the menus:

Select function mode:

Color single Color detection, with a color sensor.

Underpressure Qualified leak test, with vacuum.
Overpressure Qualified leak test, with overpressure.
Tube 2 ending Qualified leak test, with two end tubes.
Color dual Color detection, with two color sensors.
Tube 3 ending Qualified leak test, with three end tubes.
External sensor Stand-alone qualified leak test
Tube 4 ending Qualified leak test, with four end tubes.
Factory default No function.

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7.4.5.3 Setup the selected function

In this example, the pressure sensor 7 bar (Range 30%) is used.

Select function mode: Select the ‘Overpressure’ option with /

Color single buttons.
Underpressure
Overpressure
Then press .
Tube 2 ending
Color dual
Tube 3 ending
External sensor
Tube 4 ending
Factory default

Set parameter Use the / buttons to set the start

start pressure: pressure of the installed pressure sensor.
Selected pressure sensor 7 bar i.e., Range = 30%
-> 30% according to table (see page 30).

Then press .

Set parameter Use the / buttons to set the holding

hold time: time for which the pressure must be held in the
plug chamber.
-> 6 sec. According to customer specification 6 seconds.

Then press .

Set parameter Use the / keys to set the max.

max. leak: pressure loss after the dwell time in percent.
According to customer specification 0.3 bar (from
-> 14% 2.1 bar = 14%).

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7.4.5.4 Transfer data

Set parameter
max. leak: After all parameters are defined, they are
written to the permanent memory of the connected
IntelliMod board.
-> 14%

Press .

Write new parameter…

Check new parameter… The data are transferred and checked.
OK!

Press key… Press any button to continue e.g., .

IntelliMod is ready: Disconnect the programming cable from the

please disconnect IntelliMod board.
IntelliMod

Press key…

Press any button to continue e.g., .

Choose action:
Start detect You will return to the Start menu.
Repair settings
Program device
Info Switch off the IntelliMod programmer.

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8. Test Mode

See description in the documents:

‚CS_WIN_nx_Operating manual’ ‚CT30ix_Operating manual’

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9. Maintenance and care

9.1 Tips on spare parts

Use only TSK spare parts. All spare parts may only be replaced by authorized expert personnel in your
company.
Only TSK service personnel may carry out settings on the test system.
This also applies to the use of components that do not appear on the spare parts list.

9.1.1 Maintenance unit/compressed air connections

Check the set compressed air (see ‘Technical data’) on the maintenance unit once a week.
Inspect the water separator once a week and empty it if it contains fluid.

If the system does not have a maintenance unit attached, make sure that a suitable,
filtered supply of compressed air is available in your plant.
Filtered/dried compressed air (quality class ISO 8573-1:5/5/4) must be provided on site.

Make sure the compressed air does not fall below 5 bar at all outputs of the pneumatic
rail. This may occur e.g., when systems have a length of 2,400 mm or more.
In cases such as this, you must disconnect the compressed air distribution on and beyond this
pneumatic rail and establish the compressed air distribution anew using a second supply (incl.
maintenance unit).

9.2 Test adapter

Pay attention to the ‘Safety information’ in the ‘Test adapter’ section.

Clean surfaces once a week using a commercially available cleaning agent and a soft cloth.
Material residues from plastic connectors collect on the contours of the test adapter. Clean the contours
daily to make sure the test adapter continues to function properly. Remove material residues using a
commercially available vacuum cleaner and/or by blowing out with compressed air.

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9.2.1 Release button

Clean the surfaces with a commercial glass cleaner and soft cloth.
If the release button on the test adapter does not work or no longer reacts correctly, you must replace it.

9.2.2 Test adapter levels

Most test adapters are produced with moving levels that push the contact pins against the connector
contacts. To make sure this mechanism functions without problem, you must check the ease of movement
of the guide pins at regular intervals.

Maintenance-free anti-friction bushes and bearings are generally used. Therefore, no

lubrication is required.
If anti-friction bushes and bearings have been used that require lubrication at appropriate
intervals, we provide a specific notice to this effect.

9.2.3 Replacing contact pins (GKS)

Defective contact pins are replaced using a suitable special tool that you can order from TSK.

See ‘Accessories, spare and wearing parts list’ – ‘Test probe screwdriver’.
Contact pins (GKS) may be fitted with differently shaped heads for different test requirements.

