MD-490M Manual PDF

MD490M PORTABLE
HELIUM LEAK DETECTOR
OPERATION MANUAL
MANUAL- MD-490M PORTABLE HELIUM LEAK DETECTOR
MD490M PORTABLE
HELIUM LEAK DETECTOR
OPERATION MANUAL
861-033MAN- REV - A MD490M 966-493 Page I of III

TABLE OF CONTENTS
SECTION 1.0 - INSTALLATION AND OPERATION ............................................................. 1

UNCRATING ........................................................................................................................... 1
GETTING THE UNIT READY FOR OPERATION ................................................................... 1
OPERATING MODES ............................................................................................................. 1
UTILITY CONNECTIONS ....................................................................................................... 2
EXTERNAL MANIFOLD .......................................................................................................... 2
FORE-LINE CONNECTION .................................................................................................... 3
FORELINE ISOLATION VALVE.............................................................................................. 3
INTERNAL MANIFOLD ........................................................................................................... 4
OPTIONAL SNIFF PROBE VALVE / SNIFF ISOLATION VALVE........................................... 4
CALIBRATOR VALVE ............................................................................................................. 5
SECTION 2.0 - SYSTEM START UP ........................................................................................ 6
ADJUSTING SENSITIVITY ..................................................................................................... 6
TURBO SPEED ...................................................................................................................... 6
EMISSION SETTING .............................................................................................................. 6
GAIN SETTING ....................................................................................................................... 7
ADJUSTING SNIFF MODE SENSITIVITY .............................................................................. 7
SNIFF FLOW VALVE .............................................................................................................. 7
SNIFF CALIBRATION PROCEDURE ..................................................................................... 7
SECTION 3.0 - CONTROL AND MONITORING I/O ............................................................. 8
PLC I/O CONSISTS OF THE FOLLOWING CONTROLS....................................................... 8
AC HOT / AC RTN OR DC+ / DC- .......................................................................................... 8
SETPOINT 1 AND SETPOINT 2 ............................................................................................. 9
READY .................................................................................................................................... 9
AUTO ZERO ........................................................................................................................... 9
AUXILIARY I/O INTERFACE USES A 25-PIN D-SUB CONNECTOR. ................................... 9
LEAK RATE OUTPUTS ........................................................................................................ 10
LEAK RATE SIGNAL BAR GRAPH ...................................................................................... 10
SECTION 4.0 – SYSTEM COMPONENTS ............................................................................. 11
MASS SPECTROMETER ASSEMBLY ................................................................................. 11
ION SOURCE ....................................................................................................................... 11
MAGNET ............................................................................................................................... 11
COLLECTOR AND AMPLIFIER ............................................................................................ 12
TURBO-MOLECULAR PUMP ............................................................................................... 12
TURBO PUMP ELECTRONIC DRIVE MODULE. ................................................................. 12
CONVECTRON VACUUM GAUGE: ..................................................................................... 13
INTERNAL HELIUM LEAK STANDARD ............................................................................... 13
FRONT PANEL CONTROLS ................................................................................................ 13
INDICATORS ........................................................................................................................ 14
861-033MAN- REV - A MD490M 966-493 Page II of III
NAVIGATING THE MENU .................................................................................................... 15

SECTION 5.0 – GENERAL MAINTENANCE ....................................................................... 19
MAINTENANCE SCHEDULE ................................................................................................ 19
GENERAL REMARKS ON CLEANING PROCEDURES ...................................................... 20
Vacuum System ...................................................................................................................................................................................... 20
Gaskets ................................................................................................................................................................................................... 20
Solvents .................................................................................................................................................................................................. 21
External Fore-pump ................................................................................................................................................................................ 21
MAINTENANCE OF THE VACUUM SYSTEM ...................................................................... 21
MASS SPECTROMETER TUBE ........................................................................................... 22
Source removal/installation for filament plate replacement.................................................................................................................... 22
Collector Removal/Installation ............................................................................................................................................................... 24
Magnet Removal/Installation.................................................................................................................................................................. 25
Removal/Installation of Complete Spectrometer Tube ........................................................................................................................... 26
VACUUM SYSTEM MAINTENANCE .................................................................................... 27
Turbo-molecular Pump Removal/Installation......................................................................................................................................... 27
Turbo Pump Lubricant Reservoir Replacement...................................................................................................................................... 28
Sniff Orifice Replacement ...................................................................................................................................................................... 29
Needle Valve Replacement..................................................................................................................................................................... 31
ELECTRONIC ASSEMBLIES ............................................................................................... 32
Main Power Supply Removal/Installation .............................................................................................................................................. 32
PC Board Removal/Installation .............................................................................................................................................................. 33
SECTION 6. 0- TROUBLE SHOOTING ................................................................................. 35

ALPHANUMERIC DISPLAY.................................................................................................. 35
ERROR MESSAGES ............................................................................................................ 35
SECTION 7.0 – RECOMMENDED SPARE PARTS .............................................................. 37
SECTION 8.0 – BILL OF MATERIALS ................................................................................. 39

EXTERNAL MANIFOLDS PART NUMBER .......................................................................... 46
PUMPING ASSEMBLY PART NUMBER .............................................................................. 46
OPTIONAL CONVERTER BOX ............................................................................................ 46
SECTION 9 – POWER REQUIREMENTS:............................................................................ 47
APPENDIX 1 - COMMUNICATION OPTION ...................................................................... 48
861-033MAN- REV - A MD490M 966-493 Page III of III

SECTION 1.0 - INSTALLATION AND OPERATION
UNCRATING
Carefully remove the MD-490M PORTABLE LEAK DETECTOR from its shipping container. Do not
tip the unit on its side or turn upside down when removing from the container.
NOTE:
WE RECOMMEND SAVING THE ORIGINAL SHIPPING CARTON SO THAT IN THE EVENT
THE UNIT IS SENT BACK FOR MAINTENANCE IT CAN BE PACKAGED PROPERLY.
GETTING THE UNIT READY FOR OPERATION
Air pressure is required for operation of the internal vacuum isolation valve. Supply air pressure at 80
PSIG.
The unit contains a universal power supply and DC operated internal valves. This design allows the
operation from a voltage supply meeting the following specifications:
100-240VAC 50—60Hz, 3.15 Amps.
Please note the external manifold valves and PLC I/0 are voltage dependent and must be specified as
either 24VDC or 115VAC for more information see section 3.
The unit does not contain and internal vacuum pump or testing manifold. An external vacuum pump
and manifold must be connected to either the top or bottom test port .
The unit can accept universal voltage between 100 – 240 VAC 50/60 Hz.
After the power switch is turned on the unit will begin its start-up process.
OPERATING MODES
The unit operates in either a vacuum (system) or optional sniffer mode. The primary mode of operation
is chamber testing with an external manifold. SNIFF mode is available for checking system or
component leaks.
The unit will automatically enter the vacuum mode following power up. Sniffer mode is enabled via the
front panel KEY or through the hardware I/O or RS232 port.
Press SNIFF to enable sniff testing.
861-033MAN- REV - MD490M 966-493 Page 1 of 53

UTILITY CONNECTIONS
The rear panel provides the utility connections for shop air and vacuum.
Shop Air: 60psi - 80psi.
Vacuum: Used for Sniff Option. Connects to external

pump secondary vacuum port.
Rear Panel
EXTERNAL MANIFOLD
The external manifold connects to the inlet flange and provides

the leak test control valves. Connection can be made at the top or
bottom of the test port. The connections labeled TEST and
GROSS are the leak test sample valves. The connection labeled
PURGE is provided to purge the sample line. Other manifold
connections provide a tee connection for the fore-pump and a
purge gas inlet. The purge inlet is used to introduce low
pressure N2 or Air into the sample line for rapid cleanup
following a Helium test.
Manifold Assy, 24VDC Valves

652-152
Manifold Assy, 120VAC Valves

652-153

FORE-LINE CONNECTION
Foreline vacuum is the pressure at the connection between the inlet test port and external vacuum pump.
Internally, the turbo exhaust is also connected to this point provided the isolation valve is open.
Foreline pressure can be viewed on the alphanumeric display by pressing DIAG.
The required FORE-LINE vacuum level is dependent on Turbo speed. At higher turbo speeds a higher
Fore-Line pressure can be tolerated. When the Fore-Line pressure is above the limits below the Fore-
Line isolation valve closes.
TURBO SPEED FORELINE CUTOFF

Above 1000 Hz 7500 mT
Between 700 and 1000 Hz 4000 mT
Below 700 Hz 2000 mT
For vacuum or sniff testing an external fore pump must be installed.
FORE-LINE ISOLATION VALVE
The Fore-Line Isolation valve closes when power is disconnected or

if the pressure in the test port becomes too high.
473-791-1016

INTERNAL MANIFOLD
Installed in the unit is a fast clean-up sniffer manifold. This manifold is design to allow rapid switching
between sniff and vacuum testing. The manifold is shown below.
Manifold
Assembly
Calibrator Valve
Internal Calibrator
Sniffer Probe
Connection
Sniffer Probe and
Sniff Isolation
Valves
OPTIONAL SNIFF PROBE VALVE / SNIFF ISOLATION VALVE
The sniff isolation valve and the probe valve are energized from the same signal. When energized the
isolation valve isolates the vacuum test port and opens the sniffer probe valve. Probe flow is controlled
manually from the needle valve located on the back of the unit.
Sniff testing transports a gas sample from a remote location to the leak detector. The transport system
consists an external vacuum source, sniff manifold, sniff hose and probe.

SNIFFER FLOW VACUUM SOURCE
SNIFFER FLOW
VACUUM SOURCE
VIC# 013644600
In addition to the foreline vacuum pump, the sniff mode requires a vacuum.
Vacuum for the sniff system is supplied by the fore-pump inter-stage port.
Inter-stage adapter (VIC# 013644600) is required.
CALIBRATOR VALVE
The calibrator valve isolates the Helium reference from being exposed to the mass spectrometer tube. A
manual command via the menu opens this valve for sensitivity checks. This valve automatically opens
during the “PEAK” routine.

SECTION 2.0 - SYSTEM START UP
Insure the unit is connected to an appropriate power source and an external foreline vacuum pump.
Startup will begin immediately after the power switch is tuned on.
When power is applied the unit performs the following start-up sequence.
1. Self check for proper Fore-Line vacuum.

