Inficon AP29ECO User manual

Original operating instructions
AP29ECO
Sampling Probe for Sentrac Desktop and Sentrac Panel
ninb69en1-02-(2401)
Catalog No.
590-035 (3 cc/sec sample flow), 590-036 (1 cc/sec sample flow)
From software version
4.01 or higher

INFICON AB
Wahlbecksgatan 25A
SE-582 13 Linköping
Sweden

INFICON Table of Contents
AP29ECO_Operating-instructions-ninb69en1-02-(2401) iii
Table of Contents
1 Introduction .................................................................................................................................................... 6
1.1 General .................................................................................................................................................... 6
1.2 Equipment ................................................................................................................................................ 6
1.3 Safety Aspects ......................................................................................................................................... 6
2 System Description........................................................................................................................................ 8
2.1 Connect Tracer Gas filler ......................................................................................................................... 9
2.2 System based on a Sensistor Sentrac, Desktop Model or Panel Model.................................................. 9
2.3 Test Sequence ....................................................................................................................................... 10
2.3.1 Accumulating Time (Settings / Probe / APC 1) ........................................................................... 11
2.3.2 Sampling Time (Settings / Probe / APC 1).................................................................................. 11
2.3.3 Measuring Time (Settings / Probe / APC 1)................................................................................ 11
2.3.4 After Test Purging Time (Settings / Probe / APC 1).................................................................... 11
2.3.5 Purge Trigger (Settings / Probe / APC 2).................................................................................... 11
2.3.6 Other important software parameters .........................................................................................12
3 Quick Start .................................................................................................................................................... 13
3.1 Installation .............................................................................................................................................. 13
3.2 Setup Settings........................................................................................................................................14
3.3 Measuring .............................................................................................................................................. 15
3.4 Remote Control AP29ECO .................................................................................................................... 15
4 Installation .................................................................................................................................................... 16
4.1 Placement of Sample Probe .................................................................................................................. 17
4.2 Cable Connections.................................................................................................................................18
4.2.1 Sensor Cable .............................................................................................................................. 18
4.2.2 Bus Cable ................................................................................................................................... 19
4.3 Pneumatic Connections for AP29ECO .................................................................................................. 20
4.3.1 Sample Inlet ................................................................................................................................ 21
4.3.2 Calibration Gas ........................................................................................................................... 22
4.3.3 Pressure regulator ...................................................................................................................... 22
4.3.4 Reference Air .............................................................................................................................. 23
4.3.5 Exhaust ....................................................................................................................................... 23
4.4 Master Controls......................................................................................................................................24
4.4.1 Manual switches .........................................................................................................................25
4.4.2 Programmable Logic Controller etc. ........................................................................................... 25

Table of Contents INFICON
iv AP29ECO_Operating-instructions-ninb69en1-02-(2401)
4.4.3 Programmable Logic Controller with Sentrac External DSUB IO Adapter.................................. 26
4.5 Test area ................................................................................................................................................ 27
4.5.1 Tracer gas supply ....................................................................................................................... 27
4.5.2 Pressure regulator ...................................................................................................................... 27
4.5.3 Tracer gas exhaust ..................................................................................................................... 28
4.5.4 Fresh air...................................................................................................................................... 28
5 Operation ...................................................................................................................................................... 31
5.1 Measure Sequence Flow Chart.............................................................................................................. 31
5.2 Measure Sequence Signals ................................................................................................................... 32
5.3 Calibration .............................................................................................................................................. 32
5.4 Calibration Sequence Signals ................................................................................................................ 32
5.5 Setting up your Application .................................................................................................................... 33
5.5.1 Parameters ................................................................................................................................. 33
5.5.2 General Parameters.................................................................................................................... 33
5.5.3 Sampling parameters.................................................................................................................. 33
6 Preventive Maintenance .............................................................................................................................. 36
6.1 Toolkit..................................................................................................................................................... 36
6.2 Maintenance plan...................................................................................................................................36
6.3 Cleaning Port Filters............................................................................................................................... 37
6.4 Membrane Pump.................................................................................................................................... 38
6.5 Replacing Gas Sensor ........................................................................................................................... 39
7 Trouble Shooting.......................................................................................................................................... 41
8 Spare Parts ................................................................................................................................................... 42
9 Electric Diagram ........................................................................................................................................... 43
10 Pneumatic Diagram...................................................................................................................................... 44
11 Technical Data .............................................................................................................................................. 45
11.1 General .................................................................................................................................................. 45
11.1.1 Sensitivity.................................................................................................................................... 45
11.1.2 Sniffer flow alarm ........................................................................................................................ 45
11.1.3 Calibration gas ............................................................................................................................ 45
11.1.4 Temperature range ..................................................................................................................... 45
11.1.5 Protection rating.......................................................................................................................... 45
11.1.6 Dimensions ................................................................................................................................. 45
11.1.7 Weight......................................................................................................................................... 45

