SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-03-X-XX-X.X USER MANUAL

Transcription

1 SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-03-X-XX-X.X ESAT UM ESAT UM Revision 2.0 June 02nd, 2016 Page 1 of 43

2 INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF OPTOSENSE LLC. ANY REPRODUCTION IN PARTS OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF OPTOSENSE LLC IS PROHIBITED. Document revisions Rev. Date Common changes 1.0 August 12 th, 2015 Released version 1.1 October 09 th, 2015 Corrected internal sensor capacitance C i 1.3 October 30 th, 2015 In section 4 upper limit of P0 has been changed from 0.25 W to 0.13 W. Title of Fig. 10 has been changed from MIPEX-03-1-XX-X.X to MIPEX-03-2-XX-X.X. Tolerances in Table 7, Table 8 and Table 9 have been changed. 2.0 June 02 nd, 2016 Formatting. Changed analog output variability. ESAT UM Revision 2.0 June 02nd, 2016 Page 2 of 43

3 Table of contents 1. Introduction Description Technical specifications Intrinsic safety Handling precautions Installation and service Preparation Mounting Electrical conditions Sensor setup Analog output description Setting up the output mode Setting up voltage range of analog output Conversion of analog output voltage to concentration Storage and transportation Warranty Contacts Appendix A. Sensor types and characteristics Appendix B. Connection diagram Appendix C. UART communication protocol Appendix C.1. General information Appendix C.2. Communication protocol commands Appendix C.2.1. Commands for requesting measured data and diagnosing Appendix C.2.2. Commands for requesting the factory settings and properties Appendix C.2.3. Commands for sensor configuring and span calibrating Appendix C.2.4. Commands for configuring analog output Appendix D. Sensor zeroing and span calibration Appendix D.1. Span calibration and zeroing Appendix D.2. Temperature dependence of zero adjustment Appendix E. Dust filter attaching Appendix F. Troubleshooting ESAT UM Revision 2.0 June 02nd, 2016 Page 3 of 43

4 1. INTRODUCTION This user manual (UM) is intended to describe design and operation of small-sized gas sensor MIPEX-03-X-XX-X.X (hereinafter MIPEX-03). UM contains basic technical data, recommendations and other information necessary for proper operation, maintenance and storage of sensor. Sensor is intended for automatic continuous measurement of hydrocarbons concentration in hazardous areas atmosphere. Sensor can be used as a part of gas-analyzing equipment groups I and II according to IEC in the explosion-hazardous zones classes 0, 1, 2 according to IEC , and Class I, Division 1, Group A, B, C, D according to UL Std. 913, CAN/CSA Std. C22.2 No List of abbreviations: ADC Analog-to-Digital Converter. DAC Digital-to-Analog Converter. LEL Lower Explosive Limit. LED Light Emitting Diode. MPC Maximum Permissible Concentration. CGM Control Gas Mixture. NDIR Non-Dispersive Infra-Red. UART Universal Asynchronous Receiver/Transmitter. CRC Cyclic Redundancy Check. IP Ingress Protection. PCB Printed Circuit Board. Any command stated in this UM as <X>, where X stands for a command text consisted of any number of characters, must be read and/or sent without the symbols < and >. Optosense LLC reserves the right to make changes to this manual, excluding intrinsically safe sensor parameters. ESAT UM Revision 2.0 June 02nd, 2016 Page 4 of 43

5 2. DESCRIPTION Sensor has several modifications for specific needs. They differ by housing types, photodiode and LED, calibration gases, interface types, measuring ranges etc. (see Appendix A). Sensor is a smart integrated system and includes mirror optical system, photodiode and LED, signal amplifiers, microcontroller, current driver of the infrared LED, UART interface signal generator, supply forming voltage unit and unit generating output analog signal. Sensor microcontroller performs storage of unique sensor calibration constants, processing of measurement results and concentration of measured gas, and information exchange. Sensor operating principle is based on NDIR technology, i.e. on selective infrared radiation absorption by gas molecules. Infrared radiation from LED permeates through a measuring diffusion-type gas cell and arrives on signal and reference photodetectors, one of which detects radiation only in the wavelength range of infrared radiation absorbed by gases, while the other one detects radiation only in the wavelength range of μm. Gas flowing through the cell absorbs the radiation of the operating wavelength (λ s ) and does not affect the radiation of the reference wavelength (λ ref ). Amplitude of the photodetector operating and reference signals, U s and U ref, varies with the target gas concentration in accordance with the following equation: where: U s U ref = exp( [K(λ s ) K(λ ref )] C L) К(λ) absorption coefficient at the predetermined wavelength; L optical length of the cell; С measured concentration of gas; U s, U ref photodetector signals amplitude. Differential dual wavelength method allows eliminating of water vapor, optical elements contamination and other non-selective hindrances influence. Term target gas is introduced in this UM. Target gas is a gas which sensor is intended to detect and measure its concentration (see Table 1). ESAT UM Revision 2.0 June 02nd, 2016 Page 5 of 43

6 Table 1. Target gases for the MIPEX-03 sensors Target gas Analytical tasks description Optical elements code (see Appendix A) Spectral characteristic maximum Notes CH 4 Analyzing a gas mixture containing methane as the main component m For optical elements sensitivity to other hydrocarbons, see Fig. 9. C 3 H 8 Analyzing a gas mixture containing heavy hydrocarbons. The presence of methane is negligible m For optical elements sensitivity to other hydrocarbons, see Fig. 10. CH 4 /CH 4 +C 2 H 6 The atmosphere of objects of group I (mine) in accordance with ГОСТ Р m For optical elements sensitivity to other hydrocarbons, see Fig. 11. ESAT UM Revision 2.0 June 02nd, 2016 Page 6 of 43

