“Optosense” LLC
OKP 42 1514
TN VED 9027 10 100 0
SMALL-SIZE EXPLOSIVE GAS MEASURING TRANSDUCER
MIP EX-02-Х-X
MAINTENANCE MANUAL
ECAT.413347.002 RE
St. Petersburg
2011
Table of Contents
Introduction .........................................................................................................................3
1.
Purpose of article .......................................................................................................4
2.
Specifications .............................................................................................................5
3.
Design and operation .................................................................................................6
4.
Ensuring explosion protection .................................................................................7
5.
Safety instructions .....................................................................................................8
6.
Marking and sealing ...................................................................................................9
7.
Use for direct purpose .............................................................................................10
8.
Repair. Storage and transportation ........................................................................11
9.
Warranty obligations. Manufacturer’s address .....................................................12
Appendix А ........................................................................................................................13
Appendix B ........................................................................................................................14
Appendix C ........................................................................................................................15
Appendix D ........................................................................................................................16
Appendix E ........................................................................................................................18
Introduction
The present Maintenance Manual (MM) is intended for studying structure, design and
principle of operation of a small-size explosive gas measuring transducer MIP EX-02-Х-Х (further referred to as “transducer”). The MM comprises basic specifications, maintenance recommendations as well as other data required for proper operation, repair and storage of the transducer.
Field of application – a transducer can be used as part of gas-analyzing equipment of
groups I and II in the explosion-hazardous zones of classes 0, 1, 2.
Principle of measurement – infrared absorption.
Sampling method– diffusion.
Working position of sensor in space – arbitrary.
Mode of operation – continuous.
Analyzed medium – air in working zone to GOST 12.1.005-88.
Abbreviations and designations adopted in the present MM:
LEL – lower flame spreading concentration limit;
CGM – control gas mixture.
1.
Purpose of article
1.1. The transducer is intended for automatic continuous measurement of concentration of explosive hydrocarbonic gases in ambient atmosphere.
The transducer complies with the requirements of GOST 12.2.007.0,
GOST Р 52350.0 (IEC 60079–0:2004),
GOST Р52350.11
(IEC 60079–11:2006),
GOST Р 52136-2003 (IEC 61779–1), GOST Р 52137-2003 (IEC 61779–2), GOST Р 521392003 (IEC 61779–4), GOST 13320, GOST 26.013.
1.2.The transducer is intended to be used as a transmitter (sensor) of gas analyzers of groups I
and II to GOST Р 52136-2003 (IEC 61779–1).
The transducer ensures output of information about measured concentration value via digital serial interface UART, exchange protocol is given in Appendix D.
1.3. The versions and modifications of the transducer are given in Appendix А.
1.4.The transducer operating conditions are as follows:
•
ambient temperature depending on transducer modification – according
to Table А.1 of Appendix А;
•
relative humidity – up to до 98 %;
•
atmospheric pressure – from 80 to 120 kPа;
•
content of mechanical and aggressive admixtures in the tested medium
shall not exceed the maximum permissible concentration level according to
GOST 12.1.005.
2.
Specifications
2.1 Type and level of the transducer explosion protection corresponds to
ExiаIU/ExiaIICU to GOST Р 52350.0 (IEC 60079–0:2004), GOST Р 52350.11 (IEC 60079–
11:2006).
2.2 Degree of personal protection against electrical shock caused by the transducer
corresponds to class III to GOST 12.2.007.0.
2.3 Overall dimensions, mm, not more than ø 20×22.6.
Transducer mass, g, not more than: 16.
2.4 Supply voltage, V: 3–4.5 DC.
2.5 Rated power consumed by transducer, mW, not more than: 5.
2.6 Transducer measurement range is 0–100 % of LEL, in response to special request
a measurement range can be extended for modification MIP EX-02-1-Х up to 100 % vol. СН4.
2.7 Component, to which transducer is graduated: in accordance with modification
according to Appendix А.
2.8 Limit of basic measurement error (∆bas), in accordance with Table А.1 of
Appendix А.
2.9 Step response time limit, s, not more than: 30.
2.10 Transducer warm-up time limit, s, not more than: 60.
2.11 Limit of additional error of measurement:
•
in accordance with Table А.1 of Appendix А in the course of measuring
ambient temperature within a range of operation;
•
in accordance with Table А.1 of Appendix А in the course of measuring
ambient pressure in the range of 80 to 120 kPa;
•
in accordance with Table А.1 of Appendix А in the course of measuring
ambient humidity in the range of 0 to 98 % (relative) at temperature of 40 °С.