INFICON Table of Contents
AP29ECO_Operating-instructions-ninb69en1-02-(2401) v
11.1.8 Electrical ratings.......................................................................................................................... 45
11.1.9 Electromagnetic Compatibility..................................................................................................... 46
11.2 Sniffer Flow Options...............................................................................................................................46
11.2.1 Standard flow .............................................................................................................................. 46
11.2.2 Optional flow 1 ............................................................................................................................ 46

1 | Introduction INFICON
6 / 48 AP29ECO_Operating-instructions-ninb69en1-02-(2401)
1 Introduction
1.1 General
The Sampling Probe AP29ECO forms together with the Hydrogen Leak Detector
Sensistor Sentrac Panel a complete industrial leak-detection unit.
Sampling probe AP29ECO is intended for intermittent or continuous sampling of a test
point or test chamber. It performs quick and accurate accept/reject testing.
Sample Probe AP29ECO can only be controlled by Sensistor Sentrac Panel and
Desktop Leak Detector with software version 4.01 or higher.
Typical applications for the AP29ECO are:
• Integral testing in accumulating test chamber
• Point testing of pipe joints. For example, refrigeration and automotive pipes
• Automatic surface or weld seam scanning
1.2 Equipment
The equipment which is delivered:
• Sampling Probe AP29ECO
• Sentrac External DSUB IO Adapter
• Bus Cable (2 m, male-to-male, pin-to-pin, 25 pin D-type)*
• Sensor Cable (3 m, black with 5 pin LEMO connectors)*
• Operating instructions
* Other lengths available.
1.3 Safety Aspects
WARNING
Always switch power off before disconnecting or connecting any cable. Failure to
comply with this rule can result in personal injury or serious damage to the equipment.
WARNING
Make sure there is proper ventilation. 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.

INFICON Introduction | 1
AP29ECO_Operating-instructions-ninb69en1-02-(2401) 7 / 48
WARNING
Pure Hydrogen is a flammable gas. Use only ready-made mixtures of 5% Hydrogen 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 Nitrogen in proportions 5% H2 – 95% N2.
WARNING
The normal risks with all compressed gases must also be considered.
WARNING
Before connecting tracer gas: Confirm that your connectors or test fixture is designed
for working at the specified test pressure.
WARNING
Always carefully secure gas bottles before connecting pressure regulator.
Compressed gases contain much energy.
NOTICE
The tracer gas used is a mixture of 5% Hydrogen (H2) in 95% Nitrogen (N2). It is not
flammable, non-poisonous and environmentally friendly.

2 | System Description INFICON
8 / 48 AP29ECO_Operating-instructions-ninb69en1-02-(2401)
2 System Description
Considerably higher sensitivities can be achieved for point testing applications by
using the accumulation technique supported by the Sensistor Sentrac software.
Consult your supplier for best system design for your particular application.
The AP29ECO is equipped with one sniffer port that has one constant flow with two
functions. One flow (Samplings flow) does not measure the hydrogen concentration
while the other (Measuring flow) does. With that technology, you can e.g. take home a
sample from an accumulation chamber to measure the hydrogen concentration or you
can create a steady-state condition, e.g. obtain a leak point before measuring the
hydrogen concentration.
The constant sniffer flows are created by an electrical pump pulling air through two
high precision ruby orifices. A critical flow type situation is obtained.
The orifices are protected by built-in filters. The flow is supervised by two differential
pressure switches activated by the pressure drop across the orifices. The switches are
factory set to open at 75% of the nominal sniffer flow.
The Sampling probe AP29ECO is equipped with an overexposure protection mode
purging the sensor with reference air as soon as the signal goes above the rejection
threshold. This reduces the recovery time of the sensor enabling the system to work
with high speed testing applications.
The unit is also equipped with a calibration mode. This allows for fast and automatic
calibration adjustment, with a certified gas mixture of Hydrogen in Air.
See the calibration section below.
The Sensistor Sentrac system offers 24 VDC logic signals for valve control, leak
alarms, sniffer flow alarm, etc. for easy interfacing to any PLC system. The AP29ECO
is designed for minimum maintenance and easiest possible service.