7 3. TECHNICAL SPECIFICATIONS Table 2. General specifications (for available options see Appendix A) Gas sampling method Operating principle Diffusion Non-Dispersive Infra-Red (NDIR) CH 4 Target gas* CH 4 /CH 4 +С 2 Н 6 C 3 H 8 Operating, storage and transportation conditions: Relative humidity, % up to 98 Atmospheric pressure, kpa Temperature**, C Temperature range, C Overall dimensions, mm (without pins) (without pins) Pins length, mm 4.4 Warm-up time, sec (standard housing, stainless steel) Weight, g 16.3 (fast response housing, stainless steel) 6.4 (plastic) Housing material Stainless steel (standard and fast response) Plastic Life time expectancy*** (not less than), years 10 Shelf life time 8 IP rating 20 (without dust filter) 54 (if a dust filter is applied) * See Appendix A for details. ** Term operating temperature refers to ambient temperature at which sensor operates and its intrinsic safety is ensured, but sensor accuracy stated in Table 3 is provided only in specified temperature range (see Table 5 and Table 6). *** To provide metrological properties during sensor lifetime, zeroing and span calibration should be performed periodically (see Appendix D.1). ESAT UM Revision 2.0 June 02nd, 2016 Page 7 of 43

8 Table 3. Measurement specifications Measurement range, % vol Basic variability ( ⁰C)* Variability of analog output (additional variability)** Response time (T90), sec Response time (T90) with dust filter (see Appendix E), sec ± 0.1% vol. or ± 5% of indication (whichever is greater) for CH 4 ± 0.05% vol. or ± 5% of indication (whichever is greater) for C 3 H 8 ± 1% of measurement range or ± 2% of indication (whichever is greater) 5 (fast response housing) 20 (standard and plastic housings) 10 (fast response housing) 30 (standard and plastic housings) * For variability in whole operating temperature range for any sensor modification see Table 6. ** Additional variability of analog output is caused by DAC resolution. Thus when analog output is used it is necessary to add variability of analog output value to basic variability value whether UART is available or not. Table 4. Electrical specifications, marking and standards compliance Operating supply voltage, VDC (min max) UART Communication interface analog output Power consumption, mw < 5 UART and analog output Degree of personal protection against electrical shock caused by sensor meets the requirement of class III ГОСТ Ex ia I Ma U/Ex ia IIC Ga. U acc. to ГОСТ Р МЭК , ГОСТ Р МЭК , ТР ТС 012/2011 Ex ia I Ma / Ex ia IIC Ga. acc. to IEC , IEC Ta +60 C Marking and standards compliance IM 1/II 1 G Ex ia I Ma / Ex ia IIC Ga. acc. to EN , EN Ta +60 C ESAT UM Revision 2.0 June 02nd, 2016 Page 8 of 43

9 4. INTRINSIC SAFETY Sensor s intrinsic safety is provided by: limiting parameters of its electrical circuits to intrinsically safe values in accordance with EN ; providing the required electrical clearances and creepage paths in accordance with EN ; insulation between intrinsically safe circuit and sensor housing which withstands test voltage of 500 V in accordance with EN ; Combined intrinsically safe sensor circuits parameters are as follows: IECEx/ATEX: U i = 5.0 V, I i = 200 ma, P i = 0.13 W, C i = 26 µf, L i = 0 mh. CAN/CSA: V max = 5.0 V, I max = 200 ma, P max = 0.13 W, C i = 26 µf, L i = 0 mh. It is allowed to connect sensor only to intrinsically safe circuits with the rated direct current output voltage (U 0 ) within the range of V, with the output power (P 0 ) range of W in accordance with IEC , IEC and which parameters conform MIPEX-03 intrinsic safety values pointed above. Current provided by power supply unit must be 25 ma I ma. ESAT UM Revision 2.0 June 02nd, 2016 Page 9 of 43

10 5. HANDLING PRECAUTIONS Do not use damaged sensor. It must be repaired only by personnel authorized by manufacturer. Keep sensor out of contact with aggressive substances e.g. acidic environments which can react with the metals, as well as solvents which may affect polymeric materials. Diffusion holes of sensor should be protected against ingress of dust and sprayed materials. Sensor is not intended to measure hydrocarbons contained in fluids. Maximum allowable pressure for metal housing: on the central part of sensor reflecting cover or on sensor side surface 2 MPa, on sensor upper edge 100 MPa. Maximum allowable pressure for plastic housing: on the central part of sensor reflecting cover or to sensor s side surface 20 kpa, on sensor upper edge 2 MPa. Sensor updates information about concentration every 1.28 seconds (this interval may increase up to 1.36 seconds when UART is active). Sending any command more often than one time per second (1 Hz) may reduce sensor accuracy. Correct measurement is provided when ambient temperature changes not faster than 0.6 C/min. Covering diffusion holes of sensor increases its response time (T90). When operating sensor, observe conditions stated in Table 2 and Table 4. Inspection and maintenance should be carried out by suitably trained personnel in accordance with the applicable code of practice (e.g. EN ). Persons, who have studied this UM, must be briefed on safety precautions when operating electrical equipment intended for use in explosive areas in due course. When dealing with cylinder containing gas mixture under pressure, it is necessary to follow the safety regulations. Dumping of CGM into the work area is not allowed. There is no risk of pollution and negative impact on human health. Sensor does not contain any harmful substances that may be released during its normal operation. It is strictly prohibited to remove label from sensor or to damage marking information in any way. ESAT UM Revision 2.0 June 02nd, 2016 Page 10 of 43

11 6. INSTALLATION AND SERVICE MIPEX-03 may accumulate an electrostatic charge on its housing. Thus, there is risk of electrostatic discharge. Clean only using a damp cloth. Note this during installation and use of sensor in the end-user equipment. MIPEX-03-X-XX-1.X and MIPEX-03-X-XX-2.X modifications have been tested and were found to have maximum capacitance of ungrounded metal frame equal 17.4 pf. Sensor must be mounted using sockets only, as soldering the pins may damage sensor. It is not allowed to use excessive pressure on sensor housing. Maximum allowable pressure for the metal housing: on the central part of sensor reflecting cover or on sensor side surface 2 MPa, on sensor upper edge 100 MPa. Maximum allowable pressure for the plastic housing: on the central part of sensor reflecting cover or on sensor side surface 20 kpa, on sensor upper edge 2 MPa. Zeroing and span calibration are necessary in following cases: after durable storage, after transportation, during the initial installation to gas analyzers, after filter is applied, as well as while preparation for the yearly tests (refer to Appendix D for details). Correct measurement is provided when ambient temperature changes not faster than 0.6 C/min Preparation If sensor has been kept in transport containers at temperatures below zero centigrade, leave it at C for not less than one hour. Remove the packaging. Check presence of the certification markings; make sure there are no mechanical injuries on sensor surfaces Mounting Use intrinsically safe circuit connections represented in Appendix B. It is recommended to use sockets Cambion or similar for sensor mounting. Sensor pinout is shown in Appendix A. End user instrument design has to provide that sensor is free of excessive pressure on the housing, ingress of dust, dirt and condensed moisture, as these factors may affect the accuracy of measurement. It is recommended to use dust filter (available as an option; see Appendix E). Filter has to be checked regularly and replaced when fouling is significant. ESAT UM Revision 2.0 June 02nd, 2016 Page 11 of 43

