Page 1 of 107
Report No. CA/QPS/ExTR08.0002/00
IECEx Ex TEST REPORT COVER
ExTR Reference Number ..... :
CA/QPS/ExTR08.0002/00
ExTR Free Reference
Number:
X35222-1
Approved by + signature
(ExCB)
Tom Bartoffy, P.Eng.
Date of issue ........................ :
November 17, 2008
Ex Certification Body (ExCB) :
QPS Evaluation Services Inc.
Address ................................ :
81 Kelfield Street, Units 7-9, Toronto, ON M9W 5A3,
Canada
Ex Testing Laboratory (ExTL):
QPS Evaluation Services Inc.
Address ................................ :
81 Kelfield Street, Units 7-9, Toronto, ON M9W 5A3,
Canada
Applicant’s name.................. :
Sperian Protection
Address ................................ :
651 South Main Street,
Middletown, CT USA
06457
Standards ............................ :
IEC60079-0 (4th ed) and IEC60079-11 (5th ed)
Test procedure ..................... :
IECEx Scheme
Test Report Form No. .......... :
ExTR Cover_2
TRF Originator ..................... :
Underwriters Laboratories Inc. (UL)
Master TRF .......................... :
dated 2008-09
IECEx Test Report National Differences attached
............................................. :
(Yes)
Instructions for Intended Use of Cover Sheet:
This document is to be compiled and reviewed by the ExTL, with the ExCB giving the
final approval, or compiled by the ExCB without the involvement of the ExTL. It is to
serve as the sole cover for an ExTR package, which may be comprised of a single ExTR
document or multiple ExTR documents. This ExTR Cover is to be completed and
attached to the completed ExTR package.
Copyright © 2008 International Electrotechnical Commission Scheme for
Certification to Standards Relating to Equipment for use in Explosive
Atmospheres (IECEx), Geneva, Switzerland. All rights reserved.
This publication may be reproduced in whole or in part for non-commercial purposes as
long as the IECEx is acknowledged as copyright owner and source of the material.
IECEx takes no responsibility for and will not assume liability for damages resulting from
the reader's interpretation of the reproduced material due to its placement and context.
Page 2 of 107
Report No. CA/QPS/ExTR08.0002/00
Test item description ............ :
Hand-Held Multi-Gas Detector
Trademark............................ :
-
Model/type reference ........... :
PhD6
Manufacturer ........................ :
Sperian Protection
Address ................................ :
651 South Main Street,
Middletown, CT USA
06457
Code (e.g. Ex
Ex d ia IIC 170C (T3)
II
T ) ... :
Rating .................................. :
IP60
-20C to +50C
Copy of Marking Plate
Particulars: test item vs. test requirements
Classification of installation and use ...................... : hand-held
Ingress protection ..................................................: IP60
Rated ambient temperature range (°C) ...................: Ambient Range -20C to +50C
General remarks:
General product information:
This is a battery operated multi-gas detector for measuring combustible, oxygen and toxic
gases and includes an optional, detachable pump assembly. It is powered by either 3 AA
alkaline batteries or a single Li-Ion battery rated a nominal 4 volts. A Docking
Station/Charger for use outside the hazardous area is provided and rated as associated
equipment.
Manufacturer’s Documents
Title:
Drawing No.:
Refer to Descriptive
Report Section
Various
Rev. Level:
Date:
Page 3 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Checklist
Page 4 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
1
SCOPE
2
NORMATIVE REFERENCES
3
TERMS AND DEFINITIONS
4
APPARATUS GROUPING AND TEMPERATURE CLASSIFICATION
4.1
Apparatus grouping
Group II apparatus
Pass
4.2
Group II
Group II apparatus
Pass
4.2.1
Group II subdivisions
Gas group IIC
Pass
4.2.2
Group II – Surface
temperature marking
Temperature class marking is affixed on Pass
the equipment.
4.2.3
Apparatus for a particular
explosive atmosphere
No use in a particular explosive
atmosphere. Surface temperature
marking according to 4.2.2
Pass
5
TEMPERATURES
5.1
Environmental influences
5.1.1
Ambient temperatures
Equipment is used in a temperature
range between -20°C and 40°C.
Additional marking is not required.
Pass
5.1.2
External source of heating
or cooling
No external source of heating and
cooling present.
Pass
5.2
Service temperature
Service temperature was determined
Pass
for rated duty of the electrical apparatus
with surrounding temperature and linear
calculated to maximum ambient
temperature.
5.3
Maximum surface temperature
Determination of maximum Maximum surface temperature was
determined under fault conditions and
surface temperature
surrounding temperature and linear
calculated to maximum ambient
temperature.
5.3.1
60079-0_4:2004 4th ed.(ver 4a)
Result – Remark
Verdict
Pass
Page 5 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
Result – Remark
5.3.2
Limitation of maximum
surface temperature
See following subchapters.
5.3.2.1
Group I electrical
apparatus
No group I apparatus
5.3.2.2
Group II electrical
apparatus
Apparatus is classified in a temperature Pass
class given in Table 2 of EN/IEC 600790.
5.4
Surface temperature and
ignition temperature
Highest temperature is indicated by the
temperature class. It is in the
responsibility of the operating company
to ensure, that ignition temperatures of
surrounding substances are higher.
Pass
5.5
Small component
temperatures
Facilitation for small components was
not used.
Pass
6
REQUIREMENTS FOR ALL ELECTRICAL APPARATUS
Apparatus/Ex component for use in
General
explosive gas atmospheres complies
with the requirements of this standard,
together with one or more of the
specific standards. Compliance with
further industrial standards is in the
responsibility of the manufacturer.
Apparatus is designed for usage in
Error conditions
zone 1. Failure conditions are
considered.
Overload is not expected
Overload of apparatuses
6.1
6.Z1
6.Z2
Verdict
N/A
Pass
Pass
Pass
6.2
Mechanical strength of
apparatus
Apparatus was subjected to the tests of Pass
26.4. (as far as applicable.)
6.3
Opening times
Excluded per Table 1 of IEC 6007911:2006.
N/A
6.4
Circulating current
N/A
6.5
Gasket retention
No circulation currents possible
because of present construction.
Degree of protection provided by the
enclosure does not depend on a
gasketed joint which is intended to be
opened for installation or maintenance
purposes.
7
Pass
—NON-METALLIC ENCLOSURES AND NON-METALLIC PARTS OF
ENCLOSURES
60079-0_4:2004 4th ed.(ver 4a)
Page 6 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
7.1
General
7.1.1
Applicability
7.1.2
Specification of materials
7.1.3
Plastic materials
7.2
Thermal endurance
7.3
7.3.2
Electrostatic charges on enclosures or parts of enclosures
Applicable, external non-metallic
Applicability
materials are present.
Avoidance of a build-up of Hand-held apparatus: The inability to
store a dangerous charge by
electrostatic charge
measurement of capacitance when
tested in accordance with the test
method in 26.15.
7.4
Threaded holes
8
ENCLOSURES CONTAINING LIGHT METALS
8.1
Material Composition
8.1.1
Group I
No group I equipment.
N/A
8.1.2
Group II
Pass
8.2
Threaded Holes
Usage in zone 0: Apparatus contains
not more than 10 % in total of
aluminum, magnesium, titanium and
zirconium, or 7,5 % in total of
magnesium, titanium and zirconium.
Excluded per Table 1 of IEC 6007911:2006.
9
FASTENERS
9.1
General
Excluded per Table 1 of IEC 6007911:2006.
N/A
9.2
Special fasteners
Excluded per Table 1 of IEC 6007911:2006.
N/A
7.3.1
60079-0_4:2004 4th ed.(ver 4a)
Result – Remark
Verdict
Type of protection does not depend on
non-metallic parts of the enclosure or
non-metallic enclosure.
Not applicable, type of protection does
not depend on non-metallic parts of the
enclosure or non-metallic enclosure.
Excluded per Table 1 of IEC 6007911:2006.
Pass
Excluded per Table 1 of IEC 6007911:2006.
N/A
Excluded per Table 1 of IEC 6007911:2006.
Pass
N/A
Pass
Pass
N/A
N/A
Page 7 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
9.3
Holes for special fasteners Excluded per Table 1 of IEC 6007911:2006.
N/A
9.3.1
Thread engagement
Excluded per Table 1 of IEC 6007911:2006.
N/A
9.3.2
Tolerance and clearance
Excluded per Table 1 of IEC 6007911:2006.
N/A
9.3.3
Hexagon socket set screw
Excluded per Table 1 of IEC 6007911:2006
N/A
10
Interlocking devices
Excluded per Table 1 of IEC 6007911:2006.
N/A
11
Bushings
Excluded per Table 1 of IEC 6007911:2006.
N/A
12
Materials used for
cementing
Excluded per Table 1 of IEC 6007911:2006.
N/A
13
EX COMPONENTS
13.1
General
N/A
13.2
Mounting internal to
apparatus
Apparatus is not an ex-component.
Apparatus is not an ex-component.
13.3
Mounting external to
apparatus
Apparatus is not an ex-component.
N/A
14
CONNECTION FACILITIES AND TERMINAL COMPARTMENTS
Excluded per Table 1 of IEC 60079General
11:2006.
Excluded per Table 1 of IEC 60079Connection space
11:2006.
Excluded per Table 1 of IEC 60079Type of protection
11:2006.
Excluded per Table 1 of IEC 60079Creepage and clearance
11:2006.
14.1
14.2
14.3
14.4
15
15.1
15.2
15.3
Result – Remark
Verdict
N/A
N/A
N/A
N/A
N/A
CONNECTION FACILITIES FOR EARTHING OR BONDING CONDUCTORS
Excluded per Table 1 of IEC 60079Internal
N/A
11:2006.
Excluded per Table 1 of IEC 60079External
N/A
11:2006.
Excluded per Table 1 of IEC 60079Apparatus not requiring
N/A
11:2006.
earthing
60079-0_4:2004 4th ed.(ver 4a)
Page 8 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
Result – Remark
Verdict
15.4
Size of conductor
connection
Excluded per Table 1 of IEC 6007911:2006.
N/A
15.5
Protection against
corrosion
Excluded per Table 1 of IEC 6007911:2006.
N/A
15.6
Secureness
Excluded per Table 1 of IEC 6007911:2006
N/A
16
16.1
ENTRIES INTO ENCLOSURES
No entries to enclosure present in
General
sense of 16.1
N/A
16.2
Identification of entries
No entries to enclosure present in
sense of 16.1
N/A
16.3
Cable glands
Apparatus does not have any cable
glands.
N/A
16.4
Blanking elements
No blanking elements present.
N/A
16.5
Conductor temperature
Excluded per Table 1 of IEC 6007911:2006.
N/A
17
SUPPLEMENTARY REQUIREMENTS FOR ROTATING ELECTRICAL
MACHINES
Excluded per Table 1 of IEC 60079Fans and fan hoods
N/A
11:2006.