2. Turbo pump is accelerated.
3. Upon reaching full turbo speed the filament is powered.
4. Ready light is indicated.
Any faults encountered during startup or during operation will cause the Fault LED to light and an error
message will be displayed. Please see the Trouble Shooting section for more information.
ADJUSTING SENSITIVITY
Overall sensitivity is dependent on both internal and external parameters. External parameters include
the capacity of the chamber pump, vacuum pipe arrangement and cycle time.
Internal sensitivity parameters include turbo speed, filament emission and gain. As overall system
design is beyond the range of this manual, only the internally controlled parameters are detailed below.
TURBO SPEED
Turbo speed is adjustable from 600 to 1500 HZ, which equated to 36,000 – 90,000 RPM.
Generally, the unit will operate with a turbo speed between 600 –700 Hz. Higher turbo speeds can be
used to decrease sensitivity on systems with high Helium content.
Calibrated reading when sniffing requires a turbo speed under 700 Hz. As the turbo speed increase,
sniffer sensitivity is diminished. If a calibrated sniffer is required the turbo speed must be set below 700
Hz. Turbo speed is accessed via the MENU.
EMISSION SETTING
Emission is adjustable from 0.5 to 2.5 milliamps. Generally, the filament emission is set at 2.0 milli-
amps. Sensitivity and background directly follow changes in emission. For example, increasing
emission from 1mA to 2mA will double both the leak rate signal and back-ground. Emission is accessed
via the MENU.

GAIN SETTING
Gain is used to balance unit to unit sensitivity. Separate gain parameters are provide for A and B
filaments. Gain is accessed via the MENU.
ADJUSTING SNIFF MODE SENSITIVITY
An external calibrated leak is required to complete sniff mode calibration. The primary adjustment point is
the sniffer sample flow.
SNIFF FLOW VALVE
The sniff flow valve is located on the back panel of the unit. This
metering valve is manually controlled and will adjust the amount of
flow the probe is testing. Higher sensitivity can be achieved at a
lower probe flow, but at the expense of response time.
The general procedure for calibration is given below.

Sniff sensitivity is adjusted.
Note: Vacuum and Sniff mode share the same emission setting. Effects to Vacuum mode must be
considered before adjusting Emission. Step 3 and 7 below must be skipped if changes in Vacuum mode
sensitivity are to be avoided. Turbo speed must be below 700 HZ. for a calibrated response. If Vacuum
mode performance required Turbo speed to be above 700 Hz, calibrated sniff reading may not be possible.
SNIFF CALIBRATION PROCEDURE
1. Confirm Turbo speed is <700 Hz.

2. Complete AUTO PEAK
3. Press SNIFF
4. Adjust EMISSION to 2.0 milli amps and GAIN to 100.
5. Press AUTO ZERO
6. Sniff the calibrated leak.
7. Adjust needle valve as required to read the leak on scale.
8. Fine adjustments in reading can be made by adjusting GAIN or EMISSION.

SECTION 3.0 - CONTROL AND MONITORING I/O
I/O is divided into two groups, PLC and Auxiliary. PLC I/O is available for AC or DC voltages. The
Auxiliary I/O operates with DC voltages only.
PLC I/O CONSISTS OF THE FOLLOWING CONTROLS.
AC voltage version: Part# 918-509

DC voltage version: Part# 918-511
PLC I/O Interface uses a 6-Pin connector.
PIN# SIGNAL NAME LOGIC STATE
1 AC HOT or DC+ Output Common
2 AC RTN or DC- Input Common
Output, ON when
3 Setpoint 1
Leak Rate > Setpoint 1
Output, ON when
4 Setpoint 2
Leak Rate > Setpoint 2
Output, ON when
5 Ready
System is ready
Input
6 Zero
Pulse high to activate zero
AC HOT / AC RTN OR DC+ / DC-
The PLC I/O uses isolated opto-relays. An external source and sink supply must be made for operation.
Outputs will switch the AC HOT or DC+ source. Inputs use the AC RTN or DC- sink to complete the signal
return path.

SETPOINT 1 AND SETPOINT 2
Two set-points are provided for GO / NO-GO testing. Separate set-points are provided for Vacuum and
Sniff mode.
READY
The READY output is active (ON) when the unit is ready and no faults detected. The ready is active for
both vacuum and sniff mode.
AUTO ZERO
An auto zero is commanded by pulsing this input.
AUXILIARY I/O INTERFACE USES A 25-PIN D-SUB CONNECTOR.
Pin # Signal Name Electrical: Low voltage opto-coupler with 1K series

Inputs resistor.
Pin #1 is d.c. ground. Open voltage is 5.0V
2 Sniff Command Connect to Pin 1: (Hold) Open:
Sniff mode is active Port mode is active.
3 Remote Lock Connect to Pin 1: (Hold) Open:
Menu functions are locked Unlocked
4 Peak Command Connect to Pin 1: (Pulse) Open:
Peak cycle is activated. No action
Pin # Signal Name Electrical: DC sink driver (100mA Imax., 24V Vmax)
Outputs Pin #1 is sink common
15 Mode Off (open): On (0V)
Vacuum mode enabled. Sniff mode is active.
16 Peak Active Off (open): On (0V)
Peak cycle not active. Peak cycle active.
17 System Fault Off (open) On (0V)
No faults. Fault detected.

LEAK RATE OUTPUTS

The analog output span is set via jumper JP1 on the CPU board.
JP1 CPU Board Analog Span

IN 0-5
OUT 0-10
There are 2 Leak rate output connectors on the rear panel.

Twin BNC (2-Pin) connector (Shield)
Leak Rate Output

Ground (Shield)
Auxiliary Leak Rate output is a 4-Pin Connector.
Pin 1 Leak Rate Output
Pin 2 Ground
Pin 3 No Connection
Pin 4 No Connection
LEAK RATE SIGNAL BAR GRAPH
LEAK RATE SIGNAL
10 100 1000
0 1 2 3 4 5 6 7 8 9 10
The internal analog leak rate value is displayed on the bar graph and three range LED’s indicate the scale.
The bar graph displays a 10mV range with the green LED’s showing a multiplier.
Mid-scale of each LED is given below (* Shown)
Bar Graph Multiplier

Value
(mV) LED
*5 10 50mV
5 100 500mV
5 1000 5000mV

SECTION 4.0 – SYSTEM COMPONENTS
MASS SPECTROMETER ASSEMBLY
The heart of the MASS SPECTROMETER LEAK DETECTOR is the MASS

SPECTROMETER TUBE. All other components of the LEAK DETECTOR
function to create, control, measure and maintain optimum operating conditions
for this device. It is within the SPECTROMETER TUBE that the Helium tracer
gas is ionized, focused, accelerated, deflected, collected and finally transformed
into a visual indication on the LED BAR GRAPH DISPLAY.
P/N: 651-151
The SPECTROMETER TUBE may be divided into three major sections, each performing a distinct function
and yet all contributing towards the detection of small quantities of Helium. These three sections are:
ION SOURCE
Gas from the object enters the mass SPECTROMETER TUBE. In the source region the
gas molecules are subjected an electron beam. The electron beam is produced from a
coated thoria iridium filament, which is heated by passing an electric current through it.
As the electron beam bombards the incoming gas sample ions are created. Positive ions
are collimated and accelerated out of the source assembly. Since gas entering the tube
consists of several element constituents, so to does the ion beam.
P/N: 651-132
MAGNET
A 90 degree fixed magnet, which is mounted external to the vacuum system, separates
the Helium ions from all other ions in the beam.
The effect of the magnetic field is to deflect the path of the positive ions.
The degree of deflection is determined by the weight of the particles. Heavy ions, such
as nitrogen and oxygen are deflected less than other lighter ions, such as hydrogen. Only
Helium which has the target mass is deflected the required 90 degrees.
P/N: 751-104 Note: The “S” stamp indicates the magnet south pole and must be installed
with the mark facing the Spec-Tube NW40 flange.

COLLECTOR AND AMPLIFIER
The deflected Helium ions, upon their exit from the magnetic field travel toward the
Collector. Here, the ions strike the target, or collector plate, and give up their charge. The
collector plate is connected to the input of a high gain amplifier module, which is located
within the SPECTROMETER TUBE. The amplified signal is proportional to the size of
the leak in the object being tested.
P/N: 651-305
TURBO-MOLECULAR PUMP
This unit contains a hybrid turbo pump capable of high exhaust pressure. The Turbo-
molecular pump (hybrid) uses an axial blade turbine that compresses gas by momentum
transfer from high-speed rotation. The turbo pump rotor operates using a number of
angled blades. These blades are interlaced with stator blades whose angles are
diametrically opposed. The relative velocity between the rotor and the stator forces gas
molecules
From inlet to exhaust port. An external fore-pump then exhausts the gas to atmosphere.
P/N: 353-691-1018
TURBO PUMP ELECTRONIC DRIVE MODULE.
The turbo pump and the electronic drive unit (Tc100) are physically connected and together
form a single unit. The electronic drive module controls and monitors the turbo pump and is
mounted directly to the turbo pump. The electronic drive unit has two LED’s that give
information about the pump operation. Note the green LED should always be illuminated
during normal operation, upon start up the green LED with flash.
TC-100

CONVECTRON VACUUM GAUGE:
The convectron vacuum gauge measures the foreline pressure and will
close the isolation valve if the pressure in the vacuum system exceeds the
systems vacuum pressure setting. Note this will prevent damage that may
occur to the turbo pump and/or the spectrometer tube if the system
vacuum exceeds allowable pressure.
INTERNAL HELIUM LEAK STANDARD
The Helium leak reference is used for PEAKING the mass spectrometer. When opening the calibrator valve
a spike in leak rate will occur and then stabilize. Internal calibrator valve is operated via the front panel
menu.
FRONT PANEL CONTROLS
Key Function
“ENTER” Key
The ENTER key when pressed is used to open a sub menu or to confirm a set command.
“EXIT” Key
The EXIT key when pressed is used to back out of the menu or sub menu that is currently displayed.
“UP ARROW” Key

The UP arrow key when pressed will increase the value/setting that is currently displayed.
“DOWN ARROW” Key

The DOWN arrow key when pressed will decrease the value/setting that is currently displayed.
“AUDIO” Key
The AUDIO key when pressed will display the AUDIO menu, The associated LED illuminates.
Volume level is displayed and can be adjusted using the up/down arrows (0 – 100% volume).
“ZERO” Key
The ZERO key when pressed will zero out the current leak rate displayed. The zero LED indicator will
illuminate for a few seconds.

“DIAG” Key
Pressing the DIAG opens the diagnostic screen.
“SNIFF” Key
Pressing the SNIFF key will enable the sniffer operation in the unit and the associated LED illuminates.
INDICATORS
READY: Ready LED (Green) illuminates when the unit is ready for testing.
FAULT: Fault LED (Red) illuminates when a fault is present.
FILAMENT: Filament LED (Green) illuminates when filament power is present and working.
TURBO: Turbo LED (GREEN) illuminates when the turbo pump is powered and at speed
“LOCKOUT” Key
This key is located on the bottom half of the front display of the unit. The key locks all critical options that
are adjustable through the menus as well as the calibration function and turning ON/OFF of the filaments.