12 6.3. Electrical conditions During first 0.1 seconds after power up, sensor consumes up to 25 ma (see Fig. 1). During operation MIPEX-03 has pulsed current consumption. Pulse repetition period is 10±20% ms (depends on ambient temperature). During operation maximum surge current is 12 ma. Average current consumption is not more than 1 ma (see Fig. 4 and Fig. 5). It may increase up to 10 ma over about 60 ms when UART is active. For typical sensor voltage drop, see Fig. 2. During the first 40 seconds after the power is up sensor does not return the measured concentration proper value (the value is displayed as -1, hex: 8001 ). Sensor updates information about concentration every 1.28 seconds (this interval may increase up to 1.36 seconds when UART is active, see Fig. 2 and Fig. 3). Sending any command more often than one time per second (1 Hz) may reduce sensor accuracy. Use intrinsically safe circuit connections represented in Appendix B. Sensor power supply has to follow requirements of IEC and IEC , with rated output range of intrinsically safe DC voltage (U 0 ) of V, with rated power range (P 0 ) of W. Current provided by power supply unit must be 25 ma < I ma. For all MIPEX-03 modifications polarity of power supply does not matter, but one of the power pins must always be connected to GND. Sensor transmits information about measured concentration via UART interface and/or analog output (see section 7). Sensor supports embedded self-testing while operating and is designed for continuous 24/7 operation. UART transceiver and/or analog output should meet the requirements of standards IEC , IEC UART transceiver communication properties are: High logic level for transmitting line TxD is in range of V; High logic level for receiving line RxD is in range of V; Low logic level is in range of V; Maximum output current of UART is not more than 25 ma. ESAT UM Revision 2.0 June 02nd, 2016 Page 12 of 43

13 Voltage, V Optosense LLC Time, s Fig. 1. Typical sensor voltage drop after power up (input voltage 3.3 V, load resistance R = 100 Ohm) Fig. 2. Typical sensor voltage drop (5 VDC supply, resistance 100 Ohm, without load resistance on AnOut, recommended load resistance on AnOut is 1 kohm) ESAT UM Revision 2.0 June 02nd, 2016 Page 13 of 43

14 Voltage, V Optosense LLC Time, s Fig. 3. Pulse with increased current consumption while processing concentration value (analog output is off; input voltage 3.3 V, load resistance 100 Ohm) Fig. 4. Typical barrier voltage drop waveform (3.3 V input) ESAT UM Revision 2.0 June 02nd, 2016 Page 14 of 43

15 Fig. 5. Typical current consumption waveform (R = 30 Ohm, C = 20 µf) 6.4. Sensor setup Switching on/off sensor is performed automatically upon feeding/disconnecting power supply. After sensor is installed into end-user equipment check its status by sending <F> command via UART interface (if available): for communication protocol see Appendix C; for <F> command description see Appendix C.2.1; for response description see Table 11. Sensor span calibration and zeroing should be performed next. Methods of sensor span calibration and zeroing are given in Appendix D.1. ESAT UM Revision 2.0 June 02nd, 2016 Page 15 of 43

16 7. ANALOG OUTPUT DESCRIPTION Preferable analog output factory settings (range of concentration measurement and output voltage range) have to be defined in purchase order. Also analog output voltage range can be reconfigured by user via UART. For 3-pins modification this operation will require special contacting device (acquired separately) Setting up the output mode Command <DACMODEX> (where X stands for 0, 1, 2 or 3) is used to set analog output mode via UART. There are four different modes: <DACMODE0> switches off analog output. <DACMODE1> sets output voltage 0.4 V at zero gas concentration and 2.0 V at maximal concentration (see Fig. 6). <DACMODE2> sets mode when half of supply voltage corresponds to zero gas concentration and maximum output voltage corresponds to maximal concentration. This mode is similar to the thermocatalytic sensor with positive adjustment (see Fig. 7). <DACMODE3> sets mode, in which half of supply voltage corresponds to zero gas concentration and minimal output voltage corresponds to minimal concentration. This mode is similar to the thermocatalytic sensor with negative adjustment (see Fig. 8). Default mode for 4-pin modifications is DACMODE0, for 3- and 5-pin modifications default mode is DACMODE2. Depending on sensor polarity in a user device, <DACMODE2> and <DACMODE3> commands may work in converse modes Setting up voltage range of analog output Sensor provides the ability to adjust maximum and minimum voltage and concentrations corresponding to these voltages. When using DACMODE1, it is possible to set maximum and minimum digital-analog converter (DAC) voltages which differ from the default values ( V). To set minimum DAC voltage value use command <SETDAC1 XXXXX>, and to set maximum voltage value use command <SETDAC2 XXXXX>, where XXXXX stands for DAC value within the range of One DAC count approximately equals to 1.37 ± mv. Analog output voltage has upper bound set by supply voltage value. If using <SETDAC2 XXXXX> command to set upper voltage limit in excess of supply voltage, upper limit will be set equal to it. To request information about current DAC settings use command <SETDAC?>. <ALMH XXXX> command sets up gas concentration XXXX (%vol. 100) which corresponds to maximal value of output voltage. For example, to set up measuring range of 0 5% vol. for full scale voltage output it is necessary to send command <ALMH 0500>, when for measuring range of 0 100% vol. it is necessary to send command <ALMH 9999>. ESAT UM Revision 2.0 June 02nd, 2016 Page 16 of 43