Excluded per Table 1 of IEC 60079Ventilation openings for
N/A
11:2006.
external fans
17.1
17.2
17.3
17.4
17.5
Construction and mounting Excluded per Table 1 of IEC 6007911:2006.
of the ventilation systems
Excluded per Table 1 of IEC 60079Clearances for the
11:2006.
ventilating
Materials for external fans Excluded per Table 1 of IEC 6007911:2006.
and fan hoods
N/A
Excluded per Table 1 of IEC 6007911:2006.
N/A
17.6
Equipotential bonding
conductors
18
SUPPLEMENTARY REQUIREMENTS FOR SWITCHGEAR
Excluded per Table 1 of IEC 60079Flammable dielectric
11:2006.
Excluded per Table 1 of IEC 60079Disconnectors
11:2006.
18.1
18.2
60079-0_4:2004 4th ed.(ver 4a)
N/A
N/A
N/A
N/A
Page 9 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
Result – Remark
Verdict
18.3
Group I – Provisions for
locking
Excluded per Table 1 of IEC 6007911:2006.
N/A
18.4
Doors and covers
Excluded per Table 1 of IEC 6007911:2006.
N/A
19
Supplementary
requirements for fuses
Excluded per Table 1 of IEC 6007911:2006.
N/A
20
20.1
SUPPLEMENTARY REQUIREMENTS FOR PLUGS AND SOCKETS
Excluded per Table 1 of IEC 60079Interlocking
N/A
11:2006
20.2
Energized plugs
21
SUPPLEMENTARY REQUIREMENTS FOR LUMINAIRES
Excluded per Table 1 of IEC 60079General
11:2006
Excluded per Table 1 of IEC 60079Covers
11:2006
Excluded per Table 1 of IEC 60079Special lamps
11:2006
21.1
21.2
21.3
22
22.1
Excluded per Table 1 of IEC 6007911:2006
N/A
N/A
N/A
N/A
SUPPLEMENTARY REQUIREMENTS FOR CAPLIGHTS, CAPLAMPS AND
HANDLAMPS
Excluded per Table 1 of IEC 60079Group I caplights and
N/A
11:2006
handlights
Excluded per Table 1 of IEC 6007911:2006
22.2
Group II caplights and
handlights
23
APPARATUS INCORPORATING CELLS AND BATTERIES
Batteries are only formed from cells
Batteries
Pass
connected in series.
Cell types
Apparatus has either primary or
Pass
secondary cells. Primary cells
correspond with the requirements of
table 6 and Secondary cells correspond
with the requirements of table 7.
23.1
23.2
60079-0_4:2004 4th ed.(ver 4a)
N/A
Page 10 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
Result – Remark
Verdict
23.3
Cells in a battery
Pass
23.4
Ratings of batteries
23.5
Mixture of cells
23.6
Interchangeability
23.7
Charging of primary
batteries
23.8
Leakage
23.9
Connections
23.10
Orientation
23.11
Replacement of cells or
batteries
All cells in a battery are of the same
electrochemical system, cell design and
rated
capacity and made by the same
manufacturer.
All batteries are arranged and operated
so as to be within the allowable limits
defined by
the cell or battery manufacturer.
Batteries do not contain a mixture of
primary and secondary cells.
Primary and secondary cells or
batteries are not used inside the same
apparatus.
Primary batteries will not be re-charged.
No other voltage source inside
apparatus containing primary batteries.
All cells are constructed so as to
prevent leakage of electrolyte.
Manufacturer’s recommended methods
of making electrical connections to a
battery are used.
Orientation of battery is not important
for safe
Operation.
Replacement of batteries is required
and legibly and durably marked inside
the enclosure as detailed in 29.9.
24
Documentation
Documents that give a full and correct
specification of the explosion safety
aspects of the electrical apparatus are
present.
Pass
25
Compliance of prototype or The prototype or sample of the
electrical apparatus subjected to the
sample with documents
type verifications and tests complies
with the manufacturer's documents
referred to in Clause 24.
26
TYPE TESTS
26.1
General
Applicable tests were carried out.
Justification for omitted tests is given.
26.2
Test configuration
Each test was be made in the
Pass
configuration of the electrical apparatus
considered to be the
most unfavourable.
60079-0_4:2004 4th ed.(ver 4a)
Pass
Pass
Pass
Pass
Pass
Pass
Pass
Pass
pass
Pass
Page 11 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
Result – Remark
Verdict
26.3
Tests in explosive test
mixtures
See requirements of the specific IECStandard. If tests in explosive test
mixtures were carried out, gas purity in
sense of 26.3 was given.
Pass
26.4
Tests of Enclosures
See following subchapters. All tests
Pass
except Drop Test of 26.4.3 excluded
per Clause 6.1.1 of IEC 60079-11:2006
26.4.1
Order of tests
Order of tests was respected.
26.4.1.1
Metallic enclosures,
Apparatus has a non-metallic
metallic parts of enclosures enclosure.
and glass of parts of
enclosures
N/A
26.4.1.2
Non-metallic enclosures or Order of tests was respected for group
non-metallic parts of
II equipment.
enclosures
Pass
Pass
26.4.1.2.1 Group I electrical
apparatus
Apparatus is group II
N/A
26.4.1.2.2 Group II electrical
apparatus
Order of tests was respected for group
II equipment.
Pass
26.4.2
Test for resistance to
impact/Required results
All tests except Drop Test of 26.4.3
excluded per Clause 6.1.1 of IEC
60079-11:2006
N/A
26.4.3
Drop test/Required results
26.4.4
Acceptance criteria
26.4.5
Tests for the degree of
protection IP by enclosures
The drop test was carried in
Pass
accordance with requirements of
26.4.3.
The resistance to the drop test did not
Pass
produce damage so as to invalidate the
type of protection of the electrical
apparatus.
See following subchapters.
26.4.5.1
Test procedure
26.4.5.2
Acceptance criteria
26.5
Thermal tests
26.5.1
Temperature measurement Thermal tests were successfully carried Pass
out in accordance with 26.5.1.
Excluded per Table 1 of IEC 60079Thermal shock test
N/A
11:2006.
26.5.2
60079-0_4:2004 4th ed.(ver 4a)
Degree of protection is not required by
this standard or any other parts of this
series.
Excluded per Table 1 of IEC 6007911:2006.
N/A
N/A
Page 12 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
26.5.3
Small component ignition test
26.5.3.1
General
Item a) of 5.5 was not used, Test was
not carried out.
N/A
26.5.3.2
Procedure
Item a) of 5.5 was not used. Test was
not carried out.
N/A
26.5.3.3
Acceptance criteria
Item a) of 5.5 was not used. Test was
not carried out.
N/A
26.6
Torque test for bushings
26.6.1
Test procedure
N/A
26.6.2
Acceptance criteria
Excluded per Table 1 of IEC 6007911:2006.
Excluded per Table 1 of IEC 6007911:2006.
26.7
Tests of non-metallic enclosures or of non-metallic parts of enclosures
Excluded per Table 1 of IEC 60079General
N/A
11:2006.
Temperature during tests
Excluded per Table 1 of IEC 60079N/A
11:2006.
26.7.1
26.7.2
Result – Remark
Verdict
N/A
26.8
Thermal endurance to heat Excluded per Table 1 of IEC 6007911:2006.
N/A
26.9
Thermal endurance to cold Excluded per Table 1 of IEC 6007911:2006.
N/A
26.10
Resistance to light
26.10.1
Applicability
26.10.2
Test procedure
26.10.3
Excluded per Table 1 of IEC 6007911:2006.
Excluded per Table 1 of IEC 6007911:2006.
N/A
Acceptance criteria
Excluded per Table 1 of IEC 6007911:2006.
N/A
26.11
Resistance to chemical
agents for Group I
electrical apparatus
Excluded per Table 1 of IEC 6007911:2006.
N/A
26.12
Earth Continuity
Excluded per Table 1 of IEC 6007911:2006.
N/A
60079-0_4:2004 4th ed.(ver 4a)
N/A
Page 13 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
26.13
Surface resistance test of Measurement of capacitance was used. N/A
parts of enclosures of nonmetallic materials
26.14
Charging test
26.14.1
Introduction
Measurement of capacitance was used. N/A
26.14.2
Principle of the test
Measurement of capacitance was used. N/A
26.14.3
Samples and apparatus
Measurement of capacitance was used. N/A
26.14.4
Ambient conditions
Measurement of capacitance was used. N/A
26.14.5
Conditioning
Measurement of capacitance was used. N/A
26.14.6
Determination of the most efficient charging method
26.14.6.1
Method A: Rubbing with a
pure polyamide cloth
(figure 6)
Measurement of capacitance was used. N/A
26.14.6.2
Method B: Rubbing with a
cotton cloth
Measurement of capacitance was used. N/A
26.14.6.3
Method C: Charging by
influence with a d.c. highvoltage power supply
(figure 8)
Measurement of capacitance was used. N/A
26.14.7
Assessment of discharge
Measurement of capacitance was used. N/A
26.15
Measurement of capacitance
26.15.1
Test procedure
Hand held apparatus: measurement of
capacitance was used.
Pass
26.15.2
Acceptance criteria
Measurement of capacitance:
acceptance criteria were respected.
Pass
27
Routine verifications and
tests
Applicable routine tests are in the
responsibility of the manufacturer.
Pass
28
MANUFACTURER'S RESPONSIBILITY
28.1
Certificate
Certificate is prepared by the notified
body.
Pass
28.2
Responsibility for marking
Corresponding marking is the
responsibility of the manufacturer and
was verified by the notified body.
Pass
29
MARKING
60079-0_4:2004 4th ed.(ver 4a)
Result – Remark
Verdict
Page 14 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
Result – Remark
Verdict
29.1
Location
The electrical apparatus is legibly
marked on the main part of the
apparatus.
Pass
29.2
General
Pass
29.3
Different types of
protection
The marking includes all applicable
requirements of 29.2.
The enclosure is intrinsically safe ‘ia’,
and the combustible gas sensor
assembly is flameproof ‘d’
29.4
Order of marking
The order of marking is respected.
Pass
29.5
Ex components
Apparatus is not a component.
N/A
29.6
Small apparatus and Ex
components
Not small apparatus or component.
Pass
29.7
Extremely small apparatus Not extremely small apparatus or
and Ex components
component.
Pass
29.8
Warning markings
Required markings are affixed on the
apparatus.
Pass
29.9
Cells and batteries
Corresponding information is present
on the apparatus.
Pass
29.10
Example of marking
Informative
30
INSTRUCTIONS
30.1
General
Instructions are present and include
particulars as described in 30.1
Pass
30.2
Cells and batteries
Corresponding information is given in
the instructions.
Pass
Annex A
(Normative)
EX CABLE GLANDS
Excluded per Table 1 of IEC 6007911:2006.
N/A
A.1
General
A.2
Constructional requirements
60079-0_4:2004 4th ed.(ver 4a)
Pass
Page 15 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
Requirement – Test
Result – Remark
Verdict
A.2.1
Cable sealing
Excluded per Table 1 of IEC 6007911:2006.