NAVIGATING THE MENU
MENU #1 SENSITIVITY
LEVEL FUNCTION DESCRIPTION
1 Filament A/B selection Select filament A or B
2 Filament ON/OFF Turn filaments ON/OFF. Useful for

checking background
3 Emission Adjust Adjust sensitivity Range

0.5 – 2.0mA
4 Anode Voltage Adjust Manual peak spec-tube
5 System gain Adjust gain between 50 – 200

to amplify or reduce output signal
6 Leak Rate Offset Adjust Adjust the analog output voltage zero
point
MENU#2 SYSTEM SETUP
1 Adjust setpoint value System and Sniff modes each have

(2) set-points.
2 Adjust turbo speed Turbo speed can be adjusted from

600 – 1500 Hz. Higher turbo speeds
increase allowable foreline pressure
but also decreases sensitivity
3 Setpoint display ON/OFF Effects front panel display only.

Output signals are always enabled.

MENU#3 PEAK MENU
Opens or closes Helium valve. When

1 Helium Source ON/OFF open Helium source is exposed to
vacuum system.
2 Auto Peak Enables the auto peak cycle
MENU#4 RESET HOURS
1 Turbo pump hours View / Reset hours
2 Filament A hours View / Reset hours
3 Filament b hours View / Reset hours

THE FOLLOWING IS AN EXAMPLE OF NAVIGATING THOUGH THE MENUS:
MENU#1 SENSITIVITY ENTER>CHANGE

Press MENU MENU
MENU#2 SYSTEM SETUP ENTER>SELECT

Scroll Down MENU
SP#1 5000 [ENTER]

Select Setup ENTER SP#2 5000
SET TURBOSPEED
Scroll Down MENU SETPOINT 700 Hz
SET TURBOSPEED
Adjust Speed SETPOINT 710 Hz
MENU#2 SYSTEM SETUP ENTER>SELECT

Exit SetUp EXIT
Exit Menu EXIT EXIT MENU

DIAGNOSTIC MENU
LEVEL FUNCTION
1 TURBO PUMP HRS
2 A FILAMENT HRS
B FILAMENT HRS
3 TUNE STF A C
VOLTS
4 EMISSION
FILAMENT CURRENT
5 FORELINE PRESSURE
FORELINE CUTOFF
6 COLLECTOR VOLTAGE
S-PLATE VOLTAGE
7 TURBO SPEED
BOARD TEMPERATURE
8 PROGRAM REVISION

SECTION 5.0 – GENERAL MAINTENANCE
MAINTENANCE SCHEDULE
Check oil in Fore-pump Daily
“System mode operation: Perform Sensitivity Check Monthly

by performing Manual TUNE
Check unit-fan operation Daily
“Sniffer mode operation” Probe External NIST Every Hour

gas leak
Replace oil in Fore Pump 3,000 hours
Replace fore pump filter every oil change
Chang filaments: Minimum of 6,000 hours of operation
Clean Spec tube shell Minimum of 6,000 hours of operation
Disassemble manifold, clean and replace all o-rings minimum 6,0000 hours operation
Replace oil wick assembly in turbo pump: Annually (or 6000 hrs)
NOTE:
This is a suggested maintenance schedule, in order to minimize downtime and reduce operating costs the
frequency of this schedule should be modified to reflect the cleanliness of the testing environment.

GENERAL REMARKS ON CLEANING PROCEDURES
Vacuum System
In the event the vacuum system and/or SPECTROMETER TUBE becomes contaminated by high vapor
pressure materials not easily removed by pumping and mild baking, it is necessary to disassemble and clean
all component parts affected.
Many organizations have established cleaning procedures for vacuum apparatus such as electron tube parts,
test chambers, etc. These methods will normally be appropriate for cleaning the mass spectrometer and
system. Where cleaning procedures have not been established, the following remarks should prove useful to
personnel not acquainted with the problems involved.
The specific processes used in cleaning will vary according to the material to be cleaned, nature of
contaminant, facilities available and the degree of cleanliness desired. In general, the materials to be cleaned
will vary from stainless tubing to O-rings. Internal surfaces that can be reached with clean cloth swabs
should be physically swabbed out, using a minimum of degreasing solvent on the swab. Internal portions of
the system that cannot be reached must be flushed with enough solvent to allow all surfaces to be wet, and as
much physical action employed (shaking and sloshing) as practical. See section 6.3.3 for solvent types.
Gaskets
Synthetic rubber O-Rings (usually Buna N), are susceptible to absorbing large quantities of the solvents used
in cleaning. The subsequent evaporation of these solvents when a system is evacuated must be avoided,
therefore, O-Rings and gaskets should be removed from the flange grooves and treated as a separate cleaning
problem. O-Rings and gaskets are either replaced at the time of reassemble (and this is recommended), or
carefully wiped clean with a lint-free material and inspected for surface damage of any kind before they are
used again. New O-Rings should be treated in the same manner as used ones.
Never remove O-Rings with a metal tool, as this will invariably scratch the O-Ring groove, causing a
potential, if not actual, leak. Use plastic (e.g., corner of a plastic badge, etc.) or wood (e.g., toothpick), and
remove O-Ring by inserting tool between outside of O-Ring groove and sliding around O-Ring. This will
cause the O-Ring to "pop-up" (O-Ring may have to be held on opposite side to prevent turning in groove),
and generally, gives better results than trying to pry the O-Ring from the groove.

Solvents
The solvents referred to are 99% isopropyl alcohol, trichloroethylene, acetone, or methanol alcohol.
Trichloroethylene is used where deposits of grease and oil are to be removed. Acetone is preferred over
trichloroethylene although precautions must be taken in either case. The inhalation of these vapors must be
avoided, particularly in the case of trichloroethylene, and the flammable nature of the solvent presents an
added hazard in the case of acetone.
Other cleaning agents such as soaps, alkali cleansers and synthetic detergents may be used as first-step
cleaners provided complete facilities for thorough rinsing with hot distilled water are available.
External Fore-pump
Before dismantling, allow the pump to cool down. Only dismantle the pump as far as it is necessary to effect
repairs.
MAINTENANCE OF THE VACUUM SYSTEM
A foremost basic requirement of the MD-490M series Mass Spectrometer operation is system cleanliness.
The internal surface of the entire vacuum system should be maintained physically clean (lint, dust) and
chemically clean (oils, solvents). Therefore, when repairing or maintaining components of the vacuum
system, the utmost care should be exercised to prevent the entry of contaminating substances (oils, grease,
lint, dirt, etc.) into the vacuum system. Washable parts generally may be cleansed in a suitable chlorinated
solvent. Parts should be given a final rinse in clean solvent, and heat dried.

MASS SPECTROMETER TUBE
Source removal/installation for filament plate replacement
Required tools: 3/16" Nut Driver, 7/64" Hex Key Wrench, 1/8" Blade Screwdriver
NOTE:
SOURCE ASSEMBLY MAY BE RETURNED TO THE FACTORY FOR COMPLETE CLEANING
AND FILAMENT REPLACEMENT P/N 952-108.
a) Switch power switch to OFF position.
b) Remove the power cord connector from the back panel.
c) Remove cover.
d) Remove the electrical octal connectors from the source and collector assemblies.
e) Unscrew the wing nut on the NW-40 quick disconnect clamp mating the SPECTROMETER TUBE to the
Turbo pump, and be certain to hold SPECTROMETER TUBE firmly to avoid dropping.
f) Place the SPECTROMETER TUBE in a clean area for repair. Place the NW-40 clamp and seal in a clean
place.
g) Remove the three 7/64 hex socket screws securing the source assembly to the SPECTROMETER TUBE
body. The source is now free and may be removed by carefully pulling straight out of the body.
h) Make sure the source is in a clean work area where it can be disassembled without the possibility of
contamination from dirt or oils.
i) Remove sealing O-Ring from source flange.
j) The source contains a pair of thoria-coated iridium filaments. Each filament is mounted on a disposable
Stainless steel plate. To remove the filament plate, first remove the screw, which secures the filaments
electrical connection. Then, using a 3/16" nut driver, carefully remove the 3/16" nut located near the top of
the filament plate. Once this has been performed, the plate is then lifted straight out by grasping the wire
pigtail.
NOTE:
RECOMMEND THAT BOTH FILAMENTS BE REPLACED AT THE SAME TIME. THIS WILL
ENSURE THAT A SPARE NEW FILAMENT IS AVAILABLE IF NEEDED P/N 919-128.

k) At this time, the source must be properly cleaned before the new filaments are installed. Cleaning should be
accomplished by first bead-blasting each part with a FINE, DRY glass blast at a low air pressure not
exceeding 35 PSI. Then followed by blowing clean dry air over the source assembly, to remove any foreign
particles left over from the sand blasting procedure.
l) Install the new filament plates following the reverse order of procedure 7.1.10. Make certain all screws and
nuts are securely tightened.
m) Lightly lubricate the sealing O-Ring with high vacuum grease (The o-ring should appear shinny ). Before
placing O-Ring in the groove, make certain that O-Ring groove is clean. Install O-Ring.
NOTE:
IT IS RECOMMENDED THAT A NEW O-RING BE USED, CONSIDERING THE SENSITIVE
NATURE OF THE MASS SPECTROMETER TUBE. SEE GENERAL PROCEDURES FOR
CLEANING AND LUBRICATING ELASTOMER HIGH VACUUM SEALS.
n) Clean mating flange on SPECTROMETER TUBE and insert source into tube body. The proper orientation
is to have the connector key way on the source at the 2 o'clock location, when holding the
SPECTROMETER TUBE assembly with the vacuum manifold connection on the right side.
o) Insert the three 7/64" x 1/2" long hex socket screws securing the source assembly to the SPECTROMETER
TUBE body and tighten.
NOTE:
AFTER SOURCE IS SECURED IN THE SPECTROMETER TUBE, ONE FILAMENT PLATE
SHOULD BE FOUND VIEWED THROUGH THE VACUUM MANIFOLD CONNECTION.
p) Before installing SPECTROMETER TUBE, clean and lightly lubricate the NW-40 seal ring with high
vacuum lubricant.
q) Re-connect the flange to the vacuum manifold connection using NW-40 clamp. Tighten by hand only, do
not use tools.
r) Re-connect the octal electrical connections to source and collector assemblies.
s) Tilt the back panel up to its closed position. Place the cover back on and verify that the locating screws align
with their mating receptacles. Tighten the six screws.
t) Perform "Start-Up" operating procedures to return the unit back into its operating conditions.

