GAS DETECTOR
ZELLWEGER DOCUMENTATION
REFERENCE: M3-2 ATEX
PRODUCT DATASensepoint High Temperature SensorintheZoneTMHigh Temperature Sensor For CombustibleGasesThe Sensepoint High Temperature Sensor has been specifically designed for the detection ofcombustiblegases in high temperature hazardous area locations.Typical applications include turbine enclosures and drying ovens used in solvent based printing and coating machines.These applications require a sensor that provides reliable and stable detection allowing low levelalarm settings across a wide temperature range.Utilizing a specially matched pair ofSieger poisonresistant combustible gas detection elements,the Sensepoint High Temperature Sensor has a verystable baseline allowing alarm trip points to be set as low as 5% LEL across a temperature range of-40°C to +150°C (-40°F to +302°F).The gas measuring range can be configured from 0-20% LELup to 0-100% LEL depending on the type ofcontroller used.
The detector elements are housed in an explosion proofassembly,and provide an industry standard 3 wire mV bridge output which can be connected to a suitable control device or converted to ananalog output signal via a field transmitter.
Excellent Performance
• Certified for hazardous area operation up to+150°C (+302°F)
• Alarm trip points as low as 5% LEL• Fast speed ofresponse• Poison resistant detectors• Low power consumption
Flexibility
• Measuring ranges from 0-20% LEL to 0-100% LEL
• Wide range ofaccessories
Robust Construction
• 316 Stainless Steel sensor body• ATEX approved design
Cost Effective
• Low cost disposable sensor
• Greater than 5 year typical operating life
Reliable Operation
• Specially matched ‘Sieger’detectors providehighest stability
• Proven technology from the world leader in combustible gas detection
Sensepoint High Temperature Sensor
General Specification
1
58mm42mm(2.28in)(1.65in)Range:
0-20% LEL, 0-100% LEL (Control card dependent)
Speed ofResponse2
: T60 Less than 6 seconds.T90 Less than 10 seconds.
Minimum Alarm Level3:5% LELOutput Signal:
mV bridge
Operating Temperature:-40°C to +150°C (-40°F to +302°F)
Operating Humidity:Continuous: 20 to 90% RHIntermittent:
10 to 99% RH
Operating Pressure:75 to 110kPa (750 to 1100mbar)
Stability (zero):With time:
Less than ±5% LEL/year
With temperature:Less than ±3% LELWith humidity:Less than ±3% LELWith pressure:Less than ±3% LELStability (span):With time:
Less than ±5% LEL/year
With temperature:Less than ±4% LELWith humidity:Less than ±3% LELWith pressure:Less than ±3% LEL
Linearity:Better than ±5% fsdRepeatability:Better than ±2% LEL
Warm-up Time:
30 minutes
Detector Operating Life4:More than 5 years (typical)
Storage Life:Typically, no degredation has been observedin clean, stable conditions for up to 5 years
Power Consumption:0.7W at 200mAEnclosure Material:316 Stainless SteelMounting Thread:M20, M25 or 3/4 NPT
Weight:225g (7.9oz)
Certification:Baseefa02ATEX0242X II 2G EExd IICATEX:
(Assessed for Hazardous area ignition risks)
T3 (Tamb - 40°to +150°C)
Notes:1. Typical performance figures for a sensor calibrated on 10%LEL methane and tested at 20°C and 50%RH.
2. T60/T90 defined as the time to achieve 60%and 90%of the signal obtained after 5 minutes exposure to 50%FSD gas concentration.