N/A
A.2.2
Materials
Exposed parts
Excluded per Table 1 of IEC 6007911:2006.
N/A
A.2.2.1
A.2.2.2
Elastomeric sealing rings
N/A
A.2.2.3
Filling compounds
Excluded per Table 1 of IEC 6007911:2006.
Excluded per Table 1 of IEC 6007911:2006.
A.2.3
Clamping
A.2.3.1
General
N/A
A.2.3.2
Group II cable glands
Excluded per Table 1 of IEC 6007911:2006.
Excluded per Table 1 of IEC 6007911:2006.
A.2.4
Lead-in of cable
A.2.4.1
Sharp edges
N/A
A.2.4.2
Point of entry
A.2.5
Release by a tool
A.2.6
Fixing
A.2.7
Degree of protection
Excluded per Table 1 of IEC 6007911:2006
Excluded per Table 1 of IEC 6007911:2006
Excluded per Table 1 of IEC 6007911:2006
Excluded per Table 1 of IEC 6007911:2006
Excluded per Table 1 of IEC 6007911:2006
A.3
Type Tests
A.3.1
A.3.1.5
Tests of clamping of non-armoured and braided cables
Excluded per Table 1 of IEC 60079Cable glands with
11:2006
clamping by the sealing
ring
Excluded per Table 1 of IEC 60079Cable glands with
11:2006
clamping by the filling
compound
Excluded per Table 1 of IEC 60079Cable glands with
11:2006
clamping by means of a
clamping device
Excluded per Table 1 of IEC 60079Tensile test
11:2006
Excluded per Table 1 of IEC 60079Mechanical strength
11:2006
A.3.2
Tests of clamping of armoured cables
A.3.1.1
A.3.1.2
A.3.1.3
A.3.1.4
60079-0_4:2004 4th ed.(ver 4a)
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Page 16 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-0
Clause
A.3.2.1
A.3.2.1.1
A.3.2.1.2
A.3.2.2
A.3.3
A.3.4
A.3.5
A.4
Requirement – Test
Result – Remark
Excluded per Table 1 of IEC 60079Tests of clamping where
11:2006
the armourings are
clamped by a device within
the gland
Excluded per Table 1 of IEC 60079Tensile test
11:2006
Excluded per Table 1 of IEC 60079Mechanical strength
11:2006
Excluded per Table 1 of IEC 60079Tests of clamping where
11:2006
the armourings are not
clamped by a device within
the gland
Excluded per Table 1 of IEC 60079Ageing test for material
11:2006
used for elastomeric
sealing rings
Type test for resistance to Excluded per Table 1 of IEC 6007911:2006
impact
Excluded per Table 1 of IEC 60079Type test for degree of
11:2006
protection (IP) of cable
entries
Verdict
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Marking
A.4.1
Marking of cable entries
Excluded per Table 1 of IEC 6007911:2006.
A.4.2
Marking of cable sealing
rings
Excluded per Table 1 of IEC 6007911:2006.
Annex B
Table B.1 – Clauses with which Ex components shall comply
(Normative)
60079-0_4:2004 4th ed.(ver 4a)
N/A
N/A
N/A
Page 17 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Checklist
ExTR60079-11_Ed.5_Version1A
Page 18 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
1
SCOPE
2
NORMATIVE REFERENCES
3
DEFINITIONS
4
GROUPING AND CLASSIFICATION
5
LEVELS OF PROTECTION AND IGNITION COMPLIANCE
5.1
General
5.2, 5.3,
5.4
Level of protection
The equipment was examined and
tested according to the requirements
for level of protection “ia”.
5.5
Spark ignition compliance
Based on the design, no interruptions
Pass
or interconnections will occur. Where
interruptions or interconnections may
occur, the limitation of the spark energy
was assessed in accordance with 10.1.
5.6
Thermal ignition compliance
5.6.1
General
Temperatures were, as far as required, Pass
assessed after application of faults as
provided in 5.2, 5.3 and 5.4. In several
cases, measurement according to 10.2
was carried out.
5.6.2
Temperature for small
components
The exception for small components
was not applied.
N/A
5.6.3
Wiring within apparatus
The internal wiring complies with the
requirements of Table 3.
Pass
5.6.4
Tracks on printed circuit
boards
The temperature classification of tracks Pass
which are made of copper complies
with the requirements of Table 4.
ExTR60079-11_Ed.5_Version1A
Result – Remark
Verdict
Pass
Page 19 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
Result – Remark
Verdict
5.7
Simple apparatus
The equipment is not a simple
apparatus.
N/A
6
APPARATUS CONSTRUCTION
6.1
Enclosures
6.1.1
Apparatus complying with
Table 5
6.1.2
Apparatus complying with
Annex F
6.2
Facilities for connection of
external circuits
6.2.1
Terminals
6.2.2
Plugs and sockets
6.2.3
Determination of maximum
external inductance to
resistance ratio (Lo/Ro) for
resistance limited power
source
The determination of maximum
N/A
external inductance to resistance is not
relevant, because there are no external
circuits to be connected.
6.2.4
Permanently connected
cable
No integral cable for external
connections.
N/A
6.3
Separation distances
6.3.1
Separation of conductive
parts
As far as applicable, requirements
according to 6.3.1 fulfilled.
Pass
6.3.1.1
Distances according to Table The spacings comply with Table 5, no
fault conditions applicable. See
5
attached table and drawing.
Distances according to
Annex F was not applied.
Annex F
Pass
6.3.2
Voltage between conductive
parts
Pass
6.3.3
Clearance
Requirements of 6.3.2, as far as
applicable, are fulfilled.
No insulating partitions with more
than 0,9 mm thickness or conforming
with 10.6.3, present.
6.3.4
Separation distances
through casting compound
No casting compound present.
N/A
6.3.1.2
ExTR60079-11_Ed.5_Version1A
As far as applicable, requirements of
Pass
6.1 are fulfilled.
The equipment complies with Table 5
Pass
and provides an enclosure protection
of IP20 or higher. Drop test is required,
because apparatus is handheld
Annex F was not applied.
N/A
The equipment has no terminals for
non-intrinsically safe circuits.
No plugs or sockets.
N/A
N/A
N/A
N/A
Page 20 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
Result – Remark
Verdict
6.3.5
Separation distances
through solid insulation
Pass
6.3.6
Composite separations
Separation distance is in accordance
with Table 5. Solid insulation has a
dielectric strength that conforms to
6.3.12.
No composite separations.
6.3.7
Creepage distance
6.3.8
Distance under coating
N/A
Creepage distance complies with Table Pass
5 and was measured according Figure
3. CTI-value is not required, because
voltages are lower 10V.
6.3.10
Conformal coating is used. Compliance Pass
with Table 5.
Requirements for assembled Creepage and clearance distances
Pass
affect
the
intrinsic
safety
of
the
printed circuit boards
apparatus. The printed circuit conforms
to the requirements of 6.3.8 and
applies to the circuits or parts of
circuits and their fixed components as
their coating covers the connecting
pins, solder joints and the conductive
parts of the components.
Separation by earth screens No separation by earth screen.
N/A
6.3.11
Internal wiring
6.3.12
Dielectric strength
requirement
6.3.13
Relays
Minimum thickness of the insulation of Pass
the internal wiring is according to Table
5.
Enclosure has no exposed electrical
N/A
components and operates at less than
10 volts dc. Tests not performed.
No relays used
N/A
6.4
Protection Against Polarity
Reversal
No invalidation of the type of protection Pass
as a result of reversal polarity.
6.5
Earth conductors,
connections and terminals
No earthing present with the aid of
plug-in connectors
6.3.9
ExTR60079-11_Ed.5_Version1A
N/A
Page 21 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
Result – Remark
6.6
Encapsulation
Casting compound is used and
Pass
conforms to the following:
The temperature rating, specified by
the manufacturer of the casting
compound or apparatus, is
/ Compound is adherent to all
conductive parts, components and
substrates except when they are totally
enclosed by the casting compound.
/ The compound is specified by its
generic name and type designation
given by the manufacturer of the
casting compound.
/ All circuits connected to the
encapsulated conductive parts and/or
components and/or bare parts
protruding from the casting compound
are intrinsically safe. Fault conditions
within the casting compound were
assessed.
/ The casting compound is free of
voids.
7
COMPONENTS ON WHICH INTRINSIC SAFETY DEPENDS
7.1
Rating of components
The protection level is ia. The
Pass
components on which intrinsic safety
depends have the maximum values of
2/3 of its nominal rating in normal
operating and also according clause 5,
in fault conditions.
7.2
Connectors for internal
connections, plug-in cards
and components
The connectors are designed in such a Pass
manner that an incorrect connection
with other connectors in the same
electrical apparatus is not possible.
The connectors are constructed
according clause 6.5.
7.3
Fuses
Technical data that meets the
requirements of the standard is
provided by the manufacturer.
7.4
Primary and secondary cells Three primary batteries in series or 1
and batteries
secondary battery is used
ExTR60079-11_Ed.5_Version1A
Verdict
Pass
Pass
Page 22 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
Result – Remark
Verdict
7.4.1
General
The cell/battery conforms to 5.2
Pass
7.4.2
Electrolyte leakage and
ventilation
The cell/battery is charged within the
apparatus. The requirements of
protection level ia and of IIC are
fulfilled.
Pass
7.4.3
Cell voltages
The battery voltage is 4.5 nominal
according to EN 60079-0, Table 6 and
Table 7.
Pass
7.4.4
Internal resistance of cell or
battery
The internal resistance of the batteries
was not required for testing or
evaluation
N/A
7.4.5
Batteries in apparatus
protected by other means of
protection
7.4.6
Batteries used and replaced
in explosive gas
atmospheres
7.4.7
Batteries used but not
replaced in explosive gas
atmospheres
External contacts for
charging batteries
The battery is protected by
Pass
encapsulated fuses and infallible
current limiting resistors
The battery unit is enclosed so that
Pass
only the intrinsically safe output
terminal and suitably protected
intrinsically safe terminal for charging
purposes is exposed. The unit was
tested according clause 26.4.3 of
60079-0. The test results showed the
batteries were not ejected.
The current-limiting device is protected Pass
according 7.4.7.
7.4.8
7.4.9
Battery construction
7.5
Semiconductors
7.5.1
For the prevention of short-circuiting
Pass
and delivering ignition-capable energy
to the contacts the following type of
protection is provided: infallible current
limiting resistors and series fuses
The primary batteries are series
Pass
alkaline type and the secondary battery
is a lithium-ion type tested according
clause 10.5.3. See test results
The conformity is given by visual
examination of the batteries.
Transient effects
Transient effects in intrinsically safe
equipment are ignored.
N/A
Pass
Shunt voltage limiters
Zener diodes are used in the charger
circuit and comply with the
requirements of clause 7.5.2
7.5.2
ExTR60079-11_Ed.5_Version1A
Page 23 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
Result – Remark
Verdict
7.5.3
Series current limiters
Series current limiters are used inside
the battery packs and comply with the
requirements of clause 7.5.3
Pass
7.6
/ For the components that are not rated Pass
Failure of components,
connections and separations in accordance with 7.1, its failures are
considered as non-countable fault.