Collector Removal/Installation
a) Perform complete Shut Down of System.
b) Switch power switch to OFF position.
c) Remove the power cord connector from the back panel.
d) Remove cover.
e) Remove the electrical octal connectors from the source and collector assemblies.
f) Unscrew the wing nut on the NW-40 quick disconnect clamp mating the SPECTROMETER TUBE to the
Turbo pump, and be certain to hold SPECTROMETER TUBE firmly to avoid dropping.
g) Place the SPECTROMETER TUBE in a clean area for repair. And place the NW-40 clamp and seal in a
clean place for proceeding assembly.
h) Remove the three 7/64" hex socket screws securing the collector assembly to the SPECTROMETER TUBE
body.
i) Remove collector assembly from SPECTROMETER TUBE body by carefully pulling straight out of tube.
j) Replacement of the collector amplifier or any other component may now be performed in a clean work area
to avoid contamination from dirt or oils.
NOTE: HERE ARE TWO PRECISION EPOXY HIGH VALUE RESISTORS (1011 OHMS)
MOUNTED TO THE INTERNAL COLLECTOR BOARD ASSEMBLY. DO NOT TOUCH
THE EPOXY PORTION OF THE RESISTOR OR SUBJECT IT TO ANY FORM OF
CONTAMINATION. OILS FROM FINGERS DEPOSITED ON THE EPOXY PORTION OF
THE RESISTOR WILL CREATE A LESS ELECTRICALLY RESISTIVE PATH THAN
THE RESISTOR ITSELF. SHOULD SUCH A CONDITION EXIST, SEVERE ERRATIC
RESULTS WOULD BE ENCOUNTERED. IF ANY DOUBT EXISTS AS TO THE
CLEANLINESS OF THE RESISTORS CAREFULLY CLEAN THE EPOXY WITH A
CLOTH AND A CLEANING AGENT SUCH AS ACETONE, OR ALCOHOL.
k) Remove sealing O-Ring from flange, clean, lightly lubricate with high vacuum grease and replace in O-Ring
groove.
NOTE: SEE GENERAL PROCEDURES FOR CLEANING AND LUBRICATING RUBBER HIGH
VACUUM SEALS.

l) Clean mating flange on SPECTROMETER TUBE and insert collector into tube body.
NOTE:
PROPER CONNECTOR ORIENTATION IS TO HAVE THE KEY WAY ON THE COLLECTOR
AT THE 5 O'CLOCK POSITION, WHILE HOLDING THE SPECTROMETER TUBE ASSEMBLY
WITH THE NW-40 FLANGE FACING YOUR LEFT SIDE.
m) Insert the three 7/64" x 1/2" long hex socket screws securing the collector assembly to the
SPECTROMETER TUBE body and tighten.
n) Before installing SPECTROMETER TUBE, clean and lightly lubricate the NW-40 seal ring with high
vacuum grease.
o) Install seal ring and re-connect the spec tube flange to the turbo pump inlet using NW-40 clamp. Tighten
clamp by hand only, do not use tools.
p) Reconnect the octal electrical connections to source and collector assemblies.
q) Tilt the back panel up to its closed position. Place the cover back on and verify that the locating screws align
with their mating receptacles. Tighten the Fours screws.
r) Perform "Start-Up" operating procedures to return the unit back into its operating conditions.
Magnet Removal/Installation
b) Switch power switch to OFF position..
c) Remove the power cord connector from the back panel.
d) Remove cover.
e) Remove the 10-32 stainless steel screw securing magnet assembly to SPECTROMETER TUBE.
f) The magnet may now be removed by grasping firmly and pulling straight up out of the mounting area.
g) When installing magnet, be certain south-pole (marked with an "S") is on the same side of the
SPECTROMETER TUBE as the vacuum system connection. Failure to insure this orientation will result in
an inoperative SPECTROMETER TUBE.

h) Insure that magnet is firmly seated in the "V" shaped portion of the tube body and secure the magnet to the
SPECTROMETER TUBE body using the 10-32 screw provided.
NOTE: The magnet screw provided is made of either brass or stainless steel for non-magnetic
properties. If lost or damaged, do not replace this screw with another which is magnetic.
i) Tilt the back panel up to its closed position. Place the cover back on and verify that the locating screws align
with their mating receptacles. Tighten the four (4) screws.
j) Perform "Start-Up" operating procedures to return the unit back into its operating conditions.
Removal/Installation of Complete Spectrometer Tube
b) Switch power switch to OFF position. Remove the power cord from the power entry receptacle.
c) Remove cover.
turbo pump, and be certain to hold SPECTROMETER TUBE firmly to avoid dropping.
f) Place the SPECTROMETER TUBE in a clean area for later repairs. Place the NW-40 clamp and seal in a
clean place for proceeding assembly.
g) Before installing SPECTROMETER TUBE, clean and lightly lubricate the NW-40 seal ring with high
vacuum grease.
h) Install seal ring and re-connect the spec tube flange to the turbo pump inlet using NW-40 clamp. Tighten
clamp, by hand only do not use tools.
i) Re-connect the octal electrical connections to source and collector assemblies.
j) Tilt the back panel up to its closed position. Place the cover back on and verify that the locating screws align
with their mating receptacles. Tighten the Four (4) screws.
k) Perform "Start-Up" operating procedures to return the unit back into its operating conditions.

VACUUM SYSTEM MAINTENANCE
Turbo-molecular Pump Removal/Installation
Turbo Removal
a) Switch power switch to OFF position. Remove the power cord from the power entry receptacle.
b) Remove cover.
c) Unscrew the wing nut on the NW-16 quick disconnect clamp mating the manifold to the turbo pump, place
the wing nut, screw and clamp in a safe place for later reuse. Let the manifold hang over the side of the unit.
turbo pump, and be certain to hold SPECTROMETER TUBE firmly to avoid dropping
f) Place the SPECTROMETER TUBE in a clean. Place the NW-40 clamp and seal in a clean area for
proceeding assembly.
g) Locate and remove the G ¼ swivel fitting that connects the turbo exhaust hose. The exhaust hose is
connected between the turbo and diaphragm pump.
h) Gently bend the turbo exhaust hose out of the way being careful not to crimp the hose.
i) Remove the SPECTROMETER TUBE support bracket.
j) Locate, unlock, and remove turbo pump electrical connectors (2). Lay the cables along side the Fore-pump.
k) From underneath, remove the (4) #10-32 socket cap screws securing the turbo. Place screws and washers in
safe area for proceeding assembly. Use supplied plugs to cover all ports on the turbo pump.
l) Place original turbo vertically at the center of the workbench.

Turbo Installation
NOTE: PRIOR TO SEAL RING INSTALLATIONS, CLEAN SEAL RINGS AND LIGHTLY
LUBRICATE USING HIGH VACUUM GREASE.
a) Remove any plugs coving turbo ports. Position turbo over case bottom access hole. From underneath, attach
turbo to base plate using the four (4) #10-32 socket head screws.
b) Install G ¼ fitting with hose to turbo pump exhaust port.
b) Install two electrical connector to integral turbo pump power supply.
c) Attach manifold to turbo pump flange with NW-16 clamp and o-ring. Tighten clamp, finger tight only, DO
NOT use any tools.
d) Install spectrometer tube support bracket. Adjust height after installing spectrometer tube.
e) Install NW-40 seal ring and attach SPECTROMETER TUBE onto turbo pump inlet flange using NW-40
clamp. Tighten clamp, finger tight only, DO NOT use any tools.
f) Reconnect the octal electrical connections to source and collector assemblies.
g) Adjust spectrometer tube bracket to provide mechanical support to tube.
h) Tilt the back panel up to its closed position. Tighten the Four (4) screws.
i) Perform "Start-Up" operating procedures to return the unit back into its operating conditions.
Turbo Pump Lubricant Reservoir Replacement
NOTE: THE REPLACEMENT OF THE WICK SHOULD BE PERFORMED ONCE A YEAR OR

MORE FREQUENTLY WHEN LONG PERIODS OF USE WITH HIGH AMBIENT
TEMPERATURES OR AIR THAT HAS A HIGH PARTICULATE COUNT. THE WICK IS
PRE-LUBRICATED WITH OIL PRIOR TO SHIPMENT. IT SHOULD BE HANDLED
WITH GLOVES.
c) Remove the turbo pump from the vacuum system.

d) Locate the locking cover on the under side of the turbo pump. Remove the locking cover with an adjustable
pin key. Be careful with o-ring.
e) Lever out the lubricant reservoir with the help of two screwdrivers.
f) Use a lint free cloth to clean O-Ring, locking cover and turbo pump from dirt and debris.
g) Insert new lubricant reservoir, which is already filled with lubricant (Part# 917-126).
h) Screw in the locking cover with o-ring. The lubricant reservoir will adjust itself into the correct position
with the locking cover in place.
i) Re-install the turbo pump.
j) Perform "Start-Up" operating procedure to return the unit back into its operating conditions.
Sniff Orifice Replacement
Sniffer Block Assembly Sniffer Manifold assembly Remove all connections

Installed Installed (Sniffer, Tubes, Electrical
connectors)
Place block on clean Remove the four (4) screws Carefully separate the two
work surface. that connect both blocks. sections.

Orifice (30 micron)

P/N: 452-691-1027
O-Ring (Large)
P/N: 492-092-2010
O-Ring (Small)
P/N: 492-092-2010
Remove orifice and Clean / Replace

Two (2) O-rings Orifice and O-Rings
Wipe both sides of the Install O-Ring (Small) Install Orifice (30 Micron)
manifold surfaces clean P/N: 492-092-2006 P/N: 452-691-1027
Install O-Ring (Large)

P/N: 492-092-2010 Assemble both sides of Align both manifold pieces
manifolds block for the mounting screws

Sniffer Manifold Assembly

can now be installed into the MD490M
(Reverse the removal procedure)
Install four (4) mounting

screws (Tighten equally)
Needle Valve Replacement
Sniffer valve removal and replacement

P/N: 473-091-0002
Sniff flow control valve

Loosen set screw in knob, Remove knob
Allen key 5/64 required
Disconnect hoses from Remove nut securing

both fittings valve to the rear panel, Remove fittings from
remove valve. valve.