3. With recommended 3 month calibration period.4. In clean atmosphere.
you know you’re intheZone™6738members of the Zellweger Analytics DivisionHEADQUARTERSNETHERLANDSZellweger Analytics Zellweger Analytics BVWilstrasse 11, CH-8610 Uster, Postbus 157, NL-3740 AD Baarn, Switzerland NetherlandsTel: +41 (0)1 943 22 11 Tel: +31 (0)3554356Fax: +41 (0)1 943 18 16Fax: +31 (0)355435929Email: info@zelana.comEmail: zabl@zelana.comASIA PACIFICSPAINZellweger Analytics LimitedZellweger Analytics SAAsia Pacific Regional Office,Avda. Onze de Setembre, 263, 10 Toh Guan Road #04-05Bajos 1a Aptdo. de Correos 252 TT International Tradepark08820 El Prat de Llobregat, Singapore 608803BarcelonaTel: +65 6862 7701Tel: +34 93 379 9611Fax: +65 6862 3858 Fax: +34 93 379 8551Email: zalasia@singnet.com.sgEmail: zellana@jet.esBELGIUMUKZellweger Analytics NVZellweger Analytics LimitedLeuvensesteenweg 392a, Hatch Pond House, Chée de Louvain,4 Stinsford Road,B-1932 Zaventem, BelgiumNuffield Estate, Poole, Tel: +32 (0) 3 9 09 05Dorset BH17 0RZ, UKFax: +32 (0) 3 70 22 30 24Tel: +44 (0) 1202 676161Email: zabl@zelana.comFax: +44 (0) 1202 678011FRANCEEmail: sales@zelana.co.ukZellweger Analytics France SAUSALes Fermes Californiennes Zellweger Analytics Inc62 Avenue de I’Europe, Emerainville 405 Barclay Boulevard,77436 MARNE LA VALLEE CEDEX 2, Lincolnshire, Illinois 60069, USAFranceTel: +1 847 955 8200Tel: +33 1 60 95 45 46Toll free:+1 800 323 2000Fax: +33 1 60 95 45 50Fax: +1 847 955 8208GERMANYEmail: sales@zelana.comZellweger Analytics GmbHZellweger Analytics IncSollner Strasse 65b, 50 Bristol Industrial Way,D-81479 München, GermanySuite B & C, Tel: +49 791 920Buford, Georgia 30518, USAFax: +49 791 9243Tel: +1 770 831 4800Email: vertriebscenter@zelana.deToll free: +1 800 535 0606ITALYFax: +1 678 546 1954Zellweger Analytics srlEmail: sales@zelana.comVia F. Primaticcio 168,Zellweger Analytics IncI-20147 Milano, Italy11221 Interchange Circle South,Tel: +39 0248 3391Miramar, FL33025, USA Fax: +39 0248 3023 14Tel: +1 954 433 7000Email: zaitaly@zelana.comToll free: +1 800 433 7220MIDDLE EASTFax: +1 954 433 7730Zellweger Analytics LimitedEmail: sales@lumidor.comPO Box 52196, Dubai, UAETel: +971 4 3458 338Fax: +971 4 3458 778Email: zelana@emirates.net.aewww.zelana.comDS303 Issue 2 2106M0612
Please Note:
While every effort has been made to ensure accuracy in this publication, no responsibility can be accepted for errorsor omissions. Data may change, as well as legislation, and you are strongly advised to obtain copies of the mostrecently issued regulations, standards and guidelines.A Division of the Zellweger Luwa Group
Certificate NumberBaseefaO2A TEXO242XIssued 07 January 2003Page 2 of 2Schedule15Description of Equipment or Protective SystemThe Sensepoint HT Gas Detector Head is rated at up to 12V with a maximum power dissipation of 1 watt and comprisesa cylindrical enclosure, with an hexagonal external profile, manufactured in two parts from stainless steelIntegral with the front cover is a stainless steel sinter to facilitate the ingress of the sample gas. The body sectionincorporates a M20, M25 or 31. NPT male thread and integral connection cables for connection to a suitable terminal box orconduit.The interior of the enclosure comprises an assembly of pellistor type sensors and a printed circuit board (PCB) held inposition by an epoxy potting compound.This unit is designed to be 'sealed for life' with all joints locked with thread locking compound. No user maintenancebeyond the calibration procedures described in the manufacturer's instructions is required.This Certification is to European Directive 94/9/EC only, functional performance and compliance with other EuropeanDirectives is the responsibility of the equipment manufacturer and/or the user as appropriate16 Report NumberReport No. 02(C)O229Baseefa Certification 17Special Conditions for Safe UseThe sensor head circuit must be de-energised before connection or disconnection of the sensor head.The integral supply cables must be mechanically protected and terminated in a suitableterminal or junction facility.3.In addition to the integral earth conductor, earth equipotential bonding may be maintained via the rear mountingthread.This unit is intended for use at normal, or reduced, levels of atmospheric oxygen and pressure only (i. e. <21 %oxygen and <1.1 bar).4.18 Essential Health and Safety RequirementsAll relevant Essential Health and Safety Requirements are covered by the standards listed at item 9.19Number2106EOO40Drawings and DocumentsIssueDateDescriptionGeneral Assembly, Sensepoint H. T. Gas Detector Head411.12.02 6. FAULT FINDING
The following table provides a list of possible faults related to the sensortogether with possible causes and remedies.