17 Fig. 6. U AnOut (C) graph for DACMODE1 Fig. 7. U AnOut (C) graph for DACMODE2 Fig. 8. U AnOut (C) for DACMODE3 ESAT UM Revision 2.0 June 02nd, 2016 Page 17 of 43

18 7.3. Conversion of analog output voltage to concentration To convert analog output voltage value into a concentration value (or vice versa) use one of the following formulae (see Fig. 6, Fig. 7 and Fig. 8): Mode C(U AnOut ) U AnOut (C) DACMODE1: C = ALMH (U AnOut 0.4) 160 DACMODE2: C U AnOut = ALMH C = ALMH 50 (U AnOut 0.5) U AnOut = U sup (50 U sup C ALMH + 0.5) DACMODE3: C = ALMH 50 (0.5 U AnOut ) U AnOut = U sup ( U sup C ALMH ) where: C gas concentration, % vol.; U AnOut output voltage, V; U sup sensor power supply voltage, V; ALMH concentration value for upper voltage level, % vol For example, to set up analog output voltage range of V for the CH 4 concentration range of 0 5% vol. when sensor power supply voltage equals 3 V use following sequence: 1. Send command <DACMODE2> and check if the response is OK. 2. Send command <ALMH 0500> and check if the response is OK. 3. Converting U AnOut to C: C = (U AnOut 0.5) 3 ESAT UM Revision 2.0 June 02nd, 2016 Page 18 of 43

19 8. STORAGE AND TRANSPORTATION Transportation can be done by all means of transportation in covered vehicles as well as in a heated pressurized plane compartments in accordance with the rules of cargoes transportation actual for the respective type of transportation. Products in manufacturer s package should be kept in supplier s and customer s storages under storage conditions specified in Table 2. Ambient atmosphere should be free of any harmful impurities which can cause corrosion. ESAT UM Revision 2.0 June 02nd, 2016 Page 19 of 43

20 9. WARRANTY Manufacturer guarantees sensor compliance with specifications and requirements stated in this UM if customer follows operating, transportation and storage terms. During warranty period, manufacturer replaces or repairs for free all products which do not work because of production fault. Warranty period is 24 months since product is shipped to customer. Shipment date is registered in the ESAT PS manufacturer s certificate. Manufacturer is not responsible for sensor fault and discontinues warranty in following cases: if the rules and conditions of operation, transportation and storage stated in this UM and in datasheet for sensor were violated; if sensor has marks of unauthorized repair attempts; if any mechanical damage occurs and/or if any damage is caused by exposure to extremely high or low temperatures, corrosion, oxidation, ingression of any foreign objects, materials, liquids, insects; if sensor was damaged by using connection circuit which not complies with requirements stated in this UM; if damage is caused by force majeure, accident, intentional or careless actions of the customer or third parties; if damage (or fault) is caused by installing, editing or damaging sensor firmware and/or by making changes to the firmware settings using service codes; if damage (or fault) is caused by the fact of power and signal cables do not meet the standard or technical regulations and/or by electromagnetic interferences exceeding permissible according to EN Replacement or repairs of faulty sensor does not extend initial warranty period. Manufacturer is not responsible for any possible damage directly or indirectly caused by sensor to people and property in case it is a result of improper usage, storage and transportation or due to intentional or careless actions of the customer and/or third parties. Warranties are carried out on the territory of the manufacturer or an official representative. Risks and costs of transportation and packaging as well as other contingencies concerning product return to Manufacturer are carried out by the customer. ESAT UM Revision 2.0 June 02nd, 2016 Page 20 of 43

21 10. CONTACTS MIPEX TECHNOLOGY / Оptosense LLC 27AD, Engelsa prospekt, St. Petersburg, , Russia Tel/fax: +7 (812) , web: info@mipex-tech.com support: support@mipex-tech.com ESAT UM Revision 2.0 June 02nd, 2016 Page 21 of 43

22 APPENDIX A. SENSOR TYPES AND CHARACTERISTICS MIPEX-03-B-RX-C.D Interface options: 1. UART, 4 pins 2. analog output, 3 pins 3. UART and analog output, 5 pins Housing type: 1. Standard, stainless steel 2. Fast response, stainless steel (with side holes) 3. Plastic Application: R calibration* gas and range X temperature class and accuracy** Target gas*: 1. CH 4 (methane) 2. C 3 H 8 (propane, C m H n hydrocarbons) 4. CH 4 /CH 4 +C 2 H 6 acc. to IEC MIPEX model number * Term target gas refers to models of LED and photodiode with the spectral range adjusted for the best gas detection. Term calibration gas refers to a gas mixture used for sensor calibration. ** See Table 5 for details. ESAT UM Revision 2.0 June 02nd, 2016 Page 22 of 43

23 Table 5. Metrological properties of sensor (RX-code) Part number Target gas* Calibration gas Meas. range, % vol. Temp. range, C RX-code MIPEX C.D MIPEX C.D MIPEX C.D MIPEX C.D MIPEX C.D CH MIPEX C.D MIPEX C.D CH MIPEX C.D MIPEX C.D MIPEX C.D MIPEX C.D C 3H 8 MIPEX C.D MIPEX C.D MIPEX C.D MIPEX C.D C 3H 8 C 3H 8 MIPEX C.D MIPEX C.D MIPEX C.D MIPEX C.D MIPEX C.D MIPEX C.D MIPEX C.D CH 4/ CH 4+C 2H 6 CH MIPEX C.D MIPEX C.D MIPEX C.D MIPEX C.D * Typical sensor sensitivity to other hydrocarbons shown on Fig. 9, Fig. 10 and Fig. 11. ESAT UM Revision 2.0 June 02nd, 2016 Page 23 of 43