Install fittings as shown observing arrow on the

valve body. Fitting ends should be pointing up.
Teflon tape threaded ends.
Reverse removal procedure for installation of

the needle flow valve.
ELECTRONIC ASSEMBLIES
Main Power Supply Removal/Installation
Power Supply Removal
c) Remove cover.
d) Push back vertical support.
e) Remove Power Supply cables. Note on right side cable the red wire connects to the bottom terminal, and the
black wire connects to the top terminal.
f) From the outside of the unit, remove the four screws securing the power supply. Place screws and washers
in a safe place for proceeding assembly.
g) Slide power supply up to clear rear panel.
h) Do the reverse of the power supply removal.
i) Tilt the back panel up to its closed position. Place the cover back on and verify that the locating screws align
with their mating receptacles. Tighten the four screws.
j) Perform "Start-Up" operating procedures to return the unit back into its operating conditions.

PC Board Removal/Installation
CPU Board
Control Board
PC Board Removal
c) Remove cover as previously described.
NOTE:
IT IS NECESSARY TO WAIT ONE MINUTE AFTER PLACING THE POWER SWITCH TO THE
OFF POSITION TO BEGIN REMOVING PC BOARDS. THERE ARE HIGH VOLTAGE
CAPACITORS PRESENT WHICH NEED TO DISCHARGE IN THIS TIME AND COULD HAVE
A POTENTIALLY HIGH VOLTAGE PRESENT BEFORE ONE MINUTE DURATION.
d) Disconnect all connectors from PC boards and place out of the way.
e) Locate and remove (8) screws and washers and place in a safe location.
f) Gently lift both PC boards from unit. Place boards on the static protected work bench.
PC Board Installation
a) Do the reverse of the PC board removal.
b) Tilt the back panel up to its closed position. Place the cover back on and verify that the locating screws align
with their mating receptacles. Tighten the four screws.
c) Perform "Start-Up" operating procedures to return the unit back into its operating conditions.

ELECTROSTATIC DISCHARGE CAUTION
ELECTROSTATIC DISCHARGE CAN DAMAGE ELECTROSTATIC SENSITIVE ELECTRONIC

COMPONENTS. THEREFORE IT IS NECESSARY TO TAKE SPECIAL PRECAUTIONS WHEN
HANDLING THESE COMPONENTS AS FOLLOWS:
 BEFORE HANDLING ANY COMPONENTS OR TOUCHING ANYTHING INSIDE THE SYSTEM,

WEAR A PROPERLY CONNECTED GROUNDING STRAP. IF ONE IS NOT AVAILABLE, DISCHARGE
YOUR BODY'S STATIC CHARGE BY TOUCHING PART OF THE SYSTEMS METAL CHASSIS.
 DO NOT REMOVE ANY PARTS FROM THEIR ANTI-STATIC BAGS UNTIL YOU ARE
GROUNDED AND READY TO INSTALL THEM.
 DO NOT LAY ANY PARTS ON ANTI-STATIC BAGS, THEY ARE ONLY ANTIS-STATIC ON
THE INSIDE.
 HANDLE ANY PARTS BY THEIR EDGES AND METAL MOUNTING BRACKETS. AVOID
TOUCHING BOARD COMPONENTS OR EDGE CONNECTORS.
 DO NOT SLIDE PARTS ACROSS SURFACES, THIS INDUCES STATIC CHARGE BUILDUP.
 AVOID PLASTIC, VINYL, STYROFOAM AND FABRICS IN THE VICINITY.

SECTION 6. 0- TROUBLE SHOOTING
ALPHANUMERIC DISPLAY
The display is a user-friendly alphanumeric display (AND) that prompts the users through all system
operations. Display format is 2 x 20 characters. The following prompts will appear on the bottom half of the
display.
ERROR MESSAGES
FAULT POSSIBLE CAUSE SOLUTION

1. Check that the collector assembly connector is plugged in. If it is,
The collector voltage is replace the collector and retest.
COLLECTOR
2.. Check that the CONTROL BOARD and connections are fully
OR less than full-scale of – secured, replace the board and retest
SATURATED 10vdc 3. Check that the CPU BOARD electrical connections are fully
secure, replace the board and retest.
1. Verify that source ass’y electrical connection is plugged in a both
the source and control board
The filament is ON and 2. Switch Filaments and retest, one of the filaments may have failed.
FIL CURRENT the filament current is 3. Replace filaments
less than 1 amp. 4. There may be a short in the source assembly, perform a continuity
test between the Source plates.
5. The Control board may have failed, replace the board
1. Check the A plate voltage with the source electrical connection
attached and unplugged, if the voltage changes more than 5 vdc
than there may be a short in the source, perform a continuity test
A-PLATE
VOLTAGE
Short in the source between the Source plates.
2. Switch Filaments and retest, one of the filaments may have failed.
3. Replace filaments
4. The Control board may have failed replace the board and retest.
1. Check the STF plate voltage with the source electrical connection
attached and unplugged, if the voltage changes more than 5 vdc than
there may be a short in the source, perform a continuity test between
STF VOLTAGE
FAULT
Short in the source the Source plates.
4. The Control board may have failed replace the board and retest.
1. Check the TUNE plate voltage with the source electrical connection
attached and unplugged, if the voltage changes more than 5 vdc
than there may be a short in the source, perform a continuity test
TUNE VOLTAGE
FAULT
Short in the source between the Source plates.
4. The Control board may have failed replace the board and retest

FAULT POSSIBLE CAUSE SOLUTION

1. There is a short within the collector assembly, remove the collector
S-PLATE and perform a continuity test between the plates.
VOLTAGE FAULT
Control Board Failure 2. Inspect the collector harness connections at the control board J1
and the collector assembly.
3. Replace the control board.
1. Check the C plate voltage with the source electrical connection
attached and unplugged, if the voltage changes more than 5 vdc than
there may be a short in the source, perform a continuity test
C-PLATE FAULT Short in the source between the Source plates.
4. The Control board may have failed, replace the board and retest.
1. Verify that source ass’y electrical connection is plugged in a both the
source and control board
EMISSION Short in source or
FAULT blown filament 4. There may be and short in the source assembly, perform a continuity
test between the Source plates.
5. The Control board may have failed, replace the board
1. Is external fore-pump installed.
Turbo did not reach 2. The turbo pump electrical connection is not secured at X2 or
PUMP-DOWN
the RS 485 port. See the electrical schematic for details.
TIME-OUT operating speed after 3. The turbo has seized, remove the spectrometer tube to gain access to
FAULT three minutes the turbo blades. The blades should move easily, if they are
difficult to rotate the pump requires replacement
1. Peak anode voltage.

2. The sniffer probe tubing or probe filters may be clogged and
require replacement.
3. Is fore-pump inter-stage installed.
NO HELIUM
SENSITIVITY
Unit is not calibrated 4 The aperture disk ma be clogged and requires cleaning.
5. Probe the gas leak and increase the emission until the leak rate
corresponds to value of the calibrator
6. Check the magnet orientation, the stamped “S” should be on
the vacuum inlet side of the spectrometer tube.
1. Check that the main power of 110 or 220 VAC is being provided.
SYSTEM WILL Main power is 2. Measure FU1 to ensure it has not blown.
NOT POWER UP disconnected 3. Remove the display cable from CPU board at J10 and at the
display boar at J3 and re connect.

SECTION 7.0 – RECOMMENDED SPARE PARTS
PART # DESCRIPTION QTY. UNIT

651-151 MASS SPECTROMETER TUBE ASSY 1 EA
919-128 FILAMENT KIT 4/BOX 1 EA
651-132 Source MD 490 1 EA
651-304 Collector 490 1 EA
353-691-1020 TURBO PUMP ASSEMBLY 1 EA
917-126 REPLACEMENT PUMP FLUID RESERVOIR FOR TURBO PUMP 1 EA
919-558 Gasket kit MD 490-M 1 EA
656-400 MEMBRANE ASSY CONTROL PANEL, includes PC Boards 1 EA
719-402 MEMBRANE KEYPANEL ASSY MD490M (MD490M) 1 EA
584-330 PC BOARD DISPLAY 1 EA
583-336 PC BOARD ASSEMBLY, ALPHANUMERIC 1 EA
584-442 PC BOARD ASSEMBLY CPU DC 1 EA
584-444 PC BOARD ASSEMBLY CONTROL DC 1 EA
246-231-0024 POWER SUPPLY, 24V@150W,CHASSIS INTERGRATED POWER EA
362-381-0416 SPEAKER, 4", SQUARE MOUNT 16 OHM 1 EA
311-092-3625 FAN, CABNET, 3610, 24V, 4 EA
952-313 MD-490M MAINTENANCE KIT 1 EA
DWG # 652-152 - MANIFOLD ASSY EXTERNAL PIPING VALVES 24VDC (STANDARD) MD490M
189028400 VALVE OPERATOR 24VDC 1 EA
189028910 VALVE OPERATOR TYPE#6013 24VDC 1 EA
189028900 VALVE OPERATOR TYPE#6011 24VDC 1 EA
472-791-1034 GROSS VALVESEAT/RESTRICTOR 1 EA
# 652-153 - MANIFOLD ASSY EXTERNAL PIPING VALVES 120V/60,OPTIONAL MD490M
189028600 VALVE OPERATOR, 115 VAC 1 EA
189028911 VALVE OPERATOR120VAC 1 EA
189028901 VALVE OPERATOR 120VAC/60HZ 1 EA

SNIFF OPTION
189047000 NEEDLE VALVE 1 EA
011-213-1507 SNIFFER TUBING ( RED TUBING STD PROBE ) 1 EA
741-117 FILTER ASSEMBLY SNIFFER (BOX OF 50) 1 EA
413-613-1003 SS FILTER, PROBE ASSEMBLY 1 EA