INFICON System Description | 2
AP29ECO_Operating-instructions-ninb69en1-02-(2401) 9 / 48
2.1 Connect Tracer Gas filler
INFICON offers a range of products that can be combined for making up most of your
entire test system. The design work can therefore, often be kept to an absolute
minimum.
2.2 System based on a Sensistor Sentrac, Desktop
Model or Panel Model
Fig.1: System based on Sensistor Sentrac
1 Sensistor Sentrac Panel Model
2 COMBOX 60
3 AP29ECO
4 Accumulation Chamber

2 | System Description INFICON
10 / 48 AP29ECO_Operating-instructions-ninb69en1-02-(2401)
2.3 Test Sequence
There are four major steps in the test sequence. (Timers are set in the Sensistor
Sentrac):
1. Accumulation
2. Sampling
3. Measuring
4. Purging
See figure 2 below
Fig.2: Test sequence

INFICON System Description | 2
AP29ECO_Operating-instructions-ninb69en1-02-(2401) 11 / 48
2.3.1 Accumulating Time (Settings / Probe / APC 1)
This is the delay time, from that the test object is filled with tracer gas, until a sample is
taken from the test point. Accumulation is used to increase the hydrogen
concentration of a tracer gas into the test chamber. The concentration in the test
chamber will increase linearly during the accumulation time.
2.3.2 Sampling Time (Settings / Probe / APC 1)
This is the time needed to draw a sample from the test point to the AP29ECO. If
sampling time is too short, the sample will not reach the sensor. An excessively long
sample time may pump away the sample in a small open chamber.
The setting of the Sampling time depends on sample hose length and diameter. Test
correct time for your set-up.
2.3.3 Measuring Time (Settings / Probe / APC 1)
The sample is passed over the sensor during the Measuring time. The Measuring time
can be set to 3 seconds if your alarm level corresponds to 10 ppm or higher. For lower
levels and fine tuning, see ”Sampling parameters [}33]”.
2.3.4 After Test Purging Time (Settings / Probe / APC 1)
Purge the sampling tube with air blown out through the tube. Set the timer so that you
are sure there are no samples left in the tube for the next measurement.
2.3.5 Purge Trigger (Settings / Probe / APC 2)
Gas signal above Reject Level immediately start purging the gas sensor with air, to
avoid unnecessary tracer gas exposure. Can be set to a factor higher then Reject
Level. Provides shorter recovery times when searching for large leaks.

2 | System Description INFICON
12 / 48 AP29ECO_Operating-instructions-ninb69en1-02-(2401)
2.3.6 Other important software parameters
•Reject Level (Settings / Measure Mode / Setup)
Gas signals above the Reject Level result in REJECT.
Gas signals below the Reject Level result in ACCEPT.
•Calibration Value (Settings / Calibration / Setup 1)
Calibrate against a Calibration gas you should set Calibration Value equal to the
concentration of Hydrogen in your calibration gas. Example for 10 ppm Hydrogen
set Calibration Value = 10 ppm.
For further details refer to the Sensistor Sentrac manual.
For optimization of test parameters, see ”Setting up your Application [}33]”.

INFICON Quick Start | 3
AP29ECO_Operating-instructions-ninb69en1-02-(2401) 13 / 48
3 Quick Start
Read this manual carefully before you finalize the design of your test system. You
must understand all aspects of the detector and probe before you can realize a fully
reliable test system.
This quick start guide can be used to quickly set up your system for evaluation and
laboratory testing.
3.1 Installation
WARNING
Always switch power off before disconnecting or connecting any cable. Failure to
comply with this rule can result in personal injury or serious damage to the equipment.
CAUTION
The 25-pin D-type connector on the Sentrac External DSUB IO Adapter (598-330) is
not a computer or printer port. Connecting a printer or any other computer device may
cause permanent damage to the connected device.
1Connect Sentrac External DSUB IO Adapter to I/O (APC) port on the Sensistor
Sentrac backside.
2Connect Buscable to the Sentrac External DSUB IO Adapter and AP29ECO D-
sub port.
3Connect one Probe Cable C21 from Sentrac (front or rear) Probe Connection to
Combox60 Detector port.
4Connect one Probe Cable C21 from Combox60 Probe port and to AP29ECO
sensor (H65).
5Install hoses according to “Pneumatic Connections for AP29ECO [}20]”
below.
6Pressurize calibrate gas with pressure in the range of 0.03 – 0.1 MPa / 0.3 – 1
barg / 4.3 – 15 psig.

3 | Quick Start INFICON
14 / 48 AP29ECO_Operating-instructions-ninb69en1-02-(2401)
3.2 Setup Settings
1Open Settings / Probe / Functions and set probe Type to AP29ECO.
2Open Settings / Probe / APC 1 and if necessary, optimize timers for shortest
cycle time.