Fault
Cause/Remedy
Sensor reads non zeroGas could be present, ensureall the time
there is no combustible gas in theatmosphere.
Sensor reads non zeroAdjust the control system zerowhen no gas is presentsetting.
Sensor reads low whenAdjust the control system spangas is applied
setting.
Sensor reads high whenAdjust the control system spangas is applied
setting.
Sensor reads zero when1.Check the wiring.
gas is applied
2.Check that the protective disc
has been removed from thefilter housing.
3.Check that the filter is not
dirty/obstructed.
4.Replace the sensor if
poisoning is suspected.
11MAN0622 Issue 01 January 032106M0523
SENSEPOINT HT
COMBUSTIBLE GAS SENSOR
ediuG traSt kciuQtotal environmental solutions7. CERTIFICATION
8. SPECIFICATIONS
The following BASEEFA certification information is imprinted on adjacentDimensions:
See diagram in Installationfaces in two separate blocks on the hexagonal part of the sensor body.
section.
Manufacturer’sOperating temperature range:-40°C to +150°C.
trademark&addressOperating humidity range:
20% to 90% RH continuous.
Productname10% to 99% RH intermittent - noncondensing.IdentificationnumberofATEXnotifiedbodyOperating pressure range:75 to 110 k Pa.CEmark-conformstoallWarm up time:
Less than 10 minutes.
applicableEuropeanYearofmanufacture/2.9 V to 3.5 V bridge (at 200mA).directivesserialnumberVoltage range:Power consumption:700mW.CertificationnumberSignal output:mV bridge.
Calibration flow rate:Recommended between 1 andExplosionprotection1.5 l/min.
markandequipmentgroup&categoryPoisoning:
The sensing elements may
Certificationbecome inactive after extensivecodeexposure to silicones,
halogenated hydrocarbons,heavy metals or sulphurCautionCertifiedambienttemperaturerangecompounds.Expected operating life:5 years.
IP rating:IP65 standard; IP66/67 withWeather Protection.CE:
The sensor complies withrelevant CE directives.
ATEX Certification:II 2G EEx d IIC T3
Tamb -40o
C to +150o
CBaseefa02ATEX0242X
12131. INTRODUCTION
2. SAFETY
The Sensepoint High Temperature (HT) Combustible Gas Sensor is a sealeddisposable sensor for the detection of flammable gases. It must be fitted into aWARNINGSsuitably approved Exe or Exd high temperature junction box (e.g. Feel FlameproofEnclosures) fitted with an approved cable gland for external wiring (e.g. Peppers1.This unit is intended for use at a normal, or reduced, levels ofCable Glands, Series A3LF or CR3 CROLOCK Series).
atmospheric oxygen and pressure only, i.e. less than 21% oxygenand less than 1.1 bar. Oxygen deficient atmospheres (less thanThe sensor features a Filter Housing that retains a stainless steel mesh filter. It10%V/V) may suppress the sensor output.employs a catalytic pellistor sensor device which is used as part of a bridge2.Refer to local or national regulations relative to installation at themeasuring circuit.
site. For Europe see EN50073 and EN60079-14.Sensepoint HT is certified for hazardous areas to EN50014/EN50018 and is3.Operators should be fully aware of the action to be taken if the gasprotected against water and dust ingress to IP66/67. The sensor is available inconcentration exceeds the alarm level.M20, M25 and 3/4 NPT thread versions. The sensor accepts accessories from a4.Installation should consider not only the best placing for gas leakagespecified range (see Accessories & Spare Parts).related to potential leak points, gas characteristics and ventilation,Information notices
but also where the potential of mechanical damage is minimized oravoided.The types of information notices used throughout this handbook are as5.Only assessed for ATEX for ignition hazards.follows:
WARNINGSCAUTIONS
Indicates hazardous or unsafe practice that could result in severeinjury or death to personnel.1.Atmospheres above 100% LEL may suppress the sensor reading.2.Do not modify or alter the sensor construction as essential safetyrequirements may be invalidated.