2.12 Limit of permissible time period of transducer operation without correcting output
signal, not less than 3 months.
2.13 Transducer in transportation container is resistant to external effects within the
limits of:
•
ambient tenmperature – from -50 to 60 0C;
•
relative humidity of ambient air – from 30 to 98 %;
•
atmospheric pressure – from 84 to 106.7 kPa.
2.14 Transducer mean time before failure, not less than 10 000 h. Criterion of failure –
non-recoverable shift of basic error beyond the tolerance limits, non-fulfillment of functional
task.
2.15 Total average calendar life of transducer – not less than 10 years.
3.
Design and operation
3.1 Principle of operation
The principle of transducer operation is based on the preferential absorption of infrared
radiation by the molecules of hydrocarbons in the wavelength region of 3.3 to 3.4 µm.
The infrared radiation of a light-emitting diode takes place through a measuring diffusion-type gas cell and arrives at 2 light-sensitive cells; one of them registers radiation in the
range of wavelength of 3.3 to 3.4 µm only, while the other one registers radiation in the range
of wavelength of 3.5 to 3.7 µm. The investigated gas present in the cell absorbs radiation of the
operating wavelength (λo) and does not affect radiation of the reference operating wavelength
(λr). The amplitude Io of the light-sensitive cell operating signal changes upon changing concentration in accordance with expression:
(1)
Io/Ir = ехр {-[К(λo) – К (λr)]СL};
where:
К (λ) – coefficient of absorption at a given wavelength;
L
– optical length of cell;
С
– measured concentration of gas;
Io, Ir – amplitude of signals at light-sensitive cell.
The unknown concentration of gas is sought according to formula:
(2)
С = -Ln (Io/Ir)/(L [K (λo) – К (λr)]);
The used differential two-wave method of registration allows eliminating influence of
water vapour, contamination of optical elements and other non-selective hindrances affecting
both channels similarly.
3.2 Structure and design
Structurally, the transducer is made as a single block.
The outline drawing of the transducer is presented in Appendix C of the present MM.
The transducer gets enabled and disabled automatically in response to external power
supplied to it.
The transducer comprises an optical cell with a mirror system, infrared light-emitting
diode, receivers of measuring and reference channels, signal amplifiers, control microcontroller, current shaper for feeding infrared light-emitting diode, shaper of signals of interface
UART, supply voltages shaping unit.
The microcontroller of the transducer ensures:
- storage of unique calibration constants of a sensor;
- processing of measurement results and calculation of measured gas concentration;
- information exchange.
4.
Ensuring explosion protection
4.1. The explosion protection of transducer is ensured by the "spark-proof electrical circuit"
type of "iа" level to GOST Р 52350.11-2005 (IEC 60079–11:2006) with marking of explosion protection Ex iа I U / Ex iа II C U to GOST Р 52350.0 (IEC 60079–0).
4.2. The explosion protection of the transducer is attained due to:
- limitation of parameters of transducer electrical circuits to spark-proof values in accordance
with GOST Р 52350.11-2005 (IEC 60079–11:2006);
- provision of required electrical clearances and leakage paths to GOST Р 52350.11-2005
(IEC 60079–11:2006);
- isolation between spark-proof circuit and body of a sensor endures test voltage of 500 V in
accordance with GOST Р 52350.11 – 2005 (IEC 60079–11:2006);
-parameters of spark-proofness of sensor circuit: Pi = 0.5 W, Ui = 4.5 V, Ii = 450 mА, Ci =
37.1 µF, Li = 0.
4.3. Conformity certificate: РОСС RU.ГБ05.В03403 №0558624
5. Safety instructions
5.1 Perform power supply of the sensor from power sources featuring nominal
range of output DC voltage of not less than 3 V and not more than 4.5 V, output power (P0) – not less than 0.02 W and not more than 0.5 W, implemented
in accordance with requirements of standards GOST Р 52350.0 (IEC 60079–
0:2004), GOST Р 52350.11 (IEC 60079–11:2006)
5.2 In case of handling bottles comprising test gas mixtures under pressure, it is
necessary to observe requirements of safety precautions according to “Rules of
design and safe operation of vessels under pressure” approved by Gosgortekhnadzor (state mining inspection) of Russia dated 18.04.95.
5.3 The repair of transducer shall be carried out by the Manufacturer’s personnel
only or by the persons authorized by the Manufacturer to conduct repair operations.
5.4 It is impermissible to discharge the control gas mixture to the atmosphere of
working premises in the course of transducer calibration.