/ Components are rated in accordance
with 7.1, its failures are countable fault.
Subsequent fault or faults are
considered.
/ Failure of resistors to any value of
resistance between open circuit and
short circuit are taken into account for
the resistors that are not in
correspondence with 8.4.
/ Semiconductor devices are
considered to fail to short circuit or to
open circuit and to the state to which
they can be driven by failure of other
components.
The considerations concerning surface
temperatures, failure assumptions for
integrated circuits and voltages on
external pins of integrated circuits and
voltage converters are respected.
/Failure assumptions for connections
and free-move connections were
respected.
Clearances, creepage and separation
distances were taken into account in
accordance with 6.3.
Failure of capacitors to open-circuit,
short-circuit and any value less than
the maximum specified value were
taken into account if not in accordance
with 8.
/ No inductances present.
/ no open circuit failure of wire or
printed circuit is not safety relevant.
7.7
Piezo-electric
Piezo-electric devices are in
accordance with 10.7,
7.8
Electrochemical cells for the
detection of gases
Addition to voltages and currents which Pass
may effect spark ignition were
considered.
ExTR60079-11_Ed.5_Version1A
Pass
Page 24 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
Result – Remark
8
INFALLIBLE COMPONENTS, INFALLIBLE ASSEMBLIES OF COMPONENTS
AND INFALLIBLE CONNECTIONS ON WHICH INTRINSIC SAFETY
DEPENDS
8.1
Mains transformers
8.1.1
Protective measures
8.1.2
Verdict
N/A
Transformer construction
No mains transformers present.
No mains transformers intended for
supplying intrinsically safe circuits
present.
No transformers present.
8.1.3
Transformer type tests
No transformer present.
N/A
8.1.4
Routine test of mains
transformers
No transformer present.
N/A
8.2
Transformers other than
mains transformers
No transformer present.
N/A
8.3
Infallible windings
No damping windings present.
N/A
8.3.1
Damping windings
No damping windings present.
N/A
8.3.2
Inductors made by insulated
conductors
No inductors present.
N/A
8.4
Current-limiting resistors
Current-limiting resistors are printed
resistors as used in hybrid and similar
circuits covered by a coating
conforming to 6.3.8 or encapsulated in
accordance with 6.3.4. Requirements
of 8.4 concerning voltage and power
are respected.
Pass
8.5
Blocking capacitors
No blocking capacitors present
N/A
8.6
Shunt safety assemblies
No shunt safety assembly used.
N/A
8.6.1
General
No shunt safety assembly used.
N/A
8.6.2
Safety shunts
No shunt safety assembly used.
N/A
8.6.3
Shunt voltage limiters
No shunt safety assembly used.
N/A
8.7
Wiring, printed circuit board
tracks, and connections
Open circuit failure is not safety
relevant.
N/A
ExTR60079-11_Ed.5_Version1A
N/A
N/A
Page 25 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
Result – Remark
8.8
Galvanically separating
components
No galvanically separating components N/A
present.
8.8.1
General
N/A
8.8.2
Isolating components
between intrinsically safe
and non-intrinsically safe
circuits
No infallible isolating components
present.
No infallible isolating components
present
8.8.3
Isolating components
between separate
intrinsically safe circuits
No infallible isolating components
present.
N/A
9
DIODE SAFETY BARRIERS
9.1
General
No diode safety barrier present.
N/A
9.2
Construction
No diode safety barrier present.
N/A
9.2.1
Mounting
N/A
9.2.2
Facilities for connection to
earth
No diode safety barrier present.
No diode safety barrier present.
9.2.3
Protection of components
No diode safety barrier present.
N/A
10
TYPE VERIFICATIONS AND TYPE TESTS
10.1
Spark ignition test
10.1.1
10.1.2
10.1.3,
10.1.3.1,
10.1.3.2
Test with spark test apparatus was not
carried out. Safety was deduced from
the reference curves, Figures A.1 to
A.6 or Tables A.1 and A.2, by the
methods described in Annex A.
General
Refer to Appendix A.2 for details.
Test with spark test apparatus was not
Spark test apparatus
carried out. Safety was deduced from
the reference curves, Figures A.1 to
A.6 or Tables A.1 and A.2, by the
methods described in Annex A.
Test gas mixtures and spark Test with spark test apparatus was not
test apparatus calibration
carried out. Safety was deduced from
current
the reference curves, Figures A.1 to
A.6 or Tables A.1 and A.2, by the
methods described in Annex A.
ExTR60079-11_Ed.5_Version1A
Verdict
N/A
N/A
Pass
N/A
N/A
Page 26 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
Result – Remark
Verdict
10.1.4,
10.1.4.1,
10.1.4.2
Tests with the spark test
apparatus – circuit test,
safety factors
Test with spark test apparatus was not
carried out. Safety was deduced from
the reference curves, Figures A.1 to
A.6 or Tables A.1 and A.2, by the
methods described in Annex A.
N/A
10.1.5
Testing considerations
10.1.5.1
General
Application of curves A.1 to A.6 with
most onerous condition.
Circuits with both inductance Circuit does not contain energy stored
in both capacitance and inductance.
and capacitance
Pass
10.1.5.3
Circuits using shunt shortcircuit (crowbar) protection
No crowbar used.
N/A
10.1.5.4
Results of spark test
No test with spark test apparatus.
Application of curves A.1 to A.6
N/A
10.2
Temperature tests
Temperature tests in accordance with
10.2 and 60079-0 were successfully
carried out.
Pass
10.3
Dielectric strength tests
No dielectric strength tests performed.
Device is battery operated at less than
10 volts.
N/A
10.4
Determination of parameters No loosely specified components
of loosely specified
present.
components
10.5
Tests for cells and batteries
10.5.1
General
Batteries were prepared as described
in 10.5.1.
10.5.2
Electrolyte leakage test for
cells and batteries
10.5.3a
Spark ignition of cells and
batteries
Leakage test was successfully carried Pass
out as described in 10.5.2 according to
point (a)
Batteries have an open-circuit voltage N/A
of less than 4,5 V, and the product of
the maximum voltage and transient
current at the cell terminals exceeds 33
W. Battery terminals and control
circuitry are encapsulated so spark test
not required as per clause 6.6 2nd
paragraph
10.1.5.2
ExTR60079-11_Ed.5_Version1A
Pass
N/A
Pass
Page 27 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
10.5.3b
Surface temperature of cells Surface temperature was tested as
described in 10.5.3 b) with 10 samples
and batteries
having the internal current-limiting
devices and 10 samples without the
internal current limiting devices.
Batteries do not contain vents
Battery container pressure
tests
10.5.4
Result – Remark
Verdict
Pass
N/A
10.6
Mechanical tests
10.6.1
Casting compound
No compound present.
10.6.2
Sealing of components
before encapsulation
Encapsulation cannot enter the interior Pass
of the component and affect safety.
10.6.3
Partitions
No partitions present.
10.7
Tests for apparatus
containing piezoelectric
devices
Piezoelectric devices is not accessible. N/A
10.8
Type tests for diode safety
barriers and safety shunts
No diode safety barriers or safety
shunts present.
N/A
10.9
Cable pull test
No cables present.
N/A
10.10
Transformer tests
No transformers present.
N/A
11
ROUTINE VERIFICATIONS AND TESTS
11.1
Routine tests for diode
safety barriers
No diode safety barrier present
N/A
11.1.1
Completed barriers
No diode safety barrier present.
N/A
11.1.2
Diodes for 2-diode “ia”
barriers
No diode safety barrier present.
N/A
11.2
Routine tests for infallible
transformers
No infallible transformer present.
N/A
12
MARKING
ExTR60079-11_Ed.5_Version1A
N/A
N/A
Page 28 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
Result – Remark
12.1
General
Apparatus/associated apparatus
Pass
carries marking specified in IEC 600790.
/The text of the warning markings is
derived from 29.8 of 60079-0.
12.2
Marking of connection
facilities
No connection facility present
N/A
12.3
Warning markings
Corresponding warning markings
Pass
12.4
Examples of marking
13
DOCUMENTATION
ANNEX
A
ASSESSMENT OF INTRINSICALLY SAFE CIRCUITS (NORMATIVE)
ANNEX
B
SPARK TEST APPARATUS FOR INTRINSICALLY SAFE CIRCUITS
(NORMATIVE)
ANNEX
C
MEASUREMENT OF CREEPAGE DISTANCE, CLEARANCES AND
SEPARATION DISTANCES THROUGH CASTING COMPOUND AND
THROUGH SOLID INSULATION (INFORMATIVE)
ANNEX
D
ENCAPSULATION (INFORMATIVE)
/ WARNING – USE ONLY YYYYY BATTERIES
/ WARNING – DO NOT REPLACE BATTERY
WHEN AN EXPLOSIVE GAS ATMOSPHERE
MAY BE PRESENT
/ WARNING – DO NOT CHARGE THE BATTERY
IN HAZARDOUS LOCATION
The documentation includes the
instructions required by Clause 30 of
IEC 60079-0, and includes information
for charging, maintenance and use
ANNEX ENCAPSULATION (INFORMATIVE)
E
ExTR60079-11_Ed.5_Version1A
Verdict
Pass
Page 29 of 107
Report No. CA/QPS/ExTR08.0002/00
IEC 60079-11
Clause
Requirement – Test
ANNEX
F
ALTERNATIVE SEPARATION DISTANCES FOR ASSEMBLED PRINTED
CIRCUIT BOARDS AND SEPARATION OF COMPONENTS (NORMATIVE)
F.1
General
Annex F is not used.
N/A
F.2
Control of pollution access
Annex F is not used.
N/A
F.3
Distances for printed circuit
boards and separation of
components
Annex F is not used.
N/A
F.3.1
Level of protection “ia” and
“ib”
Annex F is not used.
N/A
F.3.2
Level of protection “ic”
Annex F is not used.
N/A
ExTR60079-11_Ed.5_Version1A
Result – Remark
Verdict
National Differences (Australia)
Based on IECEx Bulletin v3.1, there are no National Differences for Australia
Descriptive Report and Tests
Report No. CA/QPS/ExTR08.0002/00
Page 32 of 107
Issue Date: Nov. 17, 2008
SCOPE
This Report extends the approval of equipment previously evaluated to the requirements of
UL913(6th ed) to the requirements of IEC60079-0(4th ed) and 60079-11(5th ed) for use in Zone 1
hazardous locations .
PRODUCT APPROVED
Multiple Gas Detector, Model PhD6
This is a battery operated, portable, hand-held gas detector designed to measure Combustible Gas,
Oxygen and up to three types of Toxic gases with one unit. This unit is Intrinsically Safe for use in
Zone 1 hazardous areas when used with Battery Pack 54-54-106 or 54-54-107, or the Pump
Assembly 54-54-102 but has not been performance certified.
