Air Leak Testing in Industrial Quality Control
Air leak testing is a non-destructive testing (NDT) technique widely adopted in manufacturing to verify the integrity of components subject to pressure or vacuum. The method detects pressure losses in the part under examination without damaging its structure, enabling 100% production inspection. Sectors that employ it include automotive, biomedical, hydraulics, aerospace, packaging, and home appliances.

Traditionally, leak testing instruments operated autonomously or with limited serial connectivity. With the spread of Industry 4.0 paradigms, the market demands instruments capable of integrating into supervisory systems and the data infrastructure of manufacturing companies.

The Series K: Three Form Factors and Three Measurement Technologies

The Series K is organized into three form factor families
• The mini K3 format — comprising models K3060, K3890, and K3990 — measures 110×110×120 mm and weighs 0.7 kg, a compact design conceived for direct integration into automated cells.
• The small K5 format is represented by model K5990 (160×140×180 mm, 2.5 kg), positioned as an entry-level solution for stand-alone applications.
• The K7000 series comprises models K7090, K7890, and K7990 (220×140×250 mm, 4 kg), intended for production environments that require maximum connectivity and configuration flexibility.

In terms of measurement technologies, the Series K covers three distinct approaches. Absolute pressure decay measurement, available on models K3990, K5990, and K7990, is the reference method in industrial automation: the component is pressurized and the pressure decay is monitored over time using a dedicated absolute transducer. Differential measurement, featured on models K3060, K3890, and K7890, compares the pressure of the part against a reference sample.

The K7090 model implements the Dual Absolute™ technology, patented by ForTest, which combines two independent absolute transducers to obtain a differential signal without the limitations of a traditional pneumatic differential circuit. The K7090 integrates four software-selectable measurement modes: absolute decay, classic differential, Dual Absolute™, and Zero Central. The absence of wear-prone mechanical components in the differential pneumatic interface translates, according to the manufacturer, into a significant reduction in scheduled maintenance.

Connectivity and Integration with Automation Systems
All Series K models come standard with the following communication interfaces: RS232 (two ports), RS485 (one port), USB master and slave, digital I/O connector with Start, Stop, Filling, Test, Good, Reject signals and 4-bit BCD code, Ethernet, and wireless Bluetooth and Wi-Fi modules. The standard equipment also includes the Staubli fitting for calibrated leaks, the precision manual regulator, and 300 storable test programs.
The K7000 series models add optional fieldbus interfaces: Modbus RTU, Profinet, Ethernet/IP, EtherCAT, and the proprietary ForTest protocol. An auxiliary I/O connector with 8 outputs and 4 programmable inputs enables integration with PLC, SCADA, and MES systems.

All models are compatible with MyForTest, the cloud platform developed by ForTest for the collection, storage, and analysis of test data. The platform records, for each test, the parameters of pressure, temperature, measured leakage, and pass/fail outcome, and provides statistical analysis tools for process control. Access is via browser with no dedicated software required on the plant PC.

Operator Interface
The operator interface is common to all models: capacitive touch screen with 5.7" colour TFT display (800×480 pixels), dynamic LED bar for cycle status indication, and backlit keypad. The front panel is protected by high-resistance tempered glass. Programming is password-protected; program names can be up to 16 characters long.

The main technical specifications common to K7000 models include: differential measurement accuracy ±0.5% RDG+3DGT, resolution 0.001 mbar, measurement range from –1 to 15 bar, leakage accuracy in cc/min of 1%RDG+0.03 cc/min.

Availability and Information
The Series K is available through the ForTest sales network. Further technical information is available on the company’s website.

About ForTest
ForTest is an Italian company headquartered in Modena, specializing in the design and manufacture of air leak testing instruments. Founded in the Modena biomedical district, it supplies quality control instruments to manufacturers in the automotive, medical, hydraulic, aerospace, and home appliance sectors. The company holds patents in the field of differential measurement with Dual Absolute™ technology.