6. Marking and sealing
The marking applied to transducers includes the following data:
− manufacturer’s trademark or name;
− type of article;
− plant number, month and year of manufacture;
− marking of explosion-proofness;
− name or sign of certification center and number of compliance certificate.
7. Use for direct purpose
7.1. General requirements
The persons who have studied this MM, have been briefed on safety precautions when operating electrical equipment intended for operation in the explosion-hazardous zones in the established order, are admitted to operate the transducer.
The design of articles, in which transducer is installed should mandatorily meet the requirements of GOST Р 52350.0 (IEC 60079–0:2004), GOST Р 52350.11 (IEC 60079–11:2006)
7.2. Preparation to operation
7.2.1. If the transducer has been kept in the transportation package at sub-zero temperature,
hold it at temperature of 10–35 0С for at least one hour.
7.2.2. Remove the packing. Check presence of the explosion-proofness marking, ensure absence of mechanical injuries.
7.3. Installation
7.3.1. Perform switching of the transducer with the use of Cambion 450-3729-01-06-00-type or
similar sockets. Soldering of transducer contacts is impermissible.
The arrangement and purpose of contacts is in accordance with Fig. of Appendix C.
7.3.2. Provide power supply of the sensor from power sources featuring nominal range of output DC voltage of not less than 3 V and not more than 4.5 V, output power (P0) – not less than
0.02 W and not more than 0.5 W implemented in accordance with requirements of standards
GOST Р 52350.0 (IEC 60079–0:2004), GOST Р 52350.11 (IEC 60079–11:2006).
Diagram of connection is in accordance with Figure of Appendix B of this MM.
7.4. Article use
Fit transducer to sockets according to item 7.3.1. Supply power according to item 7.3.2.
The transducer ensures output of information about measured value of concentration via digital
serial interface UART.
The protocol of transducer exchange via digital interface is given in Appendix D.
The methods of setting “0” of the transducer and calibration is given in E.
The transducer is designed for round-the-clock operation.
8. Repair. Storage and transportation
8.1. In case of transducer failure within warranty period it is subject to warranty repair or
replacement by the Manufacturer.
8.2. The transportation of transducers should be performed by all means of transportation in
covered transportation vehicles as well as in the heated pressurized plane compartments in accordance with the rules of cargoes transportation effective for the respective type of transportation.
8.3. The transducers in the Manufacturer’s package should be kept in the Supplier’s and
Customer’s storages under storage conditions 1 to GOST 15150. The atmosphere of storage
premises should be free from harmful admixtures provoking corrosion.
9. Warranty obligations. Manufacturer’s address
9.1.
The Manufacturer guarantees compliance of the transducers with the requirements of
the present Specifications in case of observing conditions of operation, transportation and
storage by the Customer.
9.2. The warranty operation period is 24 months since the date of transducer shipment to a
Customer. The date of shipment is registered in the certificate of a transducer.
9.3. The warranty storage period before putting into operation is 6 months since the date of
delivery to a Customer. The date of shipment is registered in the certificate of a transducer.
9.4. The warranty repair or replacement is effected by the Manufacturer.
9.5. Manufacturer’s address:
“Оptosense” LLC
27, letter AD, Engelsa prospect, St. Petersburg, 194156,
Tel./fax: +7 (812) 633-0594, 633-0595
web-site: http://www.optosense.ru/
e-mail: info@optosense.ru
Appendix А
(mandatory)
Transducer versions and modifications
Transducer versions and modifications
Design version:
MIP EX–02–Х-Х
1 2
1 – Type of control component: 1 – methane; 2 – propane
2 – Type of version:
I – for use in gas analyzers of group I;
II – for use in gas analyzers of group II
Table А.1. Transducer parameters:
Modification
Temperature
range of operation
-10 оС …40 оС
MIP EX G-02-1-I
-40 оС …60 оС
MIP EX-02-Х-II
Limit of additional
error in case of temLimit of main perature change in the
range of operation
absolute error
±2 % of LEL
or 0.05*С%
of LEL depending on
what is higher
±5 % of LEL
or 0.1*С%
of LEL depending on
what is
higher
Limit of additional
error in case of pressure change in the
range from 80 to
120 kPа
±4 % of LEL or
0.1*С% of LEL depending on what is