Caution:
Indicates hazardous or unsafe practice which could3.Install using suitably approved and certified Exe or Exd highresult in minor injury to personnel, or product ortemperature junction box, connectors and glands.
property damage.
4.
Dispose of in accordance with local disposal regulations.Note:Provides useful/helpful/additional information.
Materials used - Stainless Steel.
If more information outside the scope of this technical handbook isrequired please contact Zellweger Analytics.Associated Documents
Sensepoint Gas Sensors Technical Handbook
Part No: 2106M0502
12
9. ACCESSORIES & SPARE PARTS
Description
Part NumberComplete replacement sensor:• M20 version2106B2310• M25 version2106B2311• 3/4 NPT version2106B2312Stainless steel filter00780-F-0018Filter Housing
00780-C-0038High Temperature Junction Box2052D0001High Temperature Weather Protection
00780-A-0076
14
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A company of the Zellweger Luwa Group3. INSTALLATIONThe Sensepoint HT Combustible Gas Sensor must be fitted into asuitably approved Exe or Exd high temperature junction box fitted withan approved cable gland for external wiring. The sensor requires a200mA current supply, nominal 3V, derived from a suitable control card.Only a qualified installation engineer should install the sensor.Install the sensor in a location free from direct heat sources and fit it sothat it either points downwards or horizontally. It is not recommendedthat the sensor points upwards. See the Sensepoint Gas SensorsTechnical Handbook for installation in forced air conditions.1.Isolate all associated power supplies and ensure that they remainOFF during the installation procedure. Ensure a gas freeatmosphere.2.Install the high temperature junction box.See the manufacturer’s instructions.3.Remove the junction box lid.4.Fit the Sensepoint HT sensor to the junction box.Ensure that the junction box thread and the sensor thread arecompatible. Push the sensor wires through the cable entry in thejunction box and screw the sensor body firmly home into the entry.Lock the sensor in place with a suitable lock-nut.5.Connect the sensor wiring to the junction box terminal strip.See the subsequent wiring diagram. Use multicore cable, three wireminimum, of conductor size 2.5mm2 max.6.Fit a suitable gland to the box, secure the control system cableand connect the field wiring to the terminal strip.See the subsequent wiring diagram.7.Refit the junction box lid.8.Unscrew the filter housing from the sensor body and removethe filter from the filter housing.Discard the filter housing with protective disc. The filter housingmaterial cannot withstand high temperatures.Note:SensorwiringGreenBrownBlueWhiteINSTALLATIONControlsystemfieldwiringEarthSensitive(S)Non-Sensitive(NS)Common125mmINSTALLATION4. CALIBRATIONSensors should be calibrated at concentrations representative of thoseto be measured. It is always recommended that Sensepoint HT iscalibrated with the target gas it is to detect. If this is not possible, thencross calibration can be used.For calibration in fast flow conditions see the Sensepoint Gas SensorsTechnical Handbook.HighTemperatureJunctionBoxPrior to calibration, allow the sensor to warm up for approximately10 minutes. Re-calibration should only be attempted by qualified servicepersonnel.1.Zero the control system with no gas present on the sensor.If combustible gas is suspected to be in the vicinity of Sensepoint HTflow clean air over the sensor using a flow housing (see below).Exe/ExdglandIn addition to the sensor's integral earth conductor, earthequipotential bonding may be maintained via the sensor rearmounting thread if required.9.If the sensor is installed:••indoors - discard the filter.outdoors - fit the previously removed filter (if required) tothe High Temperature Weather Protection accessory(Part No: 00780-A-0076) and fit the accessory to the sensor.Fit the seal supplied with the Weather Protection accessory tothe sensor body. Screw the accessory firmly onto the sensor untilit seats against the sensor body hexagon.58mm2.Fit