Battery Charger/Docking Station, Model 54-54-103-X
The battery charger assembly (including the ac adaptor) is intended for use with the PhD6 / LithiumIon battery pack 54-54-107 combination and rated for use in non-hazardous areas only.
Battery Charger/Docking Station PhD6 IQ6, Model 54-54-9000
This battery charger / docking station (including the ac adaptor) is intended for use with the PhD6
and either Battery Pack. It provides a data interface between the PhD6 and a PC or laptop computer
in order to download PhD6 readings and to provide various calibration and other data transfers.
When the Lithium-Ion Battery Pack 54-54-107 is used in the PhD6, the IQ6 also acts as a charger.
This device is rated for use in non-hazardous areas only
Battery Packs, Models 54-54-106 and 54-54-107
54-54-107 is a Lithium-Ion battery pack, and 54-54-106 is a non-rechargeable alkaline battery pack
for use with three Energizer E91, EN91, or Duracell MN1500 or MX1500 AA batteries. They are
intrinsically safe when used with the PhD6.
Pump Assembly, Model 54-54-102
This is a PhD6 add-on accessory, intrinsically safe when used with the PhD6.
RATINGS
PhD6 Gas Detector – nominally 4Vdc, Intrinsically Safe for use in Zone 1 rated 170C (T3) in -20C
to +50C ambient .
Pump Assembly – same rating as PhD6 when used with the PhD6
Battery Packs – Intrinsically safe when used with the PhD6
Battery Charger – Associated Equipment - non-hazardous areas only. Input 9 Vdc, 1000 mA
IQ6 Dock – Associated Equipment – non-hazardous areas only. Input 9Vdc, 500 mA
A.C. Adaptor – intended for used with either the Battery Charger or the IQ6 Dock – 120 Vac 20
watts nominal
Report No. CA/QPS/ExTR08.0002/00
Page 33 of 107
Issue Date: Nov. 17, 2008
APPLICABLE STANDARDS
The device was tested and evaluated to IEC60079-0 (4th edition) : Electrical apparatus for
explosive gas atmospheres and IEC60079-11 (5th edition) : Equipment protection by intrinsic
safety “i”
MODIFICATIONS REQUIRED
Upon examination of the subject product, the modifications listed below were required to bring the
product into compliance with the applicable standard and have been incorporated into the labelled
product.
The following markings shall be added to existing markings:
MARKINGS
Markings on the Equipment: The Charger, PhD6 and Battery Packs are plainly marked in a
permanent manner as follows:
Charger/Docks:
 the SGS approval mark;
 Manufacturer’s name or trademark;
 model designation;
 date code/serial number;
 complete electrical ratings
PhD6:
 The
symbol;
 The
mark;
 Manufacturer’s name or trademark; Sperian Protection
 model designation; PhD6
 date code/serial number;
 hazardous location designation and ratings; II 2 G Ex d ia II 170C (T3)
 Ambient Range; -20C to +50C
 Identification of the Battery Packs that may be used; 54-54-106 or 54-54-107
 Identification of the Charger that may be used; 54-54-103 or 54-54-9000
 Warning: To reduce the risk of Explosion, battery packs must be charged or replaced
only in an area known to be non-hazardous
 Warning : Substitution of components may impair intrinsic safety
Battery Packs:
 Manufacturer’s name or trademark;
 model designation;
 date code/serial number;
 Alkaline Pack - Warning: Use only E91, EN91, MX1500 or MN1500 type batteries. Do
not mix types or old and new batteries (this label may be affixed to the alkaline
battery pack and visible only after the battery pack has been removed from the PhD6)
Report No. CA/QPS/ExTR08.0002/00
Page 34 of 107
Issue Date: Nov. 17, 2008
 Rechargeable Pack – Warning: Rechargeable battery not user replaceable (or
equivalent)
CONDITIONS OF ACCEPTABILITY/CERTIFICATION





The product has been altered to include the required modifications outlined above.
The approved construction of the labelled product is as described below in this report.
Certification is voided if the labeled product has been modified or changed by the
manufacturer or end user after labeling, unless the changes have been reviewed and
approved in writing by QPS. Verbal approval is not permitted.
Certification covers safety from electric shock and fire/explosion hazards only and apply
only to the construction elements described in this report.
QPS did not evaluate the performance characteristics of the equipment.
DESCRIPTION of Major Components
Housing:
Moulded polycarbonate housing (drawing numbers 10-532 and 10-536 provide moulding details)
approximately 80 mm x 170 mm x 45 mm and nominally 5 mm thick, secured with eight screws and
having a removable Battery Pack in the rear. A belt clip allows the detector to be used hands-free.
The Battery Pack is secured with a slotted thumbscrew to prevent inadvertent opening or
disconnection. The front panel features an LCD panel, a Mode switch and two Cursor buttons. In
addition, there are two piezo-alarms to signal at preset levels. The PhD6 is designed with facility for
up to 5 sensors to be installed, as well as a Pump Kit. Charging of the Battery Packs is performed via
a 5-pin connection recessed in the bottom of the unit.
Sensors
Charger Contacts
Charger/Docking Station:
The charger/docking station is comprised of a charger module (54-54-103) that both holds the PhD6
in an upright display position and encloses the charger circuitry (62-701). A separate 120 Vac / 9
Vdc adaptor provides the input power for this charger. This associated equipment is designed to be
used outside the hazardous area and contains the current limiting resistors, fuse and zeners that
charge the battery. Tests and evaluations demonstrate that this station is capable of protecting the
handheld unit from any ac line faults. Consequently, the ac adaptor used as input to this station does
Report No. CA/QPS/ExTR08.0002/00
Page 35 of 107
Issue Date: Nov. 17, 2008
not need to be specified, although it must be approved and be rated as 9 Vdc with minimum 1000
mA output with a centre positive mini-plug.
Charging Pins
Charge/Power LEDs
IQ6 Dock:
This charger/docking station 54-54-9000 functions as a data link between the PhD6 and a PC or
laptop computer. This provides a way to collect readings and to update PhD6 software, calibrate the
device and charge Lithium-Ion battery packs. The charging circuitry is identical to the 62-701 used
on the 54-54-103 charger described above, but has additional circuitry to handle the computer
interface. This circuitry is considered to have no significant impact or effect on the 62-701
evaluation.
Power Adaptors
120 Vac / 9V dc - Approved device, rated 1000 mA minimum as shown in the Bills of Material, or
equivalent. Since this is not a critical component of the system, it is not necessary to control it. It is
therefore considered acceptable to use alternate vendors supplying equivalent devices.
12 Vdc / 9V dc – car adaptor. This device is not required to comply with standards as it is designed
to be used in a 12 volt car system. Rated 9Vdc and 1000 mA minimum.
Report No. CA/QPS/ExTR08.0002/00
Page 36 of 107
Issue Date: Nov. 17, 2008
Current Limiting Resistors
There are two sets of current limiting resistors; one is in the charger circuit located in the associated
equipment; while another set is located inside the battery pack. The charger circuit is used with the
rechargeable Li-Ion battery pack only and is designed to limit the current before it leaves the
associated equipment. R9 is a 5W wire-wound resistor rated 3.1 ohms. (see BoM 35-0772 and
schematic 62-701)
The Battery packs include circuits that limit the battery output current to safe levels before it leaves
the battery packs themselves. R1, R2 (1 ohm), and R3, R4 (3 ohm) as shown in schematics 62-698
and 62-699 are SMT type ceramic resistors which fail in the open mode and are considered
infallible.
Evaluations show that they all operate within 2/3 of their ratings.
Fuses
The fuses F1, F2 and F3 used in the charger and the battery packs referenced above are Littelfuse
SMD types rated 0.25 and 0.125 amps, and open within 5 seconds at 200% of the fuse ratings. The
50 amp maximum rating on these fuses is almost 10 times the maximum current available from the
batteries through the smallest resistor of 1 ohm. These fuses are encapsulated as shown below.
Zener Diodes
The protective zener diodes are located on the charger board as shown in 62-701 and are configured
in three strings of two diodes to provide the necessary redundancy. As shown in BoM 35-0772, these
are 3.3 volt 5 watt devices that operate within 2/3 of their ratings. (see Test # 8)
Battery Pack – Alkaline
The Battery Pack (54-54-106) is designed with a captive thumb screw to secure it to the PhD6 unit,
and intended to be replaced only in a non-hazardous area. See label information. The Pack itself
consists of a plastic body with a removable circuit board held in place by two screws and containing
the battery protection circuitry. Each Battery Pack is designed to hold 3 batteries. Contacts on the
circuit board mate with appropriate pins on the PhD6 Main Board. While alkaline batteries provide
for a convenient method of powering the PhD6, the various types and models of AA batteries have
such a wide range of capacities and discharge characteristics that each type must be evaluated for
suitability. The batteries listed in the Bills of Material are the only ones that have been evaluated and
are the only ones that may be used in the PhD6. The protective circuitry (62-698) contains the
current limiting resistors and fuses in an encapsulated section of the circuit board. The batteries are
physically constrained inside the Battery Pack to prevent them from losing contact with the terminal
springs. The circuit board contains two captive locking screws for attaching the board to the housing.
Report No. CA/QPS/ExTR08.0002/00
Locking Screws
Main Board Interface Contacts
Page 37 of 107
Encapsulated Circuitry
including Fuses
Issue Date: Nov. 17, 2008
Belt Clip
Battery Pack
Locking Screw
Battery Pack – Li-Ion:
The Lithium-Ion Battery Pack (54-54-107) is not intended to be user serviced but must be returned
to the manufacturer for replacement. These Packs include only one Panasonic Li-Ion battery along
with the battery protective circuitry (62-699). This contains the current limiting resistors and the
fuses that power the main board, as well as the steering/blocking diodes that form part of the
charging circuit. This battery pack has the same dimensions and contact arrangement as the Alkaline
Battery Pack to allow users the flexibility of using either type. The battery is soldered to the circuit
board to ensure a permanent connection.
Encapsulated Fuses &
Circuitry
Report No. CA/QPS/ExTR08.0002/00
Page 38 of 107
Issue Date: Nov. 17, 2008
Li-Ion Battery:
The rechargeable battery is a UL 1642 (4th edition) approved Panasonic CGR18650D or
CGR18650DA battery rated 4.3 V, 4700 mA and covered under UL’s file MH12210 (revised in
2006). This battery has both an internal PTC as well as an external protection module (SK-7210) as
shown in Fig.2. This circuit protects the battery from over-charging, deep discharging, overcurrent
and short circuits. This circuit is typically included inside the battery shrink-wrap and is normally an
un-coated board. For this application, Sperian has added an epoxy encapsulant (3M Scotch-Weld
DP-100 (NS) two-part epoxy) around the board so as to ensure that all the copper traces are coated
and thereby reduce the creepage requirements from 1.5 to 0.5 mm. The positive end of the battery is
encapsulated as shown in Fig. 12. Fig. 13 is a Critical / Control Drawing detailing the encapsulation
requirements. The typical spacing between the battery electrodes is less than 0.5 mm, and by
encapsulating this spacing to a minimum of 1 mm, the requirement to perform spark testing is
removed.