SECTION 8.0 – BILL OF MATERIALS
DWG # 966-493 - LEAK DETECTOR, MD490M

REF.# DESCRIPTION PART # QTY. UNIT
10 MD490M, LEAK DETECTOR ASSY/ OUTLINE 766-502 1 EA
20 INSP, DOC, MD490M 861-512 1 EA
30 MANUAL, MD490M 861-033 1 EA
40 LABEL-"DANGER HIGH VOLTAGE"2.5 146063600 2 EA
50 KIT, SPARES MD490M LEAK DETECTOR 919-492 1 EA
DWG # 766-502 - MD490M, LEAK DETECTOR ASSY/ OUTLINE (BY)
1 ENCLOSURE ASSEMBLY MD490M 766-613 1 EA
2 VACUUM ASSEMBLY MD490M 931-126 1 EA
3 ELECTRICAL ASSEMBLY MD490M 936-155 1 EA
4 SNIFFER ASSEMBLY MD490M 658-115 1 EA
DWG # 652-152 - MANIFOLD ASSY EXTERNAL PIPING VALVES 24VDC (STANDARD) MD490M
1 MANIFOLD WELDMENT MD490M EXTERNAL VALVES 652-154 1 EA
2 VALVE OPERATOR 24VDC 189028400 1 EA
3 VALVE OPERATOR TYPE#6013 24VDC 189028910 1 EA
4 VALVE OPERATOR TYPE#6011 24VDC 189028900 1 EA
5 GROSS VALVESEAT/RESTRICTOR 472-791-1034 1 EA
6 SEAL RING, NW-25, 441-091-2006 3 EA
7 CLAMP, NW-25 442-094-2012 3 EA
8 FILTER, 1/8 NPT 189031600 1 EA
18 CONNECTOR 289-311-0012 1 EA
DWG # 652-153 - MANIFOLD ASSY EXTERNAL PIPING VALVES 120V/60,OPTIONAL MD490M
1 MANIFOLD WELDMENT MD490M EXTERNAL VALVES 652-154 1 EA
2 VALVE OPERATOR, 115 VAC 189028600 1 EA
3 VALVE OPERATOR120VAC 189028911 1 EA
4 VALVE OPERATOR 120VAC/60HZ 189028901 1 EA
5 GROSS VALVESEAT/RESTRICTOR 472-791-1034 1 EA
6 SEAL RING, NW-25, 441-091-2006 3 EA
7 CLAMP, NW-25 442-094-2012 3 EA
8 FILTER, 1/8 NPT 189031600 1 EA
18 CONNECTOR 209-311-0013 1 EA
19 CONNECTOR 289-311-0012 1 EA

DWG # 766-613 - ENCLOSURE ASSEMBLY MD490M

1 COVER, TOP (MODIFIED) 490M 463-021-0018 1 EA
2 COLLAR, TRIM RING 490M 463-021-0011 1 EA
3 COVER, TRIM RING 490M 463-021-0012 1 EA
6 KEY SWITCH PANEL MD-490M 464-091-0013 1 EA
7 REAR PANEL, SCREENED MD-490M 461-021-0003 1 EA
8 PANEL ASSY, KEYPAD MD490M (MD490M) 656-400 1 EA
9 HINGE, REAR PANEL MD-490S 426-091-0004 1 EA
10 BRACKET, FAN MD-490S 464-091-0004 1 EA
11 BRACKET, FRONT PANEL ASSY MD-490S 464-091-0003 1 EA
12 BRACKET, VERTICAL SUPPORT MD-490S 464-091-0006 1 EA
16 ENCLOSURE,FRONT PANEL MODIFIED MD-490M 465-021-0007 1 EA
17 TRIM RING, TEST PORT 463-021-0016 2 EA
18 LANYARD, REAR PANEL SUPPORT MD-490S 426-091-0005 1 EA
19 HANDLE W/BLACK EPOXY FINISH 488-091-0001 2 EA
20 BUMPER, RUBBER 78002006 4 EA
21 PLATE, VERTICAL, MODIFIED 490 M 463-021-0014 1 EA
22 FAN, CABNET, 3610, 24V, WIRES 311-092-3625 4 EA
23 FAN GUARD, PLASTIC 3 5/8 IN 311-191-9393 4 EA
24 SPEAKER, 4", SQUARE MOUNT 16 OHM 362-381-0416 1 EA
25 LABEL ASSEMBLY MD490M 570-011 1 EA
DWG # 656-400 - PANEL ASSY, KEYPAD MD490M
10 MEMBRANE KEYPANEL ASSY MD490M (MD490M) 719-402 1 EA
20 PC, BOARD, ASSY., DISPLAY BD. MD390S 584-330 1 EA
30 PCB ASSY, ALPHANUMERIC DISPLAY (N) 583-336 1 EA
40 STANDOFF, MD180,L.E.D. MOUNT 493-096-1009 2 EA
50 SPACER,ROUND,.219ID,3/8OD3/8L 493-096-1027 8 EA
60 INSULATOR,FISH PAPER FOR VFD 292-091-0056 1 EA

DWG # 570-011 - LABEL ASSEMBLY MD490M

1 LEGEND, PORTABLE HIGH VOLTAGE 369-231-0001 1 EA
2 LABEL, HIGH VOLTAGE 487-094-1006 1 EA
3 LABEL-"DANGER HIGH VOLTAGE"2.5 146063600 1 EA
4 LABEL, CE GND (CN) 146065000 1 EA
5 LABEL, FUSE IDENTIFICATION CPU BOARD, MD490S/490M 570-010 1 EA
6 LABEL, FUSE/IDENTIFICATION MD490M 570-012 1 EA
7 LABEL, FUSE CAUTION MD490S, MD490M 570-013 1 EA
DWG # 931-126 - VACUUM ASSEMBLY MD490M
1 MASS SPECTROMETER ASSEMBLY MD490M 651-151 1 EA
2 MANIFOLD WELDMENT (TURBO) MD490M 652-156 1 EA
3 SUPPORT, MANIFOLD,WELDMENT 464-691-1052 1 EA
4 CALIBRATOR VALVE BLOCK 490M 0137-404-01 1 EA
5 TEST PORT INLET 652-166 1 EA
6 ELBOW 90DEG MITER NW16 ST. STL 429-092-4079 1 EA
7 TURBO PUMP 353-691-1020 1 EA
8 VALVE W/CONNECTOR 473-791-1018 1 EA
11 CLAMP, 1" 487-792-1000 2 EA
13 BRACKET, TEST PORT 490M 463-021-0015 1 EA
14 GAUGE, CONVECTRON 341-091-2010 1 EA
15 VALVE OPERATOR 24VDC 189028910 1 EA
17 CLAMP, NW-10/16, LOW-CLEARANCE 442-094-2036 5 EA
18 CLAMP, NW-25, 442-094-2012 1 EA
19 SEAL RING, NW-16 441-091-2007 5 EA
20 SEAL RING, NW-25, 441-091-2006 1 EA
21 SHIELD, SPLINTER 442-094-2001 1 EA
22 SEAL,CENTERING SEAL ASS'Y. 441-091-2024 1 EA
23 CLAMP,DOUBLE CLAW 133152700 4 EA
24 FLANGE, BLANK, NW-25 442-094-2018 1 EA
25 LEAK, MD-180/290 STD, CALIB. HELIUM INTERNAL PM-8 752-103 1 EA
26 CLAMP, NW-40, ALUM 442-094-2011 1 EA
27 SEAL RING, NW25 W/SCREEN 441-091-2022 1 EA
31 ORING, 7/16 X 1/16 001201300 1 EA

DWG # 931-126 - VACUUM ASSEMBLY MD490M

32 ORING, 1 5/8 X 3/16 001132600 1 EA
DWG # 651-151 - MASS SPECTROMETER ASSEMBLY MD490M
10 SOURCE ASS'Y, MD-490 SERIES LEAK DETECTORS 651-132 1 EA
20 COLLECTOR ASSY., MD490M NO MESH SCREEN 651-304 1 EA
30 MASS SPECTUBE BODY/SHELL S/S MD-490 PORTABLE 751-112 1 EA
40 MAGNET ASS'Y, SPEC TUBE 751-104 1 EA
50 PLATE, SHELL BAFFLE,.025THK. X 2 1/4"DIA.S/S,NEW COLL 451-613-1049 1 EA
60 SCREW, 4-40 X 3/16"LG VENTED S/S FLSTR HD SLOTTED 489-114-0005 2 EA
70 SCREW, 10-32 X 5/8"LG. ST.STL. 489-116-0014 1 EA
80 SCREW, 6-32 X 1/2" LG, SOCKET HEAD CAP STAINLESS STEEL 489-111-1007 6 EA
90 WASHER,FLT.205ID.440OD,.065THK ST/STL 489-798-0049 1 EA
DWG # 651-132 - SOURCE ASS'Y, MD-490 SERIES LEAK DETECTORS
1 FLANGE ASS'Y, UNIVERSAL, SPEC TUBE,MD-490 PORTABLE 651-130 1 EA
2 STANDOFF, SOURCE, S/S, PORTABLE 451-612-1024 2 EA
3 STANDOFF, INSULATING,.312 DIA. X .437 LG. CERAMIC 451-612-1003 2 EA
4 WASHER, INSULATOR, VIC SOURCE, .31 DIA.X .030 THK.TORLON 451-612-1004 4 EA
5 STANDOFF, SOURCE, CERAMIC, PORTABLE 451-612-1026 2 EA
6 STANDOFF, INSULATING, VIC SOURCE ITEM 22 451-612-1006 2 EA
7 CAP, END, TORLON, PORTABLE 451-612-1028 2 EA
8 GRID ASS'Y, ACCELERATION VIC SOURCE 651-111 1 EA
9 CONTAINMENT ASS'Y, VIC SOURCE 651-112 1 EA
10 PLATE, "A", VIC SOURCE, ITEM 19 451-612-1021 1 EA
11 PLATE, "B", VIC SOURCE , ITEM 21 451-612-1013 1 EA
12 PLATE, "C", VIC SOURCE, ITEM 23 451-612-1012 1 EA
13 ROD, THREADED,COLLECTOR/SOURCE 4-40 THREAD X 3.43 LG.,S/S 451-613-1073 2 EA
14 FILAMENT KIT, BOX OF 4,SINGLE FILAMENT ASS'Y 919-128 1 BX
15 NUT, 4-40 S/S WITH 1/4"HEX DRV 489-218-0008 5 EA
16 WASHER, FLAT #4 ID S/S.,4-40 489-798-0018 2 EA
18 RETAINER, TRIANGULAR, SOURCE, 351-611-1003 4 EA
19 BOOT, WIRE END, SOURCE ASSY. 351-611-1002 4 EA
20 O RING, BUNA-N, 492-092-2144 1 EA

DWG # 651-132 - SOURCE ASS'Y, MD-490 SERIES LEAK DETECTORS.