higher
±4 % of LEL or
0.3*С% of LEL depending on what is
higher
Limit of additional
error in case of
humidity change in
the range from 0 to
98 % rel. at temperature of 40 °С
±4 % of LEL or
0.1*С % of LEL
depending on what
is higher
±5 % of LEL or
0.1*С% of LEL depending on what is
higher in the range of
-10 оС …40 оС
±10 % of LEL or
0.2*С% of LEL depending on what is
higher in the range of
-40 оС…-10 оС
40 оС …60 оС
±5 % of LEL or
0.3*С% of LEL depending on what is
higher
±7 % of LEL or
0.15*С % of LEL
depending on
what is higher
С – current measured concentration value
*Note: The recalculation to % of LEL shall be effected in accordance with the following formula for concentration expressed in volume fraction, vol. %:
LFSCL =
100 × C
;%
C (h)
where
LFSCL is %LEL
С – component content in volume fraction, vol. %;
С(h) – LEL of component, % (constant);
С(h) = 4.4 % – for methane;
С(h) = 1.7 % – for propane;
Appendix B
(mandatory)
Diagrams of connection of MIP EX-02-Х-Х
Figure B.1. Diagrams of connection of MIP EX-02-Х-Х
Explosion-hazardous
Взрывоопасная zone
зона
Small-size
Малогабаритный
measuring
измерительный
transducer
преобразователь
MIP
МИПEX-02-Х-Х
ВГ-02-Х-Х
Net
XP
TXD
1
RXD
2
VDD
3
GND
4
Power
unit IBИБ
Блок
питания
U=<4.5
V
U=<
4.5 В
I=<450
mА
I=<
450мA
ECAT.413347.001 РЭ
Appendix C
(mandatory)
Overall dimensions of transducer MIP EX-02-Х-Х
15
ECAT.413347.001 РЭ
Appendix D
Data exchange protocol via bus UART for MIP EX-02-Х-Х
Ver. 5.02. dated 10.02.2011
UART characteristics:
exchange rate – 9600 baud
8-bit message
1 stop bit
without check for parity
Input and output logical levels of 0… 2.7 V
The symbols of commands are coded in ASCII, CR (carriage return) symbol shall be put after
command – (0Dh).
A response is coded with ASCII symbols. The words/figures of the response can be separated with
a tabulation symbol 09h or space symbol 20h (specified below for every command). The CR (carriage
return) symbol is put at the end of message – (0Dh).
1. Operation with network address
An assignment of the network address to a device is contemplated in the range of 0–FF. It allows
connecting up to 255 instruments to one UART line. The instrument is assigned 00 address after enabling. The following commands have been introduced for viewing and changing address:
!** – network address interrogation. The sensor returns network address in the format of !XX,
where XX – address in hexadecimal form.
%XXYY – address YY is assigned to a sensor with address XX.
NETON – command, in response to which a network address is saved in the instrument memory. In
case of power removal, the network address should remain.
NETOFF – command, in response to which the saving of the network address in the instrument
memory is cancelled. In case of power removal, the network address equals 00h.
If a sensor is used together with the other instruments in the same UART line, it is necessary to put
the prefix #XX before a command, where XX is a network hexadecimal address from 00 to FF.
2. Data interrogation
Command
DATA
F
1
Conc1
Term
2
3
4
Response
Number of output value
5
6
7
S
Us
Uref
St
St`
Stz
8
9
10
11
Conc
Conc1
Stzkt
Sn
A command DATA is intended for outputting information on concentration.
Response is a value of concentration Conc1 with scaling of 5-bit decimal integer number taken into
account.
The concentration is expressed in % vol. with a resolution of 0.01 % vol., e.g., 1.98 % vol. – 00198 for
the factory calibration.
A format of response – 5 byte of ASCII is a concentration value and a symbol of 0Dh.
A command F is intended for detailed analysis of sensor operation.
16
ECAT.413347.001 РЭ
A response to command F:
The first symbol in a message – 0Eh, data – 5 byte of ASCII, separation symbol between data – 09h,
after transmission of Sn (serial number) symbol 09h follows, after that a value of control sum of the
whole message follows calculated to the rule of excluding or ControlSum = ControlSum^data. Next to
that symbol 09h and symbol 0Dh proceed,
where:
Term – temperature of sensor in ADC readings;
S – relation Us/Uref taking coefficient ZERO1 into account;
Us – signal of operating receiver in ADC readings;
Uref – signal of reference receiver in ADC readings;
St – S multiplied by temperature coefficient;
St` – filtered St;
Stz – relation St` taking coefficient ZERO2 into account;
Conc – concentration (calculated according to a factory calibration);
Conc1 – scaled concentration;
Stzkt – relation Stz taking into account temperature coefficient of sensitivity;
Sn – serial number of instrument (8 symbols).