Li-Ion battery
Encapsulant
Protection Module Circuit
Sensors:
The various sensors are located just inside appropriate openings in the main housing and may be
operated either in free air or with the addition of a Pump Manifold. Sensors are used to detect carbon
monoxide, hydrogen sulphide, sulphur dioxide, oxygen, and combustible gas.
The combustible gas sensor, Model 4P-75 CiTipel is a CSA C22.2 No.30 and UL913 approved
device rated 82 mA maximum at 3 Vdc. The alternate model is a Dynament Model MSH-P-HC, UL
approved to Class I, T4 in a 60C ambient.
ATEX marked as
II 2 G EEx d IIC, IECEx Cerificate rated Ex d I and/or Ex d IIC. These sensors
are designed with and include integral flame arrestors
The other gas sensors are rated at less than 1 mA at the maximum ppm range.
These sensors are all considered to be acceptable for this application.
Report No. CA/QPS/ExTR08.0002/00
Page 39 of 107
Issue Date: Nov. 17, 2008
Display Board and
LCD panel
Housing shown in
alternate color version
for clarity
Piezo-electric alarms
Sensor pockets
Sensor cover
Recessed Alarm
Openings
Gas Sensor Manifold
Pump Outlet
Gasket with cutouts for
gas
Electrical Contact Pins
PhD6 housing with Gas sensor
manifold attached
Housing
Manifold
Securing Screw
Manifold Inlet
Recessed Electrical Contacts
Report No. CA/QPS/ExTR08.0002/00
Page 40 of 107
Issue Date: Nov. 17, 2008
Small Components:
Unless otherwise noted, all capacitors and resistors are of the SMT type manufactured as a metal
glaze on a ceramic substrate and protected by a protective over-glaze.
Piezoelectric Alarms:
Two piezoelectric alarms are utilized to indicate limit levels. These devices have the ability to
convert electricity to mechanical change (elongation/contraction) or convert mechanical
compression / expansion into generated voltage. As alarms, they react to electrical signals and
vibrate. However, since an impact could cause compression and electrical impulses, consideration
must be given to the possibility that an impact could generate hazardous energy levels. Evaluation
showed that the alarms were situated inside the enclosure in such a manner that they could not be
impacted directly, rendering them not capable of generating any voltage.
Pump (54-54-102):
This is a remotely connected device that forces the sample air/gas into the manifold for analysis by
all of the on-board sensors. Refer to BoM 35-0770. Since the pump motor is an inductor, it must be
evaluated for energy storage and spark ignition to ensure the energy stored is less than the allowed
50 uJ. The Test section shows that the maximum energy stored was less than 31 uJ and is therefore
considered acceptable.
Exposed Electrical Contacts:
As seen in the pictures above, there are five contact points on the bottom of the PhD6 that is
duplicated on the base of the pump housing. Since the unit may be placed on a table or other flat
metal surface, this must be evaluated for the consequences of shorting. Examination shows that both
sets are recessed so that they can not be shorted by placing the device on a flat metal surface. Refer
to the tests.
Associated Equipment:
While the charger/detector combination is never used in a hazardous area, the possibility of a supply
voltage fault of Umax creating domino effect damage in the gas detector must be considered and
evaluated. Refer to the test section below.
Spacings and Clearances:
All spacings, creepages and clearances on circuit boards and connectors were verified and compared
to the requirements. Where the measured values were less than those specified, they were considered
to be fallible, and used in the fault analysis. If the value was less than 1/3 of the requirement, it was
used as a non-countable fault, and if greater than 1/3 then it was a countable fault.
The contacts located on the bottom of the main housing and the pump housing are recessed so that
they can not be shorted by placing the device on a flat metal surface.
The battery pack termination pins and circuit board pads had minimum spacings of 3.6 mm where
1.5 mm were required and are considered infallible.
Report No. CA/QPS/ExTR08.0002/00
Page 41 of 107
Issue Date: Nov. 17, 2008
Circuit Boards:
All circuit boards are solder masked and conformal coated so that the required creepage spacings are
reduced to 0.5 mm. All pcbs are securely fastened to their enclosures and there is no flexing or
bending during use.
Critical Components:
Certain components are considered critical to maintaining intrinsic safety and shall not be changed,
replaced or omitted. See Critical Components Table and Critical Drawings below. These drawings
form part of the Certification but are not attached to this report. They are on file at SGS.
Bill of Material
The Bill of Material shown below provides details of major components of the PhD6
Drawings and Figures:
The List of Figures shown below lists those drawings or items considered relevant to this approval
Tests :
Refer to the Table of Tests for details of Fault Analysis and intrinsic safety test details and results. In
general, the battery charging and battery protection circuits were considered as prime candidates for
evaluation, followed by energy storage devices. The premise was that if the battery protection
circuits were found to provide the required intrinsic safety, any components downstream would tend
to be safe as long as they did not store or generate energy. The tests and evaluations demonstrated
that this equipment met the requirements of the relevant standards.
The tests listed in this section were the only ones considered necessary for this equipment.
T-Code Review and Evaluation
Under normal operating conditions, the current in the PhD6 is lower than the fuse rating of 0.25
amps. However, due to uncontrolled spacing between the battery case and the terminal of opposite
polarity, batteries can be shorted between their terminals. This is generally the case with batteries as
they are typically not designed to be intrinsically safe. Li-Ion batteries are designed with both
internal and external current limiting circuits. Tests show that the highest battery surface
temperatures occurred on Li-Ion batteries with the internal PTC bypassed. Special samples, modified
by the battery manufacturer, were used for these tests. The maximum surface temperature was
measured to be 157.6C in a 40C ambient. At the applicant’s maximum ambient of 50C, the surface
temperature would be prorated as 167.6C, and setting the Temperature Code to T3.
Report No. CA/QPS/ExTR08.0002/00
Page 42 of 107
Issue Date: Nov. 17, 2008
Critical Components Table
Component
Manufacturer
Mfg P/N
Technical Description
(Customer P/N)
SK-7210
Ratings
(electrical/other)
Agency Approval
Panasonic
CGR18650D or
CGR18650DA
Li-Ion Battery c/w encapsulated battery
protector circuit
4.3 V 4700 mAh
3M Scotch-Weld
DP-100 NS
Two-part epoxy used to encapsulate the
battery protector circuit
1100 volts/mil
N/A
14
2.2 x 10 ohm-cm
Duracell
MN1500
Alkaline Battery
1.5 V 2800 mAh
N/A
Duracell
MX1500
Alkaline Battery
1.5 V 2800 mAh
N/A
Energizer
EN91
Alkaline Battery
1.5 V 2800 mAh
N/A
Energizer
E91
Alkaline Battery
1.5 V 2800 mAh
N/A
Sperian
T Squared
Li-Ion Battery Protection Module
Maxxon
03.08.019c
UL 1604
Accepted by QPS
as a component –
info on file
Pump
Class I Grps
ABCD
CE mark. UL
tested as
component – info
on file
CITY Technology 4P-75 CiTipel
Combustible Sensor element
Class I Grps
ABCD
CSA N0. 30 and
UL 913
Dynament
MSH-P-HC
Combustible Sensor element – InfraRed Gas Class I, Grps
UL, ATEX
Sensor
ABCD, T4 in 60C
Dynament
MSH-P-CO2
CO2 sensor
Class I, Grps
UL ATEX
ABCD, T4 in 60C
Report No. CA/QPS/ExTR08.0002/00
Issue Date: Nov. 17, 2008
Page 43 of 107
Critical Drawings
Description
Drawing No.
Rev Level
Date
Main Board
03-349b
B0
Undated
Alkaline Board
03-352b
B0
Nov 7 / 2007
Charger Board
03-353b
B0
Undated
Rechargeable Board
03-355b
B0
Nov. 7 / 2007
Intrinsic Safety Concepts
62-691
A0
Mar 7 / 2007
62-697-DESC
B0
June 27 / 2007
Alkaline Battery Pack
62-698
A0
Jan 17 / 2007
Rechargeable Battery Pack
62-699
A1
Oct 17 / 2007
Pump
62-700
A0
June 29 / 2007
Charger
62-701
A0
Jan 17 / 2007
IQ6 Charger
62-937
B0
Nov. 8 / 2007
Lithium-Ion Battery Encapsulation
49-033
A1
Jan 22 / 2007
Sensor Interface
List of Figures
Drawing No.
Description
Rev Level
Date
~
~
Fig. 1
PhD6 Block Diagram
Fig. 2
Block Diagram Components
Fig. 3
SK-7210 Battery Protection Module
Fig. 4
Main Label #LBL-PHD6
A0
June 22 / 2007
Fig. 5
Charger Label #LBL-PHD6-CHGR
A0
May 14, 2008
Fig. 6
IQ6 Label #LBL-IQ6-DOCK
A0
May 14, 2008
Report No. CA/QPS/ExTR08.0002/00
Issue Date: Nov. 17, 2008
Page 44 of 107
Drawing No.
Description
Rev Level
Date
Fig. 7
Alkaline Pack Internal Label #LBL-PHD6-ALK
A0
Apr 24, 2008
Fig. 8
Alkaline Pack External Label #LBL-PHD6-BAT-A
A0
May 14, 2008
Fig. 9
Rechargeable Pack Label #LBL-PHD6-BAT-N
A0
May 14, 2008
Fig. 10
UL Report on Pump testing
Fig. 11
UL Report on Lithium Cell testing
Fig. 12
Encapsulated Lithium-Ion Battery 49-033
A1
Jan 22, 2007
Fig. 13
Control Drawing for Lithium-Ion battery encapsulation
A1
Jan 22, 2007
Fig. 14
Alkaline Battery Pack Schematic – 62-698
A0
Jan 17, 2007
Fig. 15
Rechargeable Battery Pack Schematic – 62-699
A1
Oct 17, 2007
Fig. 16
Charger – 62-701
A0
Jan 17, 2007
Fig. 17
IQ6 Charger
B0
Nov 8, 2008
Fig. 18
Main Board Schematic – 62-692
0109
Mar 2, 2007
July 12, 1999
Feb 8, 1995
Bills of Material
BoM No.
BoM Drawing
Fig. 19
BOM 35-0759
Fig. 20
Description
Rev Level
Date
Duo-Tox Sensor Board Assembly
A0
3/2/2007
BOM 35-0760
LEL – PID Sensor Board Assembly
A0
3/2/2007
Fig. 21
BOM 35-0761
Main Board Assembly
A0
3/2/2007
Fig. 22
BOM 35-0762
Oxygen Sensor Board Assembly
A0
3/2/2007
Fig. 23
BOM 35-0763
Sensor Interface Board Assembly
A0
3/2/2007
Fig. 24
BOM 35-0764
Toxic Sensor Board Assembly
A0
3/2/2007
Fig. 25
BOM 35-0770
Pump PCB Assembly
A0
3/2/2007
Report No. CA/QPS/ExTR08.0002/00
Issue Date: Nov. 17, 2008
Page 45 of 107
BoM No.