21 SCREW, 4-40 X 5/8"LG FLSTR HD PHILLIPS 489-114-0007 4 EA
22 SCREW, SET, 4-40 X 1/4"LG S/S CUP POINT, SKT DRIVE 489-118-0004 2 EA
23 WIRE, BUS 20 GAUGE U/M FEET 013-120-9001 1 FT
24 TERMINAL BLOCK, FILAMENT, VIC SOURCE, ITEM 4 451-612-1010 2 EA
25 INSULATOR, VIC SOURCE , ITEM 3 451-612-1007 8 EA
26 NUT, 4-40 S/S WITH 3/16"HEX DR 489-218-0009 2 EA
27 SCREW, 4-40, 5/16"LG PAN HD S/S 489-116-0009 2 EA
DWG # 651-304 - COLLECTOR ASSY., MD490M
10 FLANGE ASS'Y, UNIVERSAL, SPEC TUBE,MD-490 PORTABLE 651-130 1 EA
20 O RING, BUNA-N, 492-092-2144 1 EA
30 STANDOFF, COLLECTOR, S/S, MD-490 451-615-1010 2 EA
40 STANDOFF, COLLECTOR, THREADED, ST. STL. 451-613-1065 2 EA
50 STANDOFF, 1/4" X 9/32" TEFLON 451-613-1052 4 EA
60 PLATE, BAFFLE, SLOTED UNIV. ST. STL 451-615-1011 3 EA
70 CAP, END, .200" THK X 1/4" DIA NEW COLLECTOR , S/S 451-613-1048 4 EA
80 ROD, THREADED,COLLECTOR/SOURCE 4-40 THREAD X 3.43 LG.,S/S 451-613-1073 2 EA
100 TUBE, TEFLON, 1/8"OD.X .030 WALL 011-213-2101 1 FT
110 RETAINER, TRIANGULAR, SOURCE, 351-611-1003 1 EA
150 AMPLIFIER MOUNTING BRACKET 451-615-1012 1 EA
160 SCREW, 4-40 X 3/8"LG FILLISTER HEAD STL., PHILLIPS 489-114-0013 2 EA
170 MOUNTING STANDOFF, MD-490 ST.STL. 451-615-1018 2 EA
180 STANDOFF, INT. COLL. BOARD 493-096-1020 2 EA
190 PCB ASSY., INTERNAL COL MD490M SINGLE RESISTOR 585-308 1 EA
DWG # 936-155 - ELECTRICAL ASSEMBLY MD490M
10 CABLE PACKAGE, MD490M MD490M 936-164 1 EA
20 PC BOARD ASSEMBLY, CPU-DC MD490M 584-442 1 EA
30 PC BOARD ASSEMBLY, CONTROL-DC MD490S / MD490M 584-444 1 EA
40 POWER SUPPLY, 24V@150W,CHASSIS 246-231-0024 1 EA
50 POWER ENTRY ASSEMBLY MD490M 936-250 1 EA
60 SWITCH, KEYLOCK, (WASHER) (AY) 366-381-2245 1 EA
80 CONNECTOR KIT, PLC & ANALOG MD490M (EXTERNAL CONNECTORS) 919-491 1 EA

DWG # 936-164 - CABLE PACKAGE, MD490M MD490M

10 CABLE ASSY, DISPLAY TO ALPHANU MD490M 872-956 1 EA
20 CABLE ASSY, AUDIO SIGNAL 872-805 1 EA
30 CABLE ASSY, RS485 MD490S 872-915 1 EA
40 CABLE ASSY, DISPLAY RIBBON MD490S 872-904 1 EA
50 CABLE ASSY, CPU-DC POWER MD490S-CE 872-914 1 EA
60 CABLE ASSY, CNTRL-DC BD PWR IN MD490M 872-959 1 EA
70 CABLE ASSY, SOURCE MD490S 872-905 1 EA
80 CABLE ASSY, COLLECTOR MD490S 872-906 1 EA
90 CABLE ASSY, POWER SUPPLY INPUT MD490M 872-957 1 EA
100 CABLE ASSY, POWER SUPPLY OUTPT MD490M 872-958 1 EA
110 CABLE ASSY, CONVECTRON GAUGE MD490M 872-948 1 EA
120 CABLE ASSY, MAIN LEAK RATE OUT MD490M 872-949 1 EA
130 CABLE ASSY, KEY LOCK MD490S ) 872-912 1 EA
140 CABLE ASSY, RS232 MD490M 872-953 1 EA
150 PLC INTERFACE ASSY 918-513 1 EA
160 CABLE ASSY, INTERNAL ISO VALVE MD490 872-954 1 EA
170 CABLE ASSY, CAL/SNIFF VALVES MD490M 872-955 1 EA
DWG # 936-250 - POWER ENTRY ASSEMBLY MD490M
1 POWER CORD, SHIELDED 387-012-0008 1 EA
2 SWITCH, POWER ENTRY, 2-POLE 366-405-0004 1 EA
3 FUSE HOLDER, PANEL MOUNT 5X20 331-210-3002 1 EA
4 FUSE 3.15A,5X20MM, TIME DELAY (TYPE FST) 331-111-0031 1 EA
5 CABLE, 18/3, PVC JACKET 013-218-5063 1 FT
6 TERMINAL, RING TONGUE 16-14 GA (AN) 388-313-0003 1 EA
7 TERMINAL BLOCK, 388-221-4362 12 EA
8 TERMINAL, GROUNDING 388-221-3924 3 EA
9 TERMINAL BLOCK 388-221-2018 1 EA
10 TERMINAL FUSEHOLDER 388-221-2019 1 EA
11 FUSE, 5X20, 1 AMP, 250V 331-111-0020 1 EA
12 END ANCHORS, 388-221-1011 2 EA
13 TERMINAL BLOCK END CAP 388-221-3020 4 EA
14 TERMINAL BLOCK, JUMPERS 388-221-3250 1 EA
15 RAIL, RELAY MOUNT 398-091-0007 1 EA
16 TERMINAL BLOCK, MARKER 388-221-1051 1 EA

DWG # 919-491 - CONNECTOR KIT, PLC & ANALOG MD490M (EXTERNAL CONNECTORS)
1 STRAIN RELIEF, 4POS, MINI-COMB 282-801-0004 1 EA
2 CONNECTOR, 4 PIN PLUG 282-111-0010 1 EA
3 CONNECTOR, 6 PIN PLUG 282-111-0008 1 EA
4 STRAIN RELIEF, 6POS, MINI-COMB 282-801-0006 1 EA
5 CONNECTOR, TWIN BNC 288-241-6001 1 EA
6 CONNECTOR, FEMALE 282-717-0025 1 EA
7 CONN, SHIELD CABLE CLAMP 283-813-0025 1 EA
DWG # 658-120 - EXTERNAL SNIFF ASSEMBLY MD490M
1 MANIFOLD EXTERNAL SNIFF 424-051-0008 1 EA
2 VALVE OPERATOR 189028900 1 EA
3 O-RING, BUNA-N, #2-108 492-092-2108 1 EA
4 SLEEVE, DUAL SNIFFER MD490S 424-051-0002 1 EA
5 FILTER HOUSING ASS'Y 658-104 2 EA
6 CONNECTOR, FLEX PROTECTING 487-691-1005 2 EA
7 SEAL RING, NW-25 441-091-2006 2 EA
8 CLAMP, NW-25 442-094-2012 2 EA
9 TUBE, PVC, OPAQUE RED 011-213-1507 25 FT
10 PROBE BODY MACHINING 455-612-1078 1 EA
11 PROBE ASSEMBLY, MD-490M 658-122 1 EA
12 FILTER ASS'Y, SNIFFER PROBE (SEE 741-117 FOR BOX QUANTITY 741-116 1 EA
13 O-RING, BUNA-N, #2006 492-092-2006 1 EA
14 FILTER, SUPER SNIFFER S/S 413-613-1003 1 EA
15 TEE, NW-25 444-092-2022 1 EA

EXTERNAL MANIFOLDS PART NUMBER
STANDARD (+24VDC Valves)

Manifold Assembly, External
VIC PART NUMBER: 652-152
OPTIONAL (120VAC Valves)

Manifold Assembly, External
PUMPING ASSEMBLY PART NUMBER
Pump assembly (7 CFM)

Pump Bleed Assembly

OPTIONAL CONVERTER BOX
This optional converter box is used to allow the MD490M to be used on a

older ILD system wired for the MD290M.

SECTION 9 – POWER REQUIREMENTS:
Power Requirements: 115 volts, 60 hertz, 3.15 amps or 220VAC, 50 hertz, 3.15 amps
Fuse Listing refer to Main Electrical Schematic 936-164:
SIZE/ TYPE RATING LOCATION PURPOSE
5 x 20 mm Normal 10 AMP F1 Fore-pump

CPU
5 x 20 mm Normal 1 AMP F2 Valve control

CPU BOARD
5 x 20 mm Time Delay 3.15 Amp FU 1 Main Power

Back Panel
5 x 20 mm Time delay 500 ma FU3 Fan Assembly

Din Mounted

MD490M RS232
APPENDIX 1 - COMMUNICATION OPTION
This option allows an ASCII type terminal, desktop computer or a Programmable Logic Controller to remotely
monitor and control the leak detector unit using a standard RS-232 serial interface
REQUIREMENTS:
a) Null Modem RS-232 cable with DB-9 on MD490S side.
b) A host computing system able to emulate ASCII protocol and having RS232 serial port availability.
PROTOCOL DEFINITIONS:
<CR> - ASC11 13 = Carriage return

<LF> - ASC11 10 = Line Feed
PROTOCOL REQUIREMENTS:
1. The leak detector will accept three commands:
a. FUNCTION command
b. EDIT or SET command
c. ENQUIRY command
2. All command strings must end with <CR><LF>.
3. All command strings are acknowledged after <CR><LF>.
4. The host must wait until a confirmation prompt is received before transmitting.
5. All data parameters transferred will follow a specific data format.
6. Set RS232C port parameters to:
a. Baud = 9600
b. Parity = NONE
c. Data = 8 bits
d. Stop bits = 1

COMMAND STRING FORMAT:
1. FUNCTION COMMAND: <F><TYPE><CR><LF>

2. ENQUIRY COMMAND: <E><TYPE><CR><LF>
3. EDIT/SET COMMAND: <S><TYPE><=><PARAMETER><CR><LF>
ACKNOWLEDGE PROMPTS:
"= >" No errors were detected and the command was successfully parsed and executed.
"? >" A COMMAND ERROR was detected. The command was not executed because it was not understood.
For instance, this prompt would be returned if the leak detector was sent a command string, that contained
a syntax error.
"! >" An EXECUTION ERROR was detected. The command was understood but not executed. Parameter
out of range or parameter syntax incorrect.
GETTING STARTED:
Use a Personal computer with terminal emulation software to test the communication option. Install the
serial cable to the COM1 port located on the back of the leak detector.
Each command can be tested by typing the desired command string followed by a <CR><LF>. Start testing
the function commands first, for they are the simplest. Below are a few examples:
COMMAND STRING ACK. RESULTS

Fa<CR><LF> => TURN SNIFF ON
NO ERRORS
Fz<Cr><Lf> ?> COMMAND ERROR
FUNCTION Fz DOES NOT EXIST
Sa=100<CR><LF> => SET GAIN "A" TO 100
NO ERRORS
Sa=250<CR><LF> != SET GAIN "A" TO 250
EXECUTION ERROR
(OUT OF RANGE)
Sa=0100<CR><LF> != SET GAIN "A" TO 100
EXECUTION ERROR
(PARAMETER TOO LONG)
Ea<CR><LF> 250 ENQUIRY TUNE VOLTS
=> NO ERRORS

