Operating Instructions Complete Gas Injection Kit, ninm69en1-01 (1602)

Complete Gas
Injection Kit

Operating Instructions

Contents
1. General..................................................................................................................3
2. Safety Aspects.......................................................................................................3
3. Shipping contents..................................................................................................4
4. Main Parts.............................................................................................................5
5. Operation...............................................................................................................6
Connecting gas supply..........................................................................................6
Connecting panel to Injection Kit/Injection Fix Kit.................................................6
Locating the leak...................................................................................................8To pressurize a larger surface...............................................................................9Pressurizing the leak surface................................................................................96. To use the Reference Leak..................................................................................107. Maintenance........................................................................................................11Reference Leak certificate...................................................................................11
To change the Reference Leak............................................................................11
To change the Main Filter....................................................................................122

INFICON - Operating Instructions Complete Gas Injection Kit

1. GeneralComplete Gas Injection Kit is an accessory toHydrogen Leak Detector EXTRIMA, when leakdetecting 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 thefastest way to find and repair the leak by backtracing the gas. Using the Complete Gas Injection
Kit is the easiest way to get the tracer gas frombottle to leak point and it also helps you to seethat you have the correct pressure at the righttime and that your instrument is calibrated andready for use.

2. Safety Aspects
The tracer gas used is a mixture of 5% Hydrogen(H2) in Nitrogen (N2). It is non- flammable, nontoxic, non-corrosive and environmentally friendly.

Before connecting tracer gas: confirm that yourconnectors or test fixture is designed for working
at the specified test pressure.

This gas mixture contains no oxygen and releasing large amounts of gas in confined spaces
may lead to asphyxiation.

Compressed gases contain much energy. Always
carefully secure gas bottles before connecting
pressure regulator.

The normal risks with all compressed gases mustalso be considered.

WarningHazard

Pure Hydrogen is a flammable gas. Use
only ready-made mixtures of 5% Hydrogenin Nitrogen. This is a standard, industrial
gas mixture used in various industrial applications.

The recommended tracer gas mixture
contains no oxygen. Releasing large
amounts of gas in confined spaces may
displace the air and create a risk forasphyxiation.

Whenever the word Hydrogen is used throughout this manual it implies that hydrogengas is safely mixed with Nitrogen in proportions 5% H2 95%N2.

INFICON - Operating Instructions Complete Gas Injection Kit3

3. Shipping Contents
Complete Gas Injection Kit (590-621)
Case with Panel					590-619
1xReference Leak with Certificate		
591-446
1x
Allen Key for Diffuser House 		
591-476
1x
Guide Ring 9 mm				598-054
1x
Guide Ring 11 mm				598-0551x
Filter for Reference Leak			
591-475
1xReference Leak Dummy			
598-165
1x
Input Protection Cap 			591-7361x
Output Protection Cap			
591-737
1x
Leak Protection Cap				591-738
20 m 4 mm Hose					591-728
1x
Gas Out Connector
591-730+ 591-731
1x
Gas In Connector
591-730+ 591-732
1x
EX Zone 0 LED lamp			591-717
Injection Pad small 10 pcs			
Injection Pad large 10 pcs			

590-615590-616

Injection Fix Kit					590-618
1xInjection plug 40 mm				
599-055
3 x Modeling tools				591-720
1xCutting Knife					591-7111x
Injection Fix Tube 40 mm x 10		598-150
1xSealant Tape					591-7121xTape						591-71610 m Plastic Bagging Film				
591-721

4

INFICON - Operating Instructions 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%
H2 95% N2 with a pressure of 1Bar/15 PSI.

INFICON - Operating Instructions Complete Gas Injection Kit

55. Operation
Connecting gas supply
Before fitting the regulator to the gas bottle, makesure that the bottle is protected and can not fall.
Do not transport the gas bottle 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 psioutput pressure is recommended.
•Connect a suitable length of supply hose tothe output of the regulator. Use 4 mm or 5/32”
outer diameter pneumatic tubing (PA or PUR).

•Connect the hose with the quick connector tothe 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•

6Injection Fix Kit

Connect a suitable length of supply hose toGas out Port on the Injection Panel. Use 4 mmor 5/32” outer diameter pneumatic tubing (PAor PUR). Do not connect to the Injection Pad/Injection Fix Kit yet.

INFICON - Operating Instructions Complete Gas Injection Kit

•

Check that the ON /OFF valve is OFF.

• Set the correct pressure from the bottle(1 Bar / 15 PSI).

•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 tothe Pad/Fix kit.

INFICON - Operating Instructions Complete Gas Injection Kit7

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, reducepressure 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 pressureusing the output regulator.

•Repair the leak.

•When the repair has cured enough to withstandpressure, increase pressure again and checkthat the leak is tight.

8Extrima

INFICON - Operating Instructions Complete Gas Injection Kit

To pressurize a larger surface•

Clean area carefully with degreasing solvent
before applying tape or Mastik.

•Cut off a piece of plastic film and tape it overthe leaking surface as shown in the picture.
Use Seal tape or Mastik to fix the plastic filmin order to allow a higher pressure.

•Make a hole in the middle of the film and mounta small Injection Pad. Purge the hose from theGas 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 thecovered 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 andstart leak detection with Extrima.

INFICON - Operating Instructions Complete Gas Injection Kit

96. To use the Reference Leak
The Reference Leak is a reference used to calibrate the Extrima. The leak mounted in the caseleaks 5 x 10–4 mbarl/s @1 barG (See certificatefor exact value and pressure).
When a leak flow is 10–4 mbarl/s or less it isgenerally fluid tight (no stain).
10–2 mbarl/s is considered drop tight.
1 bar/15 psi gas pressure must be applied tothe 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 andcheck the signal on the Extrima. Re-move theprobe immediately when the signal has stabilized.
Note! The regulator and manometer on the Injection Panel do not affect the reference leak.

10INFICON - Operating Instructions Complete Gas Injection Kit

7. Maintenance
Reference Leak certificate
The reference leak is delivered with a certificate.
To keep the certification valid the reference leakmust be sent in to INFICON for re-calibration
once a year. The reference leak can during recalibration temporarily be replaced by the enclosed ”dummy” leak.

To change the Reference Leak•

Unscrew the diffusor. Mount the protective
cap on the reference leak, the protective cap
is found in the reference leak pack.

•Use a 14 mm spanner to remove the referenceleak.

INFICON - Operating Instructions Complete Gas Injection Kit11•Check the O-ring under the reference leakand 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 checkthat there are no leaks.

O-ringTo change the Main Filter•

Check the filter once a year and change filter
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 totighten the treads.

•Connect tracer gas to the panel and use Extrima to check that there are no leaks.

FilterSpare Parts
591-727 		
591-735		
591-446		

12

FilterO-ring 9,1 x 1,6
Reference Leak Type C

INFICON - Operating Instructions Complete Gas Injection Kit

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Document: ninm69en1-01 (1602)

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