BoM Drawing
Fig. 26
BOM 35-0771
Fig. 27
Rev Level
Date
Alkaline Pack PCB Assembly
A0
3/2/2007
BOM 35-0772
Charger Board Assembly
A0
3/2/2007
Fig. 28
BOM 35-0773
Li-Ion Battery Pack Assembly
A0
3/2/2007
Fig. 29
BOM-35-0854
IQ6 Charger Board Assembly
A0
3/10/2008
Component
Manufacturer
Description
Mfg P/N
Technical Description
Ratings (electrical/other)
(Customer P/N)
54-05-A0204
GlobTek
GT-41052-1509
Ac adaptor – Class 2 Power Supply
100-240 Vac 0.6 A.in : 9 Vdc 1.7 A. out / UL
approved
54-05-A0204
VALE Electronics
48-9-1000D
Ac adaptor – Class 2 Power Supply
120 Vac, 18 W in : 9 Vdc 1 A. out / UL approved
54-05-A0204
Ault Inc
P48091000A300G
Ac adaptor – Class 2 Power Supply
120 Vac, 19W in : 9 Vdc, 1 A. out / UL approved
Report No. CA/QPS/ExTR08.0002/00
Page 46 of 107
Issue Date: Nov. 17, 2008
Table of Tests
Test No
Description
1
Fault Analysis – Alkaline Battery Pack – battery tests
2
Fault Analysis – Alkaline Battery Pack – spark test
3
Fault Analysis – Alkaline Battery Pack – shunt resistor
4
Fault Analysis – Alkaline Battery Pack – max power in R1 and R2
5
Fault Analysis – Alkaline Battery Pack – max power in R3 and R4
6
Fault Analysis – Main board – mass fault on capacitors
7
Fault Analysis – Evaluation of inductor L1
8
Fault Analysis – External Charger evaluation
9
Fault Analysis – Rechargeable Battery Pack – Creepage and spacings
10
Fault Analysis – Rechargeable Battery Pack – Li-Ion thermal evaluation
11
Fault Analysis – Rechargeable Battery Pack – Resistors and fuses
12
Fault Analysis – Piezoelectric evaluation
13
Fault Analysis – battery protection circuit evaluation
14
Fault Analysis – Pump evaluation
15
Drop tests
16
Fault Analysis - Rechargeable Battery Pack – Thermal Tests with and without
PTC
17
Dust-Tightness test
18
Capacitance Test
Report No. CA/QPS/ExTR08.0002/00
Issue Date: Nov. 17, 2008
Page 47 of 107
Sperian PhD6 Gas Detector Block Diagram
120 Vac
adaptor /
dc output
Main Board
Li-Ion Battery Pack
Charger
Safe Area
Hazardous Area
sensor
sensor
Li-Ion Battery Pack
OR
J5
Main Board
J1
sensor
sensor
Alkaline Battery Pack
sensor
J2
External Pump
Fig. 1
Report No. CA/QPS/ExTR08.0002/00
Item
Charger
Li-Ion Battery Pack
Alkaline Battery Pack
Hand-Held
Main Board
LEL Sensor
Duotox Sensor
Oxygen Sensor
Toxic Sensor
Pump
Sensor Interface
Issue Date: Nov. 17, 2008
Page 48 of 107
Part No
BoM
Schematic
PCB
54-54-103
54-54-107
54-54-106
PhD6
35-0772
35-0773
35-0771
62-701
62-699
62-698
62-691
62-692
62-696
62-693
62-695
62-694
62-700
62-697
03-353
03-355
03-352
37-009
35-0761
35-0760
35-0759
35-0762
35-0764
35-0770
03-349
03-347
03-346
03-348
03-345
03-351
* Note: Schematics and pcb drawings form a part of this report but are not included in the attachments. They are on file at SGS and available
upon request.
Part No.
37-009
Description
Manufacturer
MFR Part No.
Pump
T-Squared
Maxon 03.08.019c
LEL Sensor
LEL Sensor
Dynament
City Technology
MSH xxxx
4P-75 CiTipel
Approvals and Ratings
CE – 3 volts, 2 watts
UL 913 – Class I T4 in 60C
ATEX Certificate (SIRA) II 2 G
EEx d IIC
CSA No.30; UL 913 Class I
Fig 2
Test Doc
37-009 Pump Motor Test.pdf
Dynamet MSH Datasheet.pdf
4P-75.pdf
Report No. CA/QPS/ExTR08.0002/00
Page 49 of 107
Fig. 3
Issue Date: Nov. 17, 2008
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Fig. 4
Fig. 5
Issue Date: Nov. 17, 2008
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Fig. 6
Fig. 7
Issue Date: Nov. 17, 2008
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Fig. 8
Fig. 9
Issue Date: Nov. 17, 2008
Report No. CA/QPS/ExTR08.0002/00
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Test record information from UL report E109447 dated 7-12-1999
Fig. 10
Issue Date: Nov. 17, 2008
Report No. CA/QPS/ExTR08.0002/00
Page 56 of 107
Issue Date: Nov. 17, 2008
Information from UL report No MH12210 vol 1 sec 13 Listed models
PRODUCT COVERED:
USR Component - Rechargeable Lithium Ion Cell, Models CGR14500, CGR17500
or RA, CGR17360, CGR17670 or RC, CGR17670A, CGR17670HC, CGR17670HG,
CGR17670HG, CGR18500, CGR18650 or RB, CGR18650A, CGR18650AF, CGR18650B,
CGR18650C, CGR18650CB, CGR18650CC, CGR18650CA, CGR18650D, CGR18650DA,
CGR18650E, NCR18650, CGR26650, CGR26650A, CGR18650CF, CGR18650H, CGR18650HG,
CGR18650HGL, CGR18650HM, CGP22485, CGP30486, CGP34506, CGP345010, CGP345010G,
CGA103450, CGA103450A, CGA103450AD, CGA103446, CGA103459A, CGA363443,
CGA453442, CGA453443, CGA633450, CGA633450A, CGA633450B, CGA504042, CGA533048,
CGA533048A, CGA523436, CGA523436A, CGA612634, CGA772530, CGA523436B,
CGA523450, CGA523450A, CGA752836, CGA523450C, CGA523450R, CGP533451,
CGA523442, CGA393848, CGA523443, NCA573536, and NCA523450.
GENERAL DESCRIPTION:
The CGR models are rechargeable cylindrical type cells. The CGP and CGA
models are a rechargeable oval (prismatic) type cell. These cells contain a
mixture of carbon black, lithium cobalt oxide and binders as the anode and a
mixture of carbon and binders as the cathode which are wound and separated by
a polyethylene separator. The electrolyte is an organic solution. Those
components are contained in a nickel plated steel or aluminum casing. Also,
the CGR and NCR Models contain a polymeric positive temperature coefficient
resistor. A "C" shaped safety vent is located on the bottom of each cell
except for Models CGR18500, CGR18650B, CGR18650C, CGR18650CA and CGR18650CB.
There are two types of Model CGR18650A, the type with “C” shaped safety vent
and the type without it. There are two types of Model CGR18650HG, the type
with “C” shaped safety vent and the type without it. These cells may have an
optional plastic jacket or shrink wrap over the cell case.
ELECTROCHEMISTRY:
All models are rechargeable and have a nominal fully charged open
circuit voltage of 4.3 V and nominal operating limits of 2.0-4.3 V.
ENGINEERING CONSIDERATIONS (NOT FOR UL REPRESENTATIVE’S USE):
USR indicates compliance with the requirements outlined in UL1642
Standard for Lithium Batteries, Fourth Edition.
Use - For use only in products where the acceptability of the
combination is determined by Underwriters Laboratories Inc.
Conditions of Acceptability - The use of these cells may be considered
generally acceptable under the conditions given below:
1. The cells are identified in accordance with "Marking" as described
below.
2. Unless the conditions of Par. 2A are met, these batteries are to
be used only in devices where servicing of the battery circuit and replacement
of the lithium battery will be done by a trained technician.
Fig. 11
Report No. CA/QPS/ExTR08.0002/00
Page 57 of 107
Issue Date: Nov. 17, 2008
Un-encapsulated
terminals
Encapsulated
terminals
Fig. 12
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Fig. 13
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Fig. 14
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Fig. 15
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Fig. 16
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Fig. 17
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Fig. 18
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Fig. 19
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Fig. 20
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Fig. 21a
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Fig. 21b
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Fig. 22
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Fig. 23
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Fig. 24
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Fig. 25
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Fig. 26
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Fig. 27
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Fig. 28
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Fig. 29
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Page 76 of 107
Issue Date: Nov. 17, 2008
Test No:
Page
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test :
1
Date : May 1, 2008
LRE1019-1
SPERIAN
PhD6 Gas Detector
Rating :
Hydrogen (21 +/- 2) %
Cal. Current :
IEC60079-11 / UL913
Edition/Date :
7.4 – Batteries
X Thermal
Spark
62-698 Alkaline Battery pack
Rev Level :
Battery Short Circuit & Temperature
IIC ia
30 – 30.5 mA
2006 / 2002
A0
Details:
Determination of Isc for the Alkaline batteries. The creepage distance between the battery case and the
electrode of the opposite polarity for each of the battery types is as shown:
E91 => 0.5 mm
EN91 => 0.5 mm
MN1500 => 0.6 mm
MX1500 => 0.6 mm
Since 1.5 mm is required, this spacing is subject to being failed.
Although there are 3 cells in a battery pack, only one can be faulted in this manner at any one time.
Equipment Used:
QPS #
622
703
1219
1218
458
917
893
10
1205
Description
Multi-meter
Battery Short Circuit jig
Amp clamp
Tektronix amplifier
Scope
Shunt
Knife switch
Data logger
DC Multi-Ohm meter
Test Parameters:
For each battery type, perform the short circuit test, determine the internal resistance, take
thermocouple readings, and calculate the maximum power delivered. Use 10 samples of each
battery type.