a flow housing and connect a cylinder of either air, for a zero,or a known concentration of gas in air, at approximately thealarm point (e.g. 50% LEL), to the flow housing.3.Pass the gas through the flow housing at a flow rate ofapproximately 1 litre to 1.5 litre/min.Threadsavailable:M20,M25,3/4NPTCertificationdata(onadjacentfaces)38mmacrossflatsSensepointHighTemperatureCombustibleGasSensor0-100%LELFilterFilterHousing4.Allow the sensor to stabilise.5.When gassing with air, adjust the control card to indicate zero.6.For span, the control card should be adjusted to indicate theconcentration of the target gas being applied.Remove the flow housing and the gas supply.Cross Calibration ProcedureWhen calibrating the Sensepoint HT sensor with a gas which is differentto the gas/vapour to be detected, the following cross calibration procedureshould be followed.Table 1 lists gases according to the reaction they produce at the detector.An eight star (8*) gas produces the highest output while a one star (1*)gas produces the lowest output. (These are not applicable at ppmlevels.)42mm10.Power-up the system and check for correct operation.3456CALIBRATIONTo calibrate the Sensepoint HT sensor carry out the following procedure:1.Obtain the star rating for both the test gas and the gas to be
detected from Table 1.2.Use the values in Table 2 to obtain the required meter setting
when a 50% LEL test gas is applied to the detector.
If a sensor is to be used to detect a gas other than that for which itwas calibrated, the required correction factor may be obtained fromTable 3. The meter reading should be multiplied by this number inorder to obtain the true gas concentration.
Important Notes:1.Since combustible sensors require oxygen for correct operation,
a mixture of gas in air should be used for calibration purposes.
2.Assuming an average sensor performance, the sensitivity
information in Tables 1 to 3 is normally accurate to ± 20%.Table 1 Star Rating of Gases
GasAcetoneAmmoniaBenzeneButaneDiethyl etherEthaneEthanolEthyl acetateEthylene
Star Rating4*7*3*4*4*6*5*3*5*
GasHexaneHydrogenMethaneOctanePropan-2-olPropaneStyrene
Tetra hydrafuranXylene
Star Rating3*6*6*3*4*5*2*4*2*
* CalibrationGas 8*7*6*5*4*3*2*1*Note:
CALIBRATIONTable 2Meter Settings
* Rating of Gas to be Detected8*5040332621---7*625041332621--6*766150403226--5*95766250403225-4*-96786350403125
3*--987963503931
2*---1*---Unit calibratedto detect8*7*6*5*4*3*2*1*
CALIBRATIONTable 3Meter Multiplication Factors
Unit used to detect
8*
7*
6*
5*
4*
3*
2*
1*
5. MAINTENANCEOnly a qualified installation engineer should service the sensor. Ensurepower is off before carrying out any maintenance procedures.
The only maintenance required is sensor replacement and filter changing(if fitted to an accessory). To replace the complete sensor refer to theSensepoint Gas Sensors Technical Handbook. To replace the filtercarry out the following procedure:
1.Remove the High Temperature Weather Protection accessory.2.Remove the old filter and replace with a fresh filter.3.Replace the Weather Protection accessory.
Ensure the Weather Protection seal is in place. Screw the accessoryfirmly onto the sensor until it seats against the sensor body hexagon.1.001.241.521.2.372.983.784.830.811.001.231.531.922.403.053.900.660.811.001.241.561.962.493.170.530.660.801.001.251.582.002.550.420.520.0.801.001.261.602.030.340.420.510.0.801.001.271.620.260.330.400.500.630.791.001.280.210.260.320.390.490.620.781.00
100-805039
-8150
These settings must only be used with a calibration gasconcentration of 50% LEL. All data at standard temperature andpressure.
Example
1.The target gas to be detected is Butane.
The calibration gas available is Methane (50% LEL).2.Look up the star rating for each gas from Table 1:
Butane = 4*Methane = 6*
3.Check the meter settings for 50% LEL calibration gas from Table 2.
The reading is 78%.
4.The control card should therefore be set to 78%.
This gives an accurate reading for Butane, using 50% LEL Methaneas a calibration gas.
710
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