24 Sensor readings % LEL Optosense LLC Table 6. Basic sensor readings variability* Calibration gas Readings variability within a temperature range Additional variability due to pressure Additional variability due to humidity CH 4 ±0.1% vol. or ±5% of indication (whichever is greater) within the range of C; ±0.2% vol. or ±10% of indication (whichever is greater) within the range of C and C; ±0.4% vol. or ±20% of indication (whichever is greater) within the range of C and C. ±0.2% vol. or ±30% of indication (whichever is greater) at 100 kpa (test: 80 kpa, 100 kpa, 120 kpa) ±0.2% vol. or ±15% of indication (whichever is greater) at 40 C (test: 20% RH, 50% RH, 90% RH) C 3 H 8 ±0.05% vol. or ±5% of indication (whichever is greater) within the range of C; ±0.1% vol. or ±10% of indication (whichever is greater) within the range of C and C; ±0.2% vol. or ±20% of indication (whichever is greater) within the range of C and C. ±0.1% vol. or ±30% of indication (whichever is greater) at 100 kpa (test: 80 kpa, 100 kpa, 120 kpa) ±0.1% vol. or ±15% of indication (whichever is greater) at 40 C (test: 20% RH, 50% RH, 90% RH) * The table shows basic variability of MIPEX-03 sensor readings. For each sensor modification, readings variability stated in Table 6 is provided within a temperature range determined by a sensor RX-code (see Table 5) CH4 C3H8 C2H6 C4H10 C6H14 C2H Gas mixture concentration, % LEL Fig. 9. Typical sensitivity of MIPEX-03-1-XX-X.X (target and calibration gas is CH 4 ) to other hydrocarbons ESAT UM Revision 2.0 June 02nd, 2016 Page 24 of 43

25 Sensor readings, % LEL Optosense LLC C3H8 C4H10 C5H12 C6H14 CH Gas mixture concentration, % LEL Fig. 10. Typical sensitivity of MIPEX-03-2-XX-X.X (target and calibration gas is C 3 H 8 ) to other hydrocarbons ESAT UM Revision 2.0 June 02nd, 2016 Page 25 of 43

26 Sensor readings, % LEL Optosense LLC CH4 C3H8 C2H6 C4H10 C6H14 60 C2H CGM concentration, % LEL Fig. 11. Typical sensitivity of MIPEX-03-4-XX-X.X (target gas is CH 4 /СН 4 +С 2 H 6 and calibration gas is CH 4 ) to other hydrocarbons Table 7. MIPEX-03-X-XX-1.X types, interfaces and overall dimensions Part number Target gas Weight, g Interface Housing type MIPEX-03-1-XX-1.1 CH MIPEX-03-2-XX-1.1 C 3 H MIPEX-03-4-XX-1.1 CH 4 /CH 4 +C 2 H MIPEX-03-1-XX-1.2 CH MIPEX-03-2-XX-1.2 C 3 H MIPEX-03-4-XX-1.2 CH 4 /CH 4 +C 2 H MIPEX-03-1-XX-1.3 CH MIPEX-03-2-XX-1.3 C 3 H MIPEX-03-4-XX-1.3 CH 4 /CH 4 +C 2 H ESAT UM Revision 2.0 June 02nd, 2016 Page 26 of 43

27 Table 8. MIPEX-03-X-XX-2.X types, interfaces and overall dimensions Part number Target gas Weight, g Interface Housing type MIPEX-03-1-XX-2.1 CH MIPEX-03-2-XX-2.1 C 3 H MIPEX-03-4-XX-2.1 CH 4 /CH 4 +C 2 H MIPEX-03-1-XX-2.2 CH MIPEX-03-2-XX-2.2 C 3 H MIPEX-03-4-XX-2.2 CH 4 /CH 4 +C 2 H MIPEX-03-1-XX-2.3 CH MIPEX-03-2-XX-2.3 C 3 H MIPEX-03-4-XX-2.3 CH 4 /CH 4 +C 2 H Table 9. MIPEX-03-X-XX-3.X types, interfaces and overall dimensions Part number Target gas Weight, g Interface Housing type MIPEX-03-1-XX-3.1 CH MIPEX-03-2-XX-3.1 C 3 H MIPEX-03-4-XX-3.1 CH 4 /CH 4 +C 2 H MIPEX-03-1-XX-3.2 CH MIPEX-03-2-XX-3.2 C 3 H MIPEX-03-4-XX-3.2 CH 4 /CH 4 +C 2 H MIPEX-03-1-XX-3.3 CH MIPEX-03-2-XX-3.3 C 3 H MIPEX-03-4-XX-3.3 CH 4 /CH 4 +C 2 H ESAT UM Revision 2.0 June 02nd, 2016 Page 27 of 43

28 APPENDIX B. CONNECTION DIAGRAM EXPLOSION HAZARDOUS AREA MIPEX-03-X-XX-X.X NET NET Combined input parameters: IECEx/ATEX: U i = 5.0 V, I i = 200 ma, P i = 0.13 W, C i = 26 µf, L i = 0 mh. Power Power RxD U 0 GND TxD Intrinsically safe power supply and monitoring circuit CAN/CSA: V max = 5.0 V, I max = 200 ma, P max = 0.13 W, C i = 26 µf, L i = 0 mh. TxD RxD Fig. 12. Connection diagram for MIPEX-03-Х-XХ-X.1 MIPEX-03-X-XX-X.X Combined input parameters: IECEx/ATEX: U i = 5.0 V, I i = 200 ma, P i = 0.13 W, C i = 26 µf, L i = 0 mh. CAN/CSA: V max = 5.0 V, I max = 200 ma, P max = 0.13 W, C i = 26 µf, L i = 0 mh. EXPLOSION HAZARDOUS AREA NET AnOut Power Power NET AnIn U 0 GND Intrinsically safe power supply and monitoring circuit Fig. 13. Connection diagram for MIPEX-03-Х-XХ-X.2 ESAT UM Revision 2.0 June 02nd, 2016 Page 28 of 43