For contact pins with a small head, test probe screwdrivers with a
solid head are used.

For contact pins with a large head, test probe screwdrivers with an
open head are used.

Removing a contact pin:

▪ First, determine what type of contact pin is used.
▪ Select the appropriate test probe screwdriver for the type.
▪ Unscrew the defective contact pin out of the sleeve from above.
▪ Remove the unscrewed contact pin from the sleeve.

Installing a contact pin:

▪ Insert a new contact pin.
▪ Screw the new contact pin into the sleeve from above as far as the stop.

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9.2.4 Replacing switching contact pins (SKS)

Defective switching contact pins are replaced using a suitable special tool that you can order from TSK.

Removing a defective switching contact pin:

▪ Take the test adapter out of the test grid.
▪ Using a soldering iron, remove the connecting cable from the switching contact pin.
▪ Unscrew the defective switching contact pin out of the sleeve from above.
(See ‘Accessories, spare and wearing parts list’ – ‘Test probe screwdriver’).
▪ Remove the unscrewed switching contact pin from the sleeve.

Inserting a new switching contact pin:

▪ Screw the new switching contact pin into the sleeve from above as far as the stop.
▪ Solder the connecting cable to the switching contact pin.

Adjusting and fixing the switching point:

▪ Insert a test piece into the test adapter contour.
▪ If the lock of the connector is activated when it is approx. 0.5 mm above the base of the contour, the
setting is correct.
▪ If the connector is not locked, you must unscrew the switching contact pin out of the sleeve once
more.
▪ If the connector locks too soon, screw the pin slightly further into the sleeve.
▪ Repeat the adjustment with the test piece until it locks correctly in the contour on insertion.

9.2.5 Spring forces of contact pins/locking contact pins

For checking the spring force of contact pins and locking contact pins, TSK developed the ‘Pin testing
system FK50 (article no.: 401443)’ and the ‘Pin testing system FK50 with CS WIN nx (article no.: 401779)’.
With this testing system, you can determine the spring forces of individual contact pins and compare them
with the target values in the specification.
We recommend checking the spring forces at regular intervals:
▪ Contact pins (GKS) (standard types) after approx. 100,000 test cycles
▪ Locking contact pins (standard types) after approx. 50,000 test cycles

The test cycles may vary for special contact pins.

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9.2.6 Operating pressure of the leak test adapter

You must check the operating pressure of the leak test adapter at regular intervals (max. every 3 months).
Check the tightness of leak test adapters if there have been changes to the connector or its sealing
material, or a change of connector supplier.

Checking tightness:
▪ Switch off the test system.
▪ Remove the leak test adapter from the test system.
▪ First, check the inlet pressure of the test adapter (see ‘Technical data’).
▪ Detach the compressed air hose from the PE converter.
▪ Insert the detached end of the hose in the inlet of the compressed air gage.
▪ Connect the second compressed air hose of the gage to the PE converter.
▪ For test purposes, switch the test system back on.
▪ Use a connector from current production for the test.
▪ The gage should show a pressure in the range 0.08 to 0.25 bar.
▪ TSK recommends a pressure setting from 0.2 to 0.25 bar (experience shows that the tightness of
95 % of all connectors can be tested in this way).
▪ If this is not the case, you can adjust the pressure to the required value using the pressure control
valve.

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10. Sources of errors and remedy

Malfunction Cause Remedy
Test adapter is not working ▪ Interruption in line between ▪ Check cable between
adapter and measuring system measuring system and test
adapter (see wiring diagram)
(replace if necessary)
▪ Faulty, dirty or worn contact ▪ Replace and/or clean contact
pins pins
▪ Levels do not have sufficient ▪ Mechanical readjustment by
ease of movement expert personnel
▪ Compressed air is too low ▪ Check whether correct
pressure is switched on the
maintenance unit (see
‘Technical data’)
▪ Faulty locking cylinders ▪ Check correct function of
locking cylinders (replace if
necessary)
▪ Connector under test does not ▪ Check or replace switching
lock correctly in test adapter contact pin (SKS)
contour
Connector under test does not lock ▪ Compressed air is too low ▪ Check whether correct
correctly in test adapter contour pressure is switched on the
maintenance unit (see
‘Technical data’)
▪ Faulty locking cylinders ▪ Check correct function of
locking cylinders (replace if
necessary)
▪ Faulty test adapter ▪ Inspection by expert personnel
only
▪ Faulty table control ▪ Inspection by expert personnel
only
Test is not functioning ▪ Tester (e.g., CTxx, IO control ▪ Switch on the tester
system, …) is not switched on
▪ Tester has faulty internal or ▪ Check correct function of test
external test point cards point cards (replace if
necessary, expert personnel
only)
▪ Faulty power pack(s) ▪ Check correct function of all
power packs (replace if
necessary)
▪ Interruption in line between test ▪ Check (based on wiring
piece and measuring system diagram) connections between
test piece and measuring
system (replace if necessary)
▪ Test piece is not locked in ▪ Check that connector under
place correctly test is correctly positioned in
test adapter