3. User commands
ZERO2 – setting to zero. In case of supplying this command, concentration Conc = 0, Conc1 = 0, relation Stz is corrected to 10000. The calculated value is retained in constant Kzero2.
CALB AAAA – calibration according to concentration. In response to this command the scale coefficient for concentration Conc1 is calculated. The calculated value is retained in constant Kscale. Next
to that the scaled concentration Conc1 = Kscale* Conc follows.
INIT – initialization of coefficients of zeroing and calibration. The coefficients KZero2 и Kscale are
assigned the value of 1. The transducer calibration returns to an original factory calibration.
SREV? – interrogation of a version of SW firmware download of the sensor microcontroller.
SRAL? – 8-bit serial number is interrogated – 8 byte of ASCII and 0Dh symbol.
17
ECAT.413347.001 РЭ
Appendix E
Methods of setting 0 and calibration of sensitivity of transducer MIP EX-02-Х-Х
1. The setting of 0 and calibration of transducer is performed in the course of the primary installation
into a gas analyzer as well as annualy during preparation to conducting a check.
2. The devices given in Figure E.1 and in the list of CGM are used in the course of conducting
operations.
3. The operations on setting 0 and calibration of transducer shall be carried out by a qualified specialist
outside of the explosion-hazardous zone at normal conditions in the following sequence:
- transducer shall be connected in accordance with Figure B.1. Adapter UART-RS232 should be connected to transducer and to PC.
- CGM adapter shall be installed on the transducer and a feeding hose in accordance with Figure E.1
shall be put onto pipe connection.
- in 5 min after power supply the СGM No.1 (pure nitrogen N2) is connected, in 1 min after СGM
supply a command ZERO2of zero setting is supplied, the transducer readings should get set to 0 with
respect to digital interface in accordance with Appendix D.
- the СGM No.2 is connected, in 1 min after CGM supply a CALB ХХХХ command is given (Ref.
Appendix D), where ХХХХ is a value of CGM concentration (e.g. 1.98% vol. – 0198). After that the
value Conc1 – (scaled concentration) should get established equal to a value assigned according to
command CALB ХХХХ. The scale coefficient shall be stored in the module memory up to the next
calibration.
- the СGM No.3 is connected and the transducer readings are checked via digital serial RS-232 in accordance with Appendix D.
If the requirements to the transducer error are not fulfilled in accordance with Table А.1, the procedure
of setting 0 and calibration shall be repeated. In case of a repeated non-compliance of transducer readings to the value of concentration of СGM No.3, a transducer is subject to replacement and dispatching
to the Manufacturer for repair.
Figure E.1. Calibration diagram
4
3
1
8
9
2
7
6
5
1. Transducer MIP EX-02-Х-Х
2. CGM Adapter
3. Electrical Cable
4. Power Source
5. CGM
6. Reducer BKO–25–MG
7. Rotameter PM–A–0,063GUZ
8. Adapter UART-RS232
9. PC
18
ECAT.413347.001 РЭ
List of CGM used for checking transducers MIP EX-02-Х-Х
*Note: the recalculation to % of LEL shall be effected in accordance with the following formula for
concentration expressed in volume fraction, vol. %:
LFSCL =
100 × C
;%
C (h)
where
LFSCL is % LEL
С – component content in volume fraction, vol. %;
С(h) – LEL of component, % (constant);
С(h) = 4.4 % – for methane;
С(h) = 1.7 % – for propane.
MIP EX–02–1-Х:
CGM Nos
according
to text
Component
composition
1
2
3
4
N2
СН4 – N2
СН4 – N2
СН4 – N2
Composition
of measured
component,
vol. %,
(% of LEL)
100
2,2 (50)
4,15 (94)
8,80 (200)
Permissible
deviation limits, vol. %
±0,25
±0,25
±1,00
Limits of
permissible
error of qualification,
vol. %
±0,04
±0,04
±0,5
Table E.1
Number as per
State Register
or Standard
designation
GOST 9392-74
3883-87
3883-87
MIP EX–02–2-II:
CGM Nos
according
to text
Component
composition
1
2
3
4
N2
С3Н8 – N2
С3Н8 – N2
С3Н8 – N2
Composition
of measured
component,
vol. %,
(% of LEL)
100
0,85 (50)
1,6 (94)
3,40 (200)
Permissible
deviation limits, vol. %
±0,05
±0,1
±1,00
Limits of
permissible
error of qualification,
vol. %
±0,015
±0,05
±0,5
Table E.2
Number as per
State Register
or Standard
designation
GOST 9392-74
5328-90
EM 06.01.648
19