29 MIPEX-03-X-XX-X.X Combined input parameters: IECEx/ATEX: U i = 5.0 V, I i = 200 ma, P i = 0.13 W, C i = 26 µf, L i = 0 mh. CAN/CSA: V max = 5.0 V, I max = 200 ma, P max = 0.13 W, C i = 26 µf, L i = 0 mh. EXPLOSION HAZARDOUS AREA NET AnOut Power Power RxD TxD NET AnIn U 0 GND TxD RxD Intrinsically safe power supply and monitoring circuit Fig. 14. Connection diagram for MIPEX-03-Х-XХ-X.3 NET NET NET Pin AnOut AnIn +5V 1 Power Power U 0 GND D- D+ 2 3 USB TxD RxD GND 4 RxD TxD NET Pin R AnOut GND 1 2 V mes MIPEX-03 USB-MIPEX interface board Fig. 15. Connection diagram for MIPEX-03 via USB-MIPEX interface board during calibration (V mes is a voltmeter) ESAT UM Revision 2.0 June 02nd, 2016 Page 29 of 43

30 Fig. 16. Example of connecting MIPEX-03 to ia intrinsic safety circuit ESAT UM Revision 2.0 June 02nd, 2016 Page 30 of 43

31 APPENDIX C. UART COMMUNICATION PROTOCOL Current manual describes firmware release Sensor communication protocol is based on UART interface. Sensor firmware could be updated or downgraded. Contact support for available compatible versions and instructions. Appendix C.1. General information Data exchange with MIPEX-03 sensors is performed via UART interface: Sensor has symbol rate of 9600 baud. Data format: 8-bit message, 1 stop bit, no parity checking. Electrical parameters of UART-transceiver are pointed in section 6.3. General command format: any command stated in this UM as <X>, where X stands for a command text consisted of any number of characters, must be read and/or sent without the symbols < and > ; ASCII code for commands and responses; command ends with carriage return symbol (hex: 0x0D ); words and/or values in a response on most commands are separated by space symbol (hex: 0x20 ) or in some cases by tabulation (hex: 0x09 ); all symbols in command must be sent as one word without delays. ESAT UM Revision 2.0 June 02nd, 2016 Page 31 of 43

32 Appendix C.2. Communication protocol commands There are several types of commands used for communication with sensor: 1. commands for requesting measured data (see Appendix C.2.1); 2. commands for requesting factory settings and properties (see Appendix C.2.2); 3. commands for sensor configuring and span calibration (see Appendix C.2.3); 4. commands for configuring analog output (see Appendix C.2.4). Always check command syntax before sending. Commands that are not listed in this user manual are prohibited. Otherwise, it may result in malfunction of sensor. In earlier versions of the firmware, some commands are unavailable. Appendix C.2.1. Commands for requesting measured data and diagnosing There are three commands available for user to request concentration value. Primary command to request measured data is as it requires minimum power to process it. Sending rate of these commands should not be more than 1 Hz. F Response description 2 bytes in hexadecimal format (see Table symbol and 2 bytes in hexadecimal format (see Table 10). 72 bytes in ASCII format and 0D symbol (see Table 11). Command description Returns sensor readings of scaled concentration C 1 (not periodically, single time only). Returns sensor readings of scaled concentration C 1 periodically (every [1.32 ± 0.04] X seconds), where X is a value within the range 0 9 in ASCII format). Returns comprehensive information on sensor readings and its status. When using this command, sensor current consumption stated in section 6.3 is not guaranteed. Table 10. Structure of response on <@> and <@*X> commands Command <@> (hex: 40 0D ) Command <@*X> (hex: 40 2A X 0D ) Byte number Byte data C 1 H* C 1 (hex: 40 ) C 1 H C 1 L High and low, bytes structure is presented on Fig. 17. Fig. 17. High and low bytes structure ESAT UM Revision 2.0 June 02nd, 2016 Page 32 of 43

33 Command <F> (hex: 46 0D ) response Byte number Byte data Data description 1 Hex: 0x0E Special character Table 11. Structure of response to <F> command 2-6 T Sensor temperature expressed in ADC counts 7 Hex: 0x09 Tabulation symbol 8-12 S t The ratio U s U ref considering the temperature correction 13 Hex: 0x09 Tabulation symbol U s Operating signal in ADC counts 19 Hex: 0x09 Tabulation symbol U ref Reference signal in ADC counts 25 Hex: 0x09 Tabulation symbol S tz0 The ratio S t considering manual zeroing coefficients calculated upon receiving <ZERO> and <ZERO2> commands 31 Hex: 0x09 Tabulation symbol S tz The ratio S tz0 considering the drift compensation algorithm 37 Hex: 0x09 Tabulation symbol S tzkt The ratio S tz considering the coefficient of temperature sensitivity 43 Hex: 0x09 Tabulation symbol C Concentration value based on default factory calibration 49 Hex: 0x09 Tabulation symbol C 1 Scaled concentration value 55 Hex: 0x09 Tabulation symbol Status word Status word (see Table 12 for details) 61 Hex: 0x09 Tabulation symbol S/N Sensor serial number 70 Hex: 0x09 Tabulation symbol 71 CRC CRC calculated using exclusive OR method 72 Hex: 0x09 Tabulation symbol 73 Hex: 0x0D Carriage return ESAT UM Revision 2.0 June 02nd, 2016 Page 33 of 43

34 Table 12. Status word values description Status word Priority level* Description Recommendations (lowest) Normal operating mode, temperature is static Sensor is warming up. Do not perform span calibration Data request rate is more than 1 Hz. Do not perform span calibration or zeroing. Decrease request frequency Dynamic temperature mode (temperature changes faster than by 0.6 C/min). Dynamic temperature mode (temperature changes faster than by 2 C/min). Dynamic temperature mode; zero shifts to negative value. One of the signal values (U s or U ref ) is lower than it is allowed The ratio S tz0 exceeds allowable upper limit. Do not perform span calibration or zeroing. Do not perform span calibration or zeroing. Do not perform span calibration or zeroing. A possibility of exposure to moisture. Dry sensor. After drying, if this status lasts longer than for 20 minutes at stable conditions, replace sensor. A possibility of exposure to moisture. Dry sensor. After drying, if this status lasts longer than for 20 minutes at stable conditions, perform zeroing (see Appendix D.1 for procedure description) Exceeding temperature limits. Check the ambient temperature An abrupt signal change (due to feeding a gas mixture to sensor atmosphere) or increased noise on sensor optical elements. Do not perform span calibration or zeroing. If this status lasts longer than for 20 minutes at stable conditions, replace sensor Complex status. Technological failure. Contact support for details 90 1 (highest) Firmware failure (flash memory issues). Contact support for details * Sensor condition is characterized by set of status word parameters. <F> command returns only one status word value in accordance with priority. NOTE: If any status word value except 00 and 21 appears, metrological properties of sensor are not provided. ESAT UM Revision 2.0 June 02nd, 2016 Page 34 of 43

