Complete Gas Injection Kit
Contents
1. with regulator fitted Fit the pressure regulator to the bottle See manufacturer s instructions for details A two stage regulator with 0 1 bar 0 15 psi output pressure is recommended Connect a suitable length of supply hose to the output of the regulator Use 4 mm or 5 32 outer diameter pneumatic tubing PA or PUR Connect the hose with the quick connector to the Gas in Port on the Injection Panel Connecting panel to Injection Pad Injection Fix Kit Apply an Injection Pad or Injection Fix Kit according to the Instruction in the pad kit package Injection Pad Injection Fix Kit Connect a suitable length of supply hose to Gas out Port on the Injection Panel Use 4 mm or 5 32 outer diameter pneumatic tubing PA or PUR Do not connect to the Injection Pad Injection Fix Kit yet GAS IN 1BAR 15PSI EI e r1 L 6 Adixen Sensistor User s Manual Complete Gas Injection Kit Q H D Check that the ON OFF valve is OFF Set the correct pressure from the bottle 1 Bar 15 PST Set output pressure to 0 1 bar 1 5 psi Before connecting hose to injection point open On Off valve for a few seconds to purge hose Close valve and immediately connect hose to the Pad Fix kit Locating the leak Open the On Off valv and increase output pressure slowly to desired pressure max 0 5 bar 7 2 psi Check that pad is not peeling off If so reduce pressur2. JAPAN Alcatel Lucent Japan Ltd 1 9 4 Kita Shin Yokohama Kohoku ku Yokohama Kanagawa 223 0059 Japan Tel 81 3 6431 7130 Fax 81 45 544 0049 KOREA Alcatel Vacuum Technology Korea 447 Banwol dong Hawsung si 445 330 Kyungki do South Korea Tel 82 031 206 6277 Fax 82 031 204 6279 NETHERLANDS Alcatel Vacuum Technology Benelux Landzichtweg 60 NL 4105 DP Culemborg The Netherlands Tel 31 345 478 400 Fax 31 345 531 076 SINGAPORE Alcatel Lucent Singapore 49 Jalan Pemimpin 3101 02 APS Industrial Building 577203 Singapore Tel 65 6254 0828 Fax 65 6254 7018 www adixen com www sensistor com SWEDEN Adixen Sensistor AB Box 76 SE 581 02 Link ping Sweden Tel 46 0 13 35 59 00 Fax 46 0 13 35 59 01 TAIWAN Alcatel Vacuum Technology Taiwan No 169 3 Sec 1 Kang Leh Rd Song Lin Village Hsin Feng 304 Hsin Chu County Taiwan R O C Tel 886 3 559 9230 Fax 886 3559 9231 UNITED KINGDOM Alcatel Vacuum Technology UK Ltd 8 Bain Square Kirkton Campus Livingston West Lothian EH54 7DQ Scotland United Kingdom Tel 44 1 506 418 000 Fax 44 1 506 418 002 USA Alcatel Vacuum Products 67 Sharp Street Hingham MA 02043 USA Tel 1 781 331 4200 Fax 1 781 331 4230
3. Publication Adixen Sensistor AB Part number AS60085 Ed 01 10 2008 All information can be modified without prior notice Complete Gas Injection Kit User s manual adixen sensistor by Alcatel Vacuum Technology Contents W e 3 2 Safety Aspects cceecceeceeeeeeeeeeeeeeeeseeeeseeeseeeeseenseeeeseeeseeeneaeees 3 3 Shipping contents esseeeseseseeseeee eene 4 CPT EU a i ot EE 5 E Le E 6 Connecting gas supply uiid mter eadieess 6 Connecting panel to Injection Kit Injection Fix Kit 6 Locating the leak ir eerie tretes 7 To pressurize a larger surface ssssssssseseseees 8 Pressurizing the leak surface sssssssseeeeee 8 6 To use the Reference Leak essen 9 VANITATIS 10 Reference Leak certificate sssssssssseeese 10 To change the Reference Leak sssssssssees 10 To change the Main Filter uk 11 2 Adixen Sensistor User s Manual Complete Gas Injection Kit 1 General Complete Gas Injection Kit is an accessory to Hydrogen Leak Detector EXTRIMA when leak detecting on aircraft fuel tanks The entry point inside the tank is often far from the exit point on the outside and tracer gas leak detection is the fastest way to find and repair the leak by back tracing the gas Using the Complete Gas Injection Kit is the easiest way to get the tracer gas from bottle to leak point a
4. e certificate for exact value and pressure When a leak flow is 10 mbarl s or less it is generally fluid tight no stain 10 mbarl s is considered drop tight 1 bar 15 psi gas pressure must be applied to the Gas in Port when using the Reference Leak For calibration see the Extrima Manual Extrima function check Put the hand probe into the reference leak as shown in the picture and check the signal on the Extrima Re move the probe immediately when the sig nal has stabilized Note The regulator and manometer on the Injection Panel do not affect the reference leak Adixen Sensistor User s Manual Complete Gas Injection Kit 9 7 Maintenance Reference Leak certificate The reference leak is delivered with a certificate To keep the certification valid the reference leak must be sent in to Adixen Sen sistor for re calibration once a year The reference leak can during re calibration temporarily be replaced by the enclosed dummy leak To change the Reference Leak Remove the two Torx screws using a Torx T25 screwdriver Lift the complete panel out of the case Unscrew the diffusor and pull out the reference leak from the panel Use a 14 mm spanner to remove the reference leak Qe Torx screws 6 9 9 9 10 Adixen Sensistor User s Manual Complete Gas Injection Kit Check the O ring under