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Malfunction Cause Remedy

Sensor is not working ▪ Faulty sensor ▪ Check function of sensor
(replace if necessary)
▪ Interruption in connecting cable ▪ Check connecting cable to
sensor (see wiring diagram)
(replace if necessary)
No compressed air in the system ▪ Interruption of on-site ▪ Check pneumatic compressed
compressed air supply air hoses
▪ Stopcock is closed ▪ Open the stopcock
▪ Faulty maintenance unit ▪ Replace the complete
maintenance unit
▪ Pressure was incorrectly set ▪ Set the pressure (see
‘Technical data’)

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11. Verification of pressure switch SMC

11.1 Leak test unit, overpressure, 24 V DC, incl. pressure switch

Art.-No.: 2344671
▪ incl.:
Pressure switch SMC ZSE30AF01BG
(Art.-No.: 110351)

▪ Pressure switch input

(compressed air from sealing cage)
▪ Pressure switch
▪ Output regulated compressed air
▪ Throttle
▪ Inlet pressure 6 bar
▪ 5/2-way solenoid valve

11.1.1 Setting – Preparation

Adjustments must always be executed with connectors or harnesses from current production!
Pull the tube from the ‘Pressure switch input’.

Example sketches

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Connect a certified digital pressure instrument

(from accredited office) via a PE converter and a
Y-connector as follows:
▪  Tube end from Y connector
 Unit ‘Input pressure switch’ .

▪  Tube end from Y connector

 disconnected tube end (that was
previously into the ‘Output regulated
compressed air’ unit).

Connect the test adapter pneumatically and

electrically, e.g., to a TSK module tester or Test
system.
▪ Test points
▪ Power supply
▪ Pneumatic

See document
‘Operating Manual_TSK_Module_Tester’ or
‘[Test system]_Operating Manual’.

11.1.2 Measuring

The pressure on the display of the sensor

must be identical to that of the certified measuring
device (from an accredited office)
e.g., 0.490 bar.

Accuracy according SMC data sheet:

▪ Display accuracy: ± 2.0 %
▪ Repeatability: ± 0.2 %

Sensor display Measuring device display

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11.2 Leak test unit, vacuum, 24 V DC, incl. pressure switch

Art.-No.: 2344672
▪ incl.:
Pressure switch SMC ZSE30AF01BG
(Art.-No.: 110351)
▪ Venturi nozzle
(Art.-No.: 110352)

▪ Pressure switch input

(compressed air from sealing cage)
▪ Pressure switch
▪ 5/2-way solenoid valve
▪ Inlet pressure 6 bar

▪ Output regulated compressed air

▪ Venturi nozzle (negative pressure or vacuum
generator)

11.2.1 Setting – Preparation

Adjustments must always be executed with connectors or harnesses from current production!
Pull the tube from the Venturi nozzle.

Example sketches

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Connect a certified digital pressure instrument

(from accredited office) via a PE converter and a
Y-connector as follows:
▪  Tube end from Y connector
 Unit ‘Input pressure switch’ .

▪  Tube end from Y connector

 disconnected tube end (that was
previously into the Venturi nozzle).

Connect the test adapter pneumatically and

electrically, e.g., to a TSK module tester or Test
system.
▪ Test points
▪ Power supply
▪ Pneumatic

See document
‘Operating Manual_TSK_Module_Tester’ or
‘[Test system]_Operating Manual’.

11.2.2 Measuring

The pressure on the display of the sensor

must be identical to that of the certified measuring
device (from an accredited office)
e.g., - 0.180 bar.

Accuracy according SMC data sheet:

▪ Display accuracy: ± 2.0 %
▪ Repeatability: ± 0.2 %

Sensor display Measuring device display

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