35 Appendix C.2.2. Commands for requesting the factory settings and properties Request syntax ID? RT? RX? Response description Summary info in ASCII format about sensor type, its serial number, characteristics and firmware version. 5 bytes in ASCII format and 0D symbol (the codes list is available upon query). 2 bytes in ASCII format and 0D symbol. See Table 5 for details. Returns sensor ID. Command description Returns sensor type. Returns sensor characteristics (temperature class, calibration range and accuracy). SRAL? 8 bytes in ASCII format and 0D symbol. Returns sensor serial number (SN). SREV? Sensor firmware version. Returns the firmware version. ESAT UM Revision 2.0 June 02nd, 2016 Page 35 of 43

36 Appendix C.2.3. Commands for sensor configuring and span calibrating Request syntax Response description Command description AZERO? AZERO ON or AZERO OFF Intended for checking current autozeroing algorithm status. AZERO OFF AZERO OFF Turns off the auto-zeroing algorithm. AZERO ON AZERO ON Turns on the auto-zeroing algorithm. CALB AAAA CALB1 XXXXX INIT ZERO ZERO0 ZERO2 CALB AAAA OK or CALB AAAA FAULT CALB1 XXXXX OK or CALB1 XXXXX FAULT INIT OK or INIT FAULT ZERO OK or ZERO FAULT ZERO0 OK or ZERO0 FAULT ZERO2 OK or ZERO2 FAULT Used for gas span calibration, where AAAA is a CGM concentration value in % vol For example, AAAA = 0198 corresponds to 1.98 % vol. See Appendix D.1 for detailed procedure description. Writes scale coefficient to sensor memory. XXXXX is the coefficient value incremented to (for example: to write the scale coefficient of 0.7 send <CALB >). This command can be used to recalibrate sensor if scale coefficient is known. The scale coefficients for different gases are individual for each sensor. To achieve cross-coefficients contact support. Resets sensor to the factory calibration settings. If sensor metrological properties stated in Table 3 are not met after using this command, it is recommended to perform span calibration operation (see Appendix D.1). Writes current temperature ADC value and ratio S t value to sensor controller memory. Erases temperature coefficients previously defined by user. Intended for zeroing sensor. It initiates calculation and storing of the unifying zero coefficient K ZERO2 within sensor memory. C and C 1 values are zeroed and ratio S tz becomes equal by this command. ESAT UM Revision 2.0 June 02nd, 2016 Page 36 of 43

37 Appendix C.2.4. Commands for configuring analog output Request syntax Response description Command description DACMODE? DACMODEX SETDAC? SETDAC1 XXXXX SETDAC2 YYYYY ALMH ZZZZ 5 bytes in ASCII format and 0D symbol. DACMODEX OK or DACMODEX FAULT two groups of 5 bytes in ASCII format each separated by 09 symbol, and 0D. SETDAC1 XXXXX OK or SETDAC1 XXXXX FAULT SETDAC2 YYYYY OK or SETDAC2 YYYYY FAULT ALMH ZZZZ OK or ALMH FAULT Returns current analog output mode. Switches sensor analog output to one of four possible modes (X stands for 0, 1, 2 or 3). Returns information about current DAC settings for DACMODE1. Sets minimum DAC voltage value for DACMODE1. XXXXX stands for DAC value within the range of One DAC count approximately equals to 1.36 ± mv. Sets maximum DAC voltage value for DACMODE1. YYYYY stands for DAC value within the range of One DAC count approximately equals to 1.36 ± mv. Sets up gas concentration ZZZZ (% vol. 100) which corresponds to maximal value of output voltage. ESAT UM Revision 2.0 June 02nd, 2016 Page 37 of 43

38 APPENDIX D. SENSOR ZEROING AND SPAN CALIBRATION Appendix D.1. Span calibration and zeroing Sensor zeroing and span calibration must be carried out during its initial installation as well as annually during the period of preparation for the test. It is also recommended to perform zeroing when sensor status-word 31 shows up (see Appendix C.2.1, Table 11 and Table 12). In any case zeroing operation should be done before span calibration. For the list of CGMs necessary for span calibration refer to Table 13 and Table Span calibration may be performed via UART interface only. 2. For 3-pins sensor this operation will require special contacting device (acquired separately), but zeroing may be performed without necessity to send any commands (the full description of this procedure read below). 3. Covering diffusion holes of sensor increases response time. 4. While span calibration is being carried out, avoid: excessive pressure on sensor housing, >98% humidity, pressure of flowing gas less than 99 kpa and more than 103 kpa; temperature change faster than by 0.6 C/min, dust ingress (if dust filter is not used), data request rate more than 1 Hz. Zeroing and span calibration should be carried out by qualified personnel outside of an explosive area under normal conditions in the following sequence: 1. Communicate sensor via UART interface (example based on USB-MIPEX interface board is shown on Fig. 18). 2. Start feeding CGM #1 into sensor atmosphere. 3. Perform zeroing of sensor readings on concentration. It can be accomplished by various methods: Auto-zeroing procedure: The auto-zeroing procedure of sensor concentration readings is started automatically during sensor self-diagnostics after sensor power on. Auto-zeroing algorithm can be switched off by <AZERO OFF> command and switched on by <AZERO ON>. To check if auto-zeroing algorithm is switched on or off use <AZERO?> command. If zero shifts when auto-zeroing algorithm is switched on, it is recommended to perform zeroing manually. Zeroing procedure carried manually by personnel via UART interface: after sensor power on, wait for minimum two minutes then send <ZERO2> command; thus sensor readings on the concentration will be set to zero forcibly; ESAT UM Revision 2.0 June 02nd, 2016 Page 38 of 43