INFICON Quick Start | 3
AP29ECO_Operating-instructions-ninb69en1-02-(2401) 15 / 48
3.3 Measuring
1Go to main menu
2Press to start a Measuring
3Press to:
ðAbort Measuring
ðGo to Standby
ðPurge the sample hose more
3.4 Remote Control AP29ECO
Go to set up remote control instead of controlling from Sentrac display read:
Manual switches [}25]
Programmable Logic Controller etc. [}25]

4 | Installation INFICON
16 / 48 AP29ECO_Operating-instructions-ninb69en1-02-(2401)
4 Installation
WARNING
► Make sure that all electric and pneumatic supplies are switched off when
connecting or disconnecting any supplies to the probe or detector. Failure to comply
with this rule can result in personal injury or serious damage to the equipment.
► This also applies to the sensor cable. The sensor can be destroyed if the power is
switched on!
CAUTION
The 25-pin D-type connector on the Sentrac External DSUB IO Adapter (598-330) is
not a computer or printer port. Connecting a printer or any other computer device will
cause permanent damage to the connected device.
Installation of the AP29ECO is very simple, follow the instructions below. The APC
system of the Sensistor Sentrac handles all vital functions. The AP29ECO can also be
controlled through the APC Bus via switches, sensors and indicators, or via a PLC/PC.
See “Electric Diagram [}43]” “and ”Pneumatic Diagram [}44]”.

INFICON Installation | 4
AP29ECO_Operating-instructions-ninb69en1-02-(2401) 17 / 48
4.1 Placement of Sample Probe
Place the sample probe as close as possible to the test object. This is done to
minimize the length of the sampling hose and thereby the length of the test cycles.
The probe can be installed in any position. We recommend that the AP29ECO is
placed with the ventilation grid facing down. This makes it harder for dirt or dust to
collect inside the box.
Fig.3: Placement of AP29ECO
The box is fastened with four screws.
• Max thread diameter is 6 mm (0.25’)
• Max head diameter is 11 mm (0.43’)
• Length is 20 mm (0.8’) + grip
For placement of the screws, see Figure 3.

4 | Installation INFICON
18 / 48 AP29ECO_Operating-instructions-ninb69en1-02-(2401)
4.2 Cable Connections
4.2.1 Sensor Cable
The sensor inside the AP29ECO is connected to the Sensistor Sentrac with two C21
cables and one COMBOX60. Several different cable lengths are available. See sensor
cable in the figure below.
Fig.4: Sensor cable
Align the red mark on the cable contact with the red mark on the panel contact and
push straight in. The contact will snap in and lock.
To disconnect, hold around the knurled part of the connector and pull straight out.

INFICON Installation | 4
AP29ECO_Operating-instructions-ninb69en1-02-(2401) 19 / 48
4.2.2 Bus Cable
The bus cable carries control signals of the Active Probe Control (APC) system in the
Sensistor Sentrac. The APC system controls the pneumatic and electric functions of
the AP29ECO.
The control cable is a 25-pin D-type cable with complete pin-to-pin configuration.
Several different cable lengths are available.
Connect the cable and tighten the locking screws on both ends.
The APC Bus is a simple discrete I/O bus. Each digital input and output has its own
pin/wire on the bus. See Table 1 below for description of which pins are used for
controlling the AP29ECO. Further details of the APC System can be found below and
in the Sensistor Sentrac Interface Description.

4 | Installation INFICON
20 / 48 AP29ECO_Operating-instructions-ninb69en1-02-(2401)
4.3 Pneumatic Connections for AP29ECO
The figure 5 shows the pneumatic connections of AP29ECO.
Exhaust Reference air Sample Inlet Calibrating gas
Fig.5: Pneumatic connections of the AP29ECO
See table below for more information about the pneumatic connections.
Type Specification Port thread Original tubing
Exhaust Exhaust of the sample pump.
Connect to ventilation system.
BSP 1/8”
(ISO 228/1-G1/8)
OD 8.0 mm
Reference Air Hydrogen-free, ambient air. Preferably
taken from outer wall of the building.
Atmospheric pressure. You must install an
external filter in the reference air hose.
BSP 1/8”
(ISO 228/1-G1/8)
OD/ID 6.0 /4.0 mm
Sample Inlet This is the test port Standard flow: 3 atm
cc/s
ISO724 M5x0.8 *
(UNF1032 can normally
be used)
ID 2 – 2.5 mm
Calibration Gas Typically 10 ppm H2 in Air (can be in
range 1 to 400 ppm and within +/- 50% of
Leak reject level)
0.03 – 0.10 MPa / 0.3 – 1.0 barg / 4.5 – 15
psig
(Consumption: Typically 15 std. cc/s at
0.05 MPa / 0.5 barg / 7 psig)
BSP 1/8”
(ISO 228/1-G1/8)
OD/ID 6.0 /4.0 mm
Table1: Pneumatic Connection