5. e and press pad back in place again Wait for gas to clear path to entry point Use Extrima to locate leaks When a leak is detected reduce pressure using the output regulator Repair the leak When the repair has cured enough to with stand pressure increase pressure again and check that the leak is tight Adixen Sensistor User s Manual Complete Gas Injection Kit 7 To pressurize a larger surface Clean area carefully with degreasing sol vent before applying tape or Mastik Cut off a piece of plastic film and tape it over the leaking surface as shown in the picture Use Seal tape or Mastik to fix the plastic film in order to allow a higher pressure Make a hole in the middle of the film and mount a small Injection Pad Purge the hose from the Gas Out port as earlier described and connect it to the Injection Pad Pressurizing the leak surface Open the ON OFF valve and adjust the pressure using the regulator on the Injection Panel to make sure that there are no leaks from the covered surface Note A larger surface normally means that you must use a considerably lower pressure Wait for gas to clear path to the entry point and start leak detection with Extrima 8 Adixen Sensistor User s Manual Complete Gas Injection Kit 6 To use the Reference Leak The Reference Leak is a reference used to calibrate the Extrima The leak mounted in the case leaks 5 x 10 mbarl s 1 barG Se
6. llen Key for Diffuser House AS132095 Ix Guide Ring 9 mm 48150299 Ix Guide Ring 11 mm AS150300 Ix Filter for Reference Leak AS132091 Ix Reference Leak Dummy AS150865 Ix Input Protection Cap AS135478 Ix Output Protection Cap 48135479 Ix Leak Protection Cap AS135480 20m 4mm Hose AS135467 Ix Gas Out Connector AS135469 AS135470 Ix Gas In Connector AS135469 AS135471 Ix EX Zone 0 LED lamp AS135451 Injection Pad small 10 pes AS90615 Injection Pad large 10 pcs AS90616 Injection Fix Kit AS90618 Ix Injection plug 40 mm AS500152 3x Modeling tools AS135459 Ix Cutting Knife AS135445 Ix Injection Fix Tube 40 mmx 10 AS150802 Ix Sealant Tape 48135446 Ix Tape 48135450 10 m Plastic Bagging Film 48135460 4 Adixen Sensistor User s Manual Complete Gas Injection Kit 4 Main Parts Gas Out Port Connection to the injection point Pad Fix kit On Off Valve Turns on off gas to the Gas Out Port Pressure Manometer Shows the regulated output pressure Regulator For regulating pressure to the Gas Out port Reference Leak Used to check and calibrate EXTRIMA Hydrogen Leak Detector Gas in Port Incoming tracer gas The tracer gas should be 5 H 95 N with a pressure of 1Bar 15 PSI Adixen Sensistor User s Manual Complete Gas Injection Kit 5 5 Operation Connecting gas supply Before fitting the regulator to the gas bottle make sure that the bottle is protected and can not fall Do not transport the gas bottle
7. nd it also helps you to see that you have the correct pressure at the right time and that your instrument is calibrated and ready for use 2 Safety Aspects The tracer gas used is a mixture of 5 Hy drogen H in Nitrogen N It is non flammable non toxic non corrosive and environmentally friendly This gas mixture contains no oxygen and releasing large amounts of gas in confined spaces may lead to asphyxiation The normal risks with all compressed gases must also be considered Warning Pure Hydrogen is a flammable gas Use only ready made mixtures of 5 Hydro gen in Nitrogen This is a standard industrial gas mixture used in various industrial applications Whenever the word Hydrogen is used throughout this manual it implies that hydrogen gas is safely mixed with Ni trogen in proportions 5 H 95 N Before connecting tracer gas confirm that your connectors or test fixture is designed for working at the specified test pressure Compressed gases contain much energy Always carefully secure gas bottles before connecting pressure regulator Hazard The recommended tracer gas mixture contains no oxygen Releasing large amounts of gas in confined spaces may displace the air and create a risk for asphyxiation Adixen Sensistor User s Manual Complete Gas Injection Kit 3 3 Shipping Contents Complete Gas Injection Kit AS90621 Case with Panel AS90619 Ix Reference Leak with Certificate AS130492 Ix A
8. the reference leak and replace it with a new O ring if necessary Replace the reference leak with a new one or mount the enclosed Reference Leak Dummy Assemble in reverse order Connect tracer gas to the panel and use Extrima to check that there are no leaks To change the Main Filter e Check the filter once a year and change fil ter when needed Remove the panel according to the description above Unscrew the filter connections using two 14 mm spanners Insert a new filter Use Loctite 577 or similar to tighten the treads Connect tracer gas to the panel and use Extrima to check that there are no leaks Spare Parts AS135466 Filter AS135474 O ring 9 1 x 1 6 48130492 Reference Leak Type C Filter Adixen Sensistor User s Manual Complete Gas Injection Kit 11 CHINA Alcatel Vacuum Technology Shanghai N 82 Lane 887 Zuchongzhi Road Zhangjiang High Tech Park Shanghai 201203 China Tel 86 21 5027 0628 Fax 86 21 3895 3815 FRANCE Head office Alcatel Vacuum Technology France 98 avenue de Brogny BP 2069 74009 Annecy cedex France Tel 33 450 65 77 77 Fax 33 4 50 65 77 89 GERMANY Alcatel Hochvakuumtechnik GmbH Am Kreuzeck 10 Postfach 1151 97877 Wertheim Germany Tel 49 9342 9610 0 Fax 49 9342 9610 30 ITALY Alcatel Vacuum Systems Via Trento 30 20059 Vimercate Mi Italy Tel 39 0396 86 38 55 Fax 39 039 66 71 25
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