39 Zeroing procedure carried manually by personnel without using UART interface: turn on and off sensor power twice within a minute (delay between power connection/disconnection must be in range 5 15 s); turning on sensor power for the third time will run zeroing algorithm automatically after sensor is warmed up (approx. 2 minutes). If done properly, these actions will run zeroing algorithm corresponding to <ZERO2> command algorithm. 4. Stop feeding CGM #1 into sensor atmosphere. 5. Start feeding CGM #2 into sensor atmosphere. 6. One minute after CGM #2 was supplied, send <CALB AAAA> command, where AAAA is a value of CGM concentration (e.g. value 0198 corresponds to 1.98% vol.). Thereafter scaled concentration value C 1 becomes equal to the sent value AAAA. Scale coefficient is stored in sensor microcontroller memory until the next span calibration. Before sending <CALB AAAA> command ensure the following conditions: 7. entered concentration value must not deviate from the current readings of more than 20 times and also cannot be zero: (C 20 > C 1 > C 0.05) && C > CGM must contain more than 0.2% vol. of target gas; 9. if these conditions are not met, sensor responds CALB AAAA FAULT. 10. Stop feeding CGM #2 into sensor atmosphere. 11. Feed CGM #3 into sensor atmosphere and check sensor readings. 12. For methane sensors calibrated up to 100% vol. repeat the procedure stated in step 11 with CGM # If requirements to sensor readings variation are not met in accordance with Table 6, zeroing and calibration procedure should be repeated. In case of the repeated mismatch between sensor readings and target gas concentration value in СGM #3, sensor should be sent to the manufacturer for repair or replacement. Gas adapter USB cable CGM PC USB converter Fig. 18. Typical scheme of MIPEX-03 span calibration ESAT UM Revision 2.0 June 02nd, 2016 Page 39 of 43

40 Converting of % vol. to % LEL is performed according to the following formula: where: LFSCL is component concentration, % LEL; С is component concentration, % vol.; LFSCL = 100 C C(h), С(h) is the lower explosive limit of component, % vol. (constant); For methane C(h) = 4.4% vol.; for propane C(h) = 1.7% vol. Table 13. CGM used for CH 4 span calibration CGM number according to text Components composition Content of methane, % vol. (% LEL) Permissible deviation limits, % vol. Limits of permissible error of qualification, % vol. A number as listed in the State Register or in the Standard designation 1 N 2 0 ISO CH 4, N (50) ±0.25 ±0.04 ГОСТ CH 4, N (94) ±0.25 ±0.04 ГОСТ CH 4, N 2 40 ±2.5 ±0.4 ГОСТ Table 14. CGM used for C 3 H 8 span calibration CGM number according to text Components composition Content of propane, % vol. (% LEL) Permissible deviation limits, % vol. Limits of permissible error of qualification, % vol. A number as listed in the State Register or in the Standard designation 1 N 2 0 ISO C 3 H 8, N (50) ±0.05 ±0.015 ГОСТ C 3 H 8, N (94) ±0.1 ±0.05 EM ESAT UM Revision 2.0 June 02nd, 2016 Page 40 of 43

41 Appendix D.2. Temperature dependence of zero adjustment User can adjust the temperature dependence of zero in two modes: automatic and manual. Adjustment may be performed for up to 8 values within operating temperature range. For example, temperature range of C is divided into equal intervals about 12.5 C each. Each interval is used for corresponding operating temperature. Automatic mode procedure: 1. Place sensor to climatic chamber filled with nitrogen and send <ZERO0> command. This command erases previously defined temperature coefficients. 2. Change temperature in the range of C with a pitch of 12.5 C. For each of 8 points of temperature range, lock the temperature for at least 20 minutes and send the <ZERO> command by which a current temperature ADC value and ratio S t value are written to sensor controller memory (see Fig. 19). Fig. 19. Scheme of adjusting the temperature coefficients in automatic mode Manual mode procedure: Please contact support for details. ESAT UM Revision 2.0 June 02nd, 2016 Page 41 of 43

42 APPENDIX E. DUST FILTER ATTACHING To improve sensor operation reliability dust filter should be attached to sensor surfaces. For sensor housing types standard and plastic, only top filter (ESAT ; see Fig. 20) should be applied. For fast response housing side filter (ESAT ; see Fig. 21) should be attached as well. Filters material is fluoroplastic membrane Владипор МФФК ТУ On the filter back side there is an adhesive layer 3M Double Linered Laminating Adhesive 7952 in hatched areas in Fig. 20 and Fig. 21. Fig. 20. Top filter dimensions Fig. 21. Side filter dimensions Perform the following steps to attach dust filter: Perform this work in a well illuminated and well ventilated area. Once a dust filter is attached to sensor surface perform zeroing procedure (see Appendix D.1 for details). 1. Degrease surface of the upper side of sensor. For MIPEX-03-X-XX-2.X sensors, perform the same operation on the side surface. 2. Extract filter from the packing and remove its substrate with tweezers. 3. Align the filter exactly to the center of the upper side of sensor with tweezers and then press on it. For the MIPEX-03-X-XX-2.X sensors, perform the same operation on the side surface. ESAT UM Revision 2.0 June 02nd, 2016 Page 42 of 43

43 APPENDIX F. TROUBLESHOOTING If there is suspicion that sensor returns wrong data and / or operates improperly, it is necessary to check its status by sending command <F> (see Appendix C.2.1). It returns comprehensive information on sensor readings and status word. If any status word value except 00 appears check its meaning in Table 12 and follow to specified recommendations. If suspicion of error or status corresponding to error persists please contact support. Contacting support, send log file with periodic responses to command <F>. In case if status word value is stable, log file with few (approx. 10) responses is enough. In case if status word varies eventually or periodically, log file must contain sufficient number of responses obtained before status word occurs and in time of its occurrence. Sensor power consumption stated in section 6.3 is not guaranteed while using <F> command. ESAT UM Revision 2.0 June 02nd, 2016 Page 43 of 43