The following are commands to inquire about system parameters.
ENQUIRY COMMANDS
CMDS DESCRIPTION DATA VALID RANGE

FORMAT
Ea TUNE VOLTS <XXX> 217-277
Eb STF VOLTS <XXX> TUNE-70
Ec A-PLATE VOLTS <XXX> TUNE-100
Ed C-PLATE VOLTS <-XXX> 100-200
Ee S-PLATE VOLTS <XXX> 150-250
Ef EMISSION CURRENT (mAMPS) <X.XX> 0.50-2.50
Eg FILAMENT CURRENT (amps) <X.X> 0.0-4.0
Eh GAIN (FILAMENT "A") <XXX> 049-201
Ei GAIN (FILAMENT "B") <XXX> 049-201
Ej TURBO SPEED (%) <XXX> 000-100
El BALLAST PRESSURE (Torr) <XXX> 000-999
En LEAK RATE (cc/sec) <SX.XE-XX> 0 - 1.0E-02
Can go NEG.
Eo SETPOINT #1 <X.XE-XX> 1.0E-6 - 9.9E-3
Ep SETPOINT #2 <X.XE-XX> 1.0E-6 - 9.9E-3
Eq MECH. & TURBO PUMP HOURS <XXXXX> 0 - 99999
Er FIL "A" & FIL "B" HOURS <XXXXX> 0 - 99999
Es 16 DISCRETE FAULTS <XXXXX> 0-65535
SEE FAULT DESCRIPTION
Et COLLECTOR VOLTS <SXX.XX> -10.00 - 10.00

The following are commands to set or edit system parameters.
SET/EDIT COMMANDS
CMDS DESCRIPTION DATA VALID RANGE
FORMAT
Sa GAIN FILAMENT "A" <XXX> 050-200
Sb GAIN FILAMENT "B" <XXX> 050-200
Sd SETPOINT #1 (cc/sec) <X.XE-XX> 0000-9999
Se SETPOINT #2 (cc/sec) <X.XE-XX> 0000-9999
Sg TUNE VOLTAGE <XXX> 218 - 277
Sh AUDIO VOLUME <XXX> 000 - 100
Si EMISSION (mAMPS) <X.XX> 0.50 - 2.50
The following are commands to enable or disable system functions.
FUNCTION COMMANDS
CMDS DESCRIPTION
Fa SNIFF ON
Fb SNIFF OFF
Fc AUTO ZERO
Fd FILAMENT A/B
Fe CALIBRATE
Fi FILAMENTS ON
Fj FILAMENTS OFF
Fk AUTO SEND LEAK RATE ON
Fl AUTO SEND LEAK RATE OFF

FAULT DESCRIPTION:
An unsigned integer is transferred to describe system faults. It has a range of 0-65535 in base 10. Using base 2, we
need 16 bits to represent this number. Each bit will represent a system fault as described in Section 10.1,
Alphanumeric Display.
B0 - High Board temp (low order bit)
B1 - Turbo speed
B2 - Filament Current
B3 - A-Plate voltage
B4 - STF Plate voltage
B5 - S-Plate voltage
B6 - C-Plate voltage
B7 - Emission fault
B8 - Tune Voltage fault
B10 - Collector Saturated
B11 - In Sniff and Filaments OFF
B12 - Gain Error
B14 – PUMP-DOWN timeout
B16 - Zero Collector watchdog fault (high order bit)

Vacuum Instrument Corporation

2099 Ninth Avenue, Ronkonkoma, NY 11779
Tel # (631) 737-0900 – Fax # (631) 737-1541
www.vacuumninst.com - vicsales@vacuuminst.com
Sales/Service Offices
California, Georgia, Indiana, Michigan, New York, Ohio, Texas
Mexico, United Kingdom, France, Germany, China, Japan
Exclusive Sales & Service Representatives Worldwide
Vacuum Instrument Corporation has the broadest experience with comprehensive leak detection solutions
required to design, build, sell, and service the most innovative and versatile leak detectors anywhere in the
world. That is because leak detection is and always has been our only business. We are dedicated to leak
detection, and our customers have made us the largest leak detector company in the world.

PARTS LIST FOR THE 651-132
SOURCE ASSEMBLY
DWG # 651-132 - SOURCE ASS'Y, MD-490 SERIES LEAK DETECTORS. (DY)

1 FLANGE ASS'Y, UNIVERSAL, SPEC TUBE,MD-490 PORTABLE (BY) 651-130 1 EA
2 STANDOFF, SOURCE, S/S, PORTABLE (AY) 451-612-1024 2 EA
3 STANDOFF, INSULATING,.312 DIA. X .437 LG. CERAMIC (AN) 451-612-1003 2 EA
4 WASHER, INSULATOR, VIC SOURCE, .31 DIA.X .030 THK.TORLON (AY) 451-612-1004 4 EA
5 STANDOFF, SOURCE, CERAMIC, PORTABLE (AN) 451-612-1026 2 EA
6 STANDOFF, INSULATING, VIC SOURCE ITEM 22 (AN) 451-612-1006 2 EA
7 CAP, END, TORLON, PORTABLE (AY) 451-612-1028 2 EA
8 GRID ASS'Y, ACCELERATION VIC SOURCE (CN) 651-111 1 EA
9 CONTAINMENT ASS'Y, VIC SOURCE (BY) 651-112 1 EA
10 PLATE, "A", VIC SOURCE, ITEM 19 (AY) 451-612-1021 1 EA
11 PLATE, "B", VIC SOURCE , ITEM 21 (AY) 451-612-1013 1 EA
12 PLATE, "C", VIC SOURCE, ITEM 23 (AY) 451-612-1012 1 EA
13 ROD, THREADED,COLLECTOR/SOURCE 4-40 THREAD X 3.43 LG.,S/S(AY) 451-613-1073 2 EA
14 FILAMENT KIT, BOX OF 4,SINGLE FILAMENT ASS'Y (N) 919-128 1 BX
16 WASHER, FLAT #4 ID S/S.,4-40 489-798-0018 2 EA
18 RETAINER, TRIANGULAR, SOURCE, .0100THK 351-611-1003 4 EA
20 O RING, BUNA-N, 492-092-2144 1 EA
21 SCREW, 4-40 X 5/8"LG FLSTR HD PHILLIPS 489-114-0007 4 EA
22 SCREW, SET, 4-40 X 1/4"LG S/S CUP POINT, SKT DRIVE 489-118-0004 2 EA
24 TERMINAL BLOCK, FILAMENT, VIC SOURCE, ITEM 4 (BY) 451-612-1010 2 EA
25 INSULATOR, VIC SOURCE , ITEM 3 (AY) 451-612-1007 8 EA
26 NUT, 4-40 S/S WITH 3/16"HEX DR 489-218-0009 2 EA
27 SCREW, 4-40, 5/16"LG PAN HD S/S 489-116-0009 2 EA
REPELLER PLATE
651-133
BAFFLE PLATE
451-615-1011
FIXED GROUND PLATE
451-613-1071
COLLECTOR
PC BOARD
585-305
O-RING
492-092-2144
FLANGE
651-130
COLLECTOR ASSEMBLY
651-304

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MD490M PORTABLE

HELIUM LEAK DETECTOR

861-033MAN- REV - A MD490M 966-493 Page I of III

SECTION 1.0 - INSTALLATION AND OPERATION ............................................................. 1

NAVIGATING THE MENU .................................................................................................... 15

SECTION 6. 0- TROUBLE SHOOTING ................................................................................. 35

SECTION 8.0 – BILL OF MATERIALS ................................................................................. 39

APPENDIX 1 - COMMUNICATION OPTION ...................................................................... 48

861-033MAN- REV - A MD490M 966-493 Page III of III

SECTION 1.0 - INSTALLATION AND OPERATION

GETTING THE UNIT READY FOR OPERATION

100-240VAC 50—60Hz, 3.15 Amps.

Press SNIFF to enable sniff testing.

861-033MAN- REV - MD490M 966-493 Page 1 of 53

Shop Air: 60psi - 80psi.

Vacuum: Used for Sniff Option. Connects to external

The external manifold connects to the inlet flange and provides

Manifold Assy, 24VDC Valves

Manifold Assy, 120VAC Valves

861-033MAN- REV - MD490M 966-493 Page 2 of 53

Foreline pressure can be viewed on the alphanumeric display by pressing DIAG.

TURBO SPEED FORELINE CUTOFF

For vacuum or sniff testing an external fore pump must be installed.

FORE-LINE ISOLATION VALVE

The Fore-Line Isolation valve closes when power is disconnected or

861-033MAN- REV - MD490M 966-493 Page 3 of 53

OPTIONAL SNIFF PROBE VALVE / SNIFF ISOLATION VALVE

861-033MAN- REV - MD490M 966-493 Page 4 of 53

SNIFFER FLOW VACUUM SOURCE

861-033MAN- REV - MD490M 966-493 Page 5 of 53

SECTION 2.0 - SYSTEM START UP

1. Self check for proper Fore-Line vacuum.

861-033MAN- REV - MD490M 966-493 Page 6 of 53

ADJUSTING SNIFF MODE SENSITIVITY

SNIFF FLOW VALVE

The general procedure for calibration is given below.

SNIFF CALIBRATION PROCEDURE

1. Confirm Turbo speed is <700 Hz.

861-033MAN- REV - MD490M 966-493 Page 7 of 53

SECTION 3.0 - CONTROL AND MONITORING I/O

PLC I/O CONSISTS OF THE FOLLOWING CONTROLS.

AC voltage version: Part# 918-509

PLC I/O Interface uses a 6-Pin connector.

PIN# SIGNAL NAME LOGIC STATE

1 AC HOT or DC+ Output Common

2 AC RTN or DC- Input Common

AC HOT / AC RTN OR DC+ / DC-

861-033MAN- REV - MD490M 966-493 Page 8 of 53

SETPOINT 1 AND SETPOINT 2

An auto zero is commanded by pulsing this input.

AUXILIARY I/O INTERFACE USES A 25-PIN D-SUB CONNECTOR.

Pin # Signal Name Electrical: Low voltage opto-coupler with 1K series

861-033MAN- REV - MD490M 966-493 Page 9 of 53

LEAK RATE OUTPUTS

JP1 CPU Board Analog Span

There are 2 Leak rate output connectors on the rear panel.

Leak Rate Output

LEAK RATE SIGNAL BAR GRAPH

LEAK RATE SIGNAL

Bar Graph Multiplier

861-033MAN- REV - MD490M 966-493 Page 10 of 53

SECTION 4.0 – SYSTEM COMPONENTS

MASS SPECTROMETER ASSEMBLY