Manufacturers of Leak Test Instruments
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Error Codes
Error Codes

HKA's series of leak testers have traditionally provided failure information by showing an '*' followed by a letter.  This section helps to illuminate possible causes and troubleshooting steps.


1.

The final leak reading was less than the set limit 

Common Causes:

  • Leak in reference part
    • Block reference port and retry test
  • Invalid calibration
    • Previous calibration was performed with a leak in the system

2.

When entering into the READ phase a positive slope was detected.  In direct flow models this indicates being over filled.

Common Causes:

  • Too much time given during 'Fast Fill'
  • 'Fast Fill' regulator set too high​
    • Pressure drop to part is too great to effectively stop fill cycle before being over pressure

 


3.

Unit received the abort signal

Common Causes:

  • A voltage bias across pins 9 and 12 of 12-pin connector

4.

At the end of test the block test was performed.  The pressure reading was not lower than the pressure limit after the set amount of time

Common Causes:

  • Part is blocked
    • Confirm with known good part
  • Blockage in seal
    • Add roll-pin or some means to avoid 'folding over'
  • Crimped air line from tester to part
    • Known good part will also fail

5.

During the calibration the SystemZero could not be calculated with confidence as the sensor input varied too greatly

Common Causes:

  • Seal movement
    • Add a hard stop for seals
    • Change seal durometer
    • Add a wait before sending the start signal after sealing
  • External air source
    • Ensure that process air is not leaking through a valve into the test circuit
  • Part still exhausting from previous test
    • Try again after waiting

6.

During the READ phase of the test, the slope was too large in the negative direction

Common Causes:

  • Insufficient time for accurate test
    • Extend times for STAB or READ
  • Movement of seals
    • Add hard stops for seals
  • Temperature effects
    • Add more cooling time or active cooling

7.

After 1 minute the pressure sensor is reviewed and is expected to be close to the programmed zero.  If not, the unit will not permit a test to start unless the pressure has been brought to zero or the unit has been tared.

Common Causes:

  • Part still clamped
  • Pressure sensor zero calibration has floated too high
    • The unit must be zero'd either by a tare or pot adjustment

8.

The flow reading was much larger than expected during the STABilization state

Common Causes:

  • Gross leak
    • Check seals for debris or damage
    • Check the tubing from the test part to the leak tester for damage
  • External air source causing flow
    • ​Ensure control air is not leaking through a valve

9.

The raw flow before a test has started was too far away from SysZero

Common Causes:

  • An external air source
    • Ensure a valve controlling test air paths isn't leaking control air
  • Part still exhausting from previous test
    • Wait and try again

10.

The test failed the secondary pressure decay check

Common Causes:

  • Leak in part, seals, or test lines

11.

Calibration Zero Error

This happens when F Zero is much different than SysZero
  F Zero: "Flow Zero" is calculated during a calibration and is the average of the final two 'Zero' readings
  SysZero: "System Zero" is sensor zero when the leak tester is unpressurized 

For versions 7 and earlier the difference cannot be larger than 500.  For versions 8 and later the difference cannot be larger than 8000

Possible Causes

Typically this is caused by invalid 'Zero' readings due to a leakage.  Possible root causes include:

  • Hole in reference part
  • Loose fittings or connections to either reference or test part
  • A valve (internal or external) leaking control air into the test circuit
  • Seal movement during the READ phase
  • Leaking seal
  • Bad part used during calibration

 


12.

The pressure decay reading during calibration was much larger than allowable

Common Causes:

  • Leak in part, seals, or test lines
    • Ensure that the part is a good part
    • Ensure seals are okay, free of debris or damage

13.

The two pressure decay readings were too different from each other 

Common Causes:

  • Seal movement
    • Ensure stand air is isolated from 'hungry' air consumers
    • Use hard stops for seals
  • External air source
    • Usually observed in raw flow readings as well as a large leak 
  • Part still exhausting from previous test
    • ​Check exhaust path to ensure air exits quickly

14.

The reading taken during COMPensation time was too negative to perform a valid test (Only with 'Temp Comp')

Common Causes:

  • Part temperature too cold for unit to compensate
    • Allow more time for part to climatize or add active cooling

15.

The reading taken during COMPensation time was too large to perform a valid test (Only with 'Temp Comp')

Common Causes:

  • Part temperature too hot for unit to compensate
    • Add cooling time or active cooling
  • Seal creep during COMP reading
    • Extend COMP time

16.

Pressure halfway through STABilization was outside the bounds set by PRESSURE HI and PRESSURE LO in the part SETUP

Common Causes:

  • Gross leak usually in seals, part, or test lines
    • Check seals and part for large leak
  • Wrong test program selected
    • External program selection may not be enabled if the stand normally changes part number.  Check setting in SYSTEM SETTINGS
  • Incorrect settings
    • Verify that settings for upper and lower limits are correct for test pressure
  • Upstream pressure is insufficient
    • Ensure pressure to leak tester is greater than required test pressure
    • Check tubing from tester to pressure source for kinks or significant holes

17.

The initial flow test was completed and failed.  Sufficient flow was not read after a set amount of time

Common Causes:

  • A blockage exists in the tested part
    • Verify system with known good part
  • A blockage or kink exists in the tubing between the leak tester and part
    • Examine tubing leading from fixture to tester
  • A blockage or kink exists in the tubing between the pressure source and leak tester
    • Examine tubing leading from tester to supply port
  • If initially setting up, parameters may be too stringent
    • Change limits to reflect nominal part response

18.

The span readings (CAL1 & CAL2) were too close to the zero readings (ZERO1 & ZERO2) in relation to the difference in zero readings

Common Causes:

  • Insufficient time for accurate test without a drain valve
    • Add a drain valve
    • Control a seal cylinder from the leak tester EXH port
    • Add time to STAB or READ

19.

During the READ phase of the test the slope was too large in the positive direction

Common Causes:

  • Insufficient time for accurate test
    • Increase READ or STAB timers
    • Ensure no kinks in line from leak tester to parts
  • Movement of seals
    • Add hard stops for seals
    • Increase sealing pressure
    • Try another seal durometer
  • Temperature effects
    • Wait for part to climatize
    • Add temperature compensation
    • Add active cooling

20.

Vacuum pressure was not achieved to the set level after the VAC1 state

Common Causes:

  • A gross leak either in the part or seal
    • Ensure seals are clean and not damaged.  Replace as required.
  • Insuffient seal pressure
    • Increase sealing pressure

21.

The 24V power supply has dropped below acceptable limits

Common Causes:

  • Insufficient supply voltage 
    • Ensure power supply rating is correct for application
  • External source drawing high current
    • Disconnect external loads to see if condition persists

22.

A cross cooler test was completed and the flow or pressure was greater than the set limit after the set amount of time

Common Causes:

  • A leak exists connecting two separate cavities within a test part
    • Check manufacturing process

23.

During a calibration the zero readings (ZERO1 & ZERO2) were too far apart

Common Causes:

  • Insufficient time for accurate test without a drain valve
    • Add a drain valve or control a seal motion using EXH port of leak tester
    • Increase STAB or READ timers