Report No. CA/QPS/ExTR08.0002/00
Page 77 of 107
Issue Date: Nov. 17, 2008
Note that Pmax is the maximum power transfer from each battery and is calculated as
Pmax = V2 / 4Rint
The test jig Shunt Resistance = Rs = 2.365 milli-Ohm (this was measured before and after each
series of 10 tests and values changed by less than 0.003 milli-Ohm)
Total circuit resistance Rt = Rs + Rint
Rt = Voc / Iscmax
Rint = Rt - Rs
Pmax = Voc2 / ( 4 * Rint)
Results & Conclusions:
Battery Type :
Energizer E91 Sample #02673 [3/21]
Battery
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
Voc
1.574
1.579
1.582
1.570
1.574
1.579
1.568
1.571
1.574
1.573
Isc
15.60
13.30
13.90
14.30
18.00
18.60
16.50
16.90
19.60
18.10
Rt
0.101
0.119
0.114
0.110
0.087
0.085
0.095
0.093
0.080
0.087
Rint
0.099
0.116
0.111
0.107
0.085
0.083
0.093
0.091
0.078
0.085
Pmax
6.29
5.36
5.61
5.74
7.28
7.55
6.63
6.81
7.95
7.32
Tmax
70.7
72.3
76.4
58.3
73.0
78.2
75.2
73.2
75.6
74.3
Tamb
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
Tadj
84.7
86.3
90.4
72.3
87.0
92.2
89.2
87.2
89.6
88.3
VI
24.6
21.0
22.0
22.5
28.3
29.4
25.9
26.5
30.9
28.5
Max Results
1.582
19.60
0.12
0.12
7.95
78.20
26.00
92.20
30.85
Battery Type :
Energizer Industrial EN91 Sample #02673 [19/21, 20/21 & 21/21]
Battery
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
Voc
1.613
1.611
1.610
1.610
1.613
1.608
1.612
1.615
1.612
1.612
Isc
20.60
15.70
17.90
19.00
19.00
16.90
15.40
23.00
22.00
21.00
Rt
0.078
0.103
0.090
0.085
0.085
0.095
0.105
0.070
0.073
0.077
Rint
0.076
0.100
0.088
0.082
0.083
0.093
0.102
0.068
0.071
0.074
Pmax
8.57
6.47
7.40
7.87
7.88
6.97
6.35
9.61
9.16
8.73
Tmax
114.0
114.2
111.1
118.2
111.7
115.9
106.1
119.6
101.9
116.9
Tamb
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
26.0
Tadj
128.0
128.2
125.1
132.2
125.7
129.9
120.1
133.6
115.9
130.9
VI
33.2
25.3
28.8
30.6
30.6
27.2
24.8
37.1
35.5
33.9
Max Results
1.62
23.00
0.10
0.10
9.61
119.60
26.00
133.60
37.15
Report No. CA/QPS/ExTR08.0002/00
Battery Type :
Page 78 of 107
Issue Date: Nov. 17, 2008
Duracell Coppertop MN1500 Sample #02673 [6/21 & 5/21]
Battery
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
Voc
1.601
1.602
1.603
1.603
1.602
1.602
1.601
1.602
1.603
1.602
Isc
23.4
18
18.9
19.4
22.6
20.9
20.6
23.8
21.1
21.8
Rt
0.068
0.089
0.085
0.083
0.071
0.077
0.078
0.067
0.076
0.073
Rint
0.066
0.087
0.082
0.080
0.069
0.074
0.075
0.065
0.074
0.071
Pmax
9.70
7.41
7.79
8.00
9.36
8.64
8.50
9.88
8.73
9.02
Tmax
75.3
81.8
80.8
80.8
76.6
81.0
83.2
81.9
78.1
79.1
Tamb
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
25.0
Tadj
90.3
96.8
95.8
95.8
91.6
96.0
98.2
96.9
93.1
94.1
VI
37.5
28.8
30.3
31.1
36.2
33.5
33.0
38.1
33.8
34.9
Max Results
1.60
23.80
0.09
0.09
9.88
83.20
25.00
98.20
38.13
Battery Type :
Duracell Ultra Digital MX1500 Sample #02673 [10/21, 12/21, 15/21]
Battery
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
Voc
1.601
1.602
1.603
1.603
1.599
1.603
1.601
1.601
1.595
1.596
Isc
30
30.8
28.6
29.7
31.1
25.6
25.1
30.3
23.1
25.4
Rt
0.053
0.052
0.056
0.054
0.051
0.063
0.064
0.053
0.069
0.063
Rint
0.051
0.050
0.054
0.052
0.049
0.060
0.061
0.050
0.067
0.060
Pmax
12.56
12.92
11.97
12.45
13.03
10.66
10.43
12.70
9.54
10.53
Tmax
111.0
117.0
110.0
110.0
125.0
118.0
107.0
113.0
113.0
120.0
Tamb
26.9
26.9
26.9
26.9
26.9
26.9
26.9
26.9
26.9
26.9
Tadj
124.1
130.1
123.1
123.1
138.1
131.1
120.1
126.1
126.1
133.1
VI
48.0
49.3
45.8
47.6
49.7
41.0
40.2
48.5
36.8
40.5
Max Results
1.60
31.10
0.07
0.07
13.03
125.00
26.90
138.10
49.73
Report No. CA/QPS/ExTR08.0002/00
Page 79 of 107
Issue Date: Nov. 17, 2008
Test No:
Page
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test :
LRE1019-1
SPERIAN
2
Date : May 12, 2008
PhD6 Gas Detector
Rating :
Hydrogen (21 +/- 2) %
Cal. Current :
IEC60079-11
Edition/Date :
5.2, 7.4.3, and 7.6
X Spark
Thermal
62-698 Alkaline Battery pack
Rev Level :
Battery Terminals
IIC ia
30 – 30.5 mA
2006
A0
Details:
Since the battery terminals are spaced at 0.5 and 0.6 mm apart depending on the battery type, these
are considered subject to fault. Spark tests are to be performed using a hydrogen mix as shown
above.
Equipment Used :
QPS #
515
1218
1219
637
458
530
622
Description
Spark Ignition Machine
Tektronix TCPA300 Current Probe Amplifier
Tektronix TCPA303 Current Probe
Timer
Tektronix TDS3014B Scope
Gas Mixing Bench
Fluke Multimeter
Test Parameters:
Setup the SI machine using all four whiskers and set timer to 5 minutes. Calibrate the machine as per
the calibration procedure. Using the same gas mixture, perform a test ignition both before and after
the battery tests to verify the equipment.
The initial and ending Voc were measured and the amp clamp was used to measure the maximum
current during the test pulses.
Report No. CA/QPS/ExTR08.0002/00
Page 80 of 107
Issue Date: Nov. 17, 2008
Conclusions:
Battery
Energizer E91
Energizer EN91
Duracell MN1500
Duracell MX1500
Voc
(Start)
Voc
(end)
Peak
Amps
1.57
1.61
1.59
1.61
1.33
1.37
1.37
1.38
4.2
4.2
4.2
5.0
There were no ignitions during any of the battery tests. During the Verification test following the
battery tests, ignition occurred in 20 seconds indicating that the gas mixture and the IS machine were
still within calibration.
These batteries were considered acceptable for this application.
Report No. CA/QPS/ExTR08.0002/00
Page 81 of 107
Issue Date: Nov. 17, 2008
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
LRE1019-1
SPERIAN
Test No:
Page
3
Date : Nov. 23/07
PhD6 Gas Detector
Rating : IIC ia
Hydrogen (21 +/- 2) %
Cal. Current : 30 – 30.5 mA
IEC60079-11
Edition/Date : 2006
7.4 – Batteries
X Calculation
Spark
Thermal
62-698 Alkaline Battery pack
Rev Level : A0
Battery Pack Shunt Resistor
Details:
Determination of Imax that can flow through R5 when the Q1 is shorted. Since this FET can easily
be faulted due to creepage distances < 0.5 mm, the 3-cell battery pack can be applied directly across
R5. Per BOM – 35 – 0771, R5 is rated 1K SMT. Manufacturer’s spec sheet shows a rating of 0.125
Watts
Voc = 1.65 V/cell or 4.95 V/pack
R = 1K
Isc = V/R = 4.95 mA
the power dissipation is calculated as P = VI = 4.95 x 4.95 mA= 24.5 mW or 0.025 W
Test Parameters:
No testing was considered necessary
Conclusions:
With the resistor R5 operating at approximately 0.025 / 0.125 = 20 % of its rating, it is considered as
not contributing any significant thermal effects.
Report No. CA/QPS/ExTR08.0002/00
Page 82 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
Test No:
Page
4
Date : Nov. 23/07
LRE1019-1
SPERIAN
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
IEC60079-11
Issue Date: Nov. 17, 2008
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006
X Calculation
Spark
Thermal
62-698 Alkaline Battery pack
Rev Level : A0
Max Power through R1 and R2 under normal operation
Details:
Evaluate the maximum current and power that R1 and R2 current limiters will see given that
they are limited by fuses F1 and F2. Both resistors metal foil on ceramic substrate construction
and will fail in the open mode. They are considered to be infallible.
Procedure:
N/A
Test Parameters/Results:
R1 = 1 ohm, 5%
½ watt F1 = 0.250 amp
Vmax = Voc = 4.95 V (3 cells)
R2 = 1 ohm, 5%
¼ watt F2 = 0.125 amp
In a worst case scenario, full Voc would appear across R1 and R2.
Since I = V / R => I1 & I2 = 4.95/1 = 4.95 amp
However, the fuses will limit this to 1.7 x the nominal rating.
So I1 = 1.7 x 0.250 = 0.425 amp
I2 = 1.7 x 0.125 = 0.213 amp
Max power through a resistor is defined as I2R watts, so
Considering tolerances, R1, R2 = 1.05 ohms
P1 = 0.425 2 x 1.05 = 0.19 watts ( ~ 38% rated)
P2 = 0.213 2 x 1.05 = 0.05 watts ( ~ 19% rated)
Conclusions:
Both Current limiting resistors operate at well below 2/3 of their power ratings under maximum
load and are considered acceptable for this application..
Report No. CA/QPS/ExTR08.0002/00
Issue Date: Nov. 17, 2008
Page 83 of 107
Test No:
Page
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
Date : Dec 3/07
LRE1019-1
SPERIAN
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
IEC60079-11
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006
X Calculation
Spark
Thermal
62-698 Alkaline Battery pack
Rev Level : A0
Max Power through R3 and R4 under normal operation
Details:
Evaluate the maximum current and power that R3 and R4 current limiters will see given that
they are limited by fuse F3. These resistors are resistive film on ceramic substrate type
construction, and since they will fail in the open-mode, are considered infallible.
Procedure:
N/A
Test Parameters/Results:
R3 = 3 ohm, 5% 1 watt
F3 = 0.250 amp
R4 = 3 ohm, 5% 1 watt
Vmax = Voc = 4.95 V (3 cells)
In a worst case scenario, full Voc would appear across R3 in series with R4.
Since I = V / R => I = 4.95/6 = 0.825 amp (ignoring tolerances)
However, the fuse will limit this to 1.7 x the nominal rating.
So Imax = 1.7 x 0.250 = 0.425 amp
Considering the 5% tolerances, Rmax would be 1.05 x 3 = 3.15 ohms
Max power through a resistor is defined as I2R watts, so
P3 = P4 = 0.425 2 x 3.15 = 0.57 watts ( ~ 60% rated)
Conclusions:
Both Current limiting resistors operate at approximately 60% of their power ratings under
maximum load. Since they are infallible and operate below 2/3 of their ratings, they are
considered acceptable for this application.
5
Report No. CA/QPS/ExTR08.0002/00
Page 84 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
Test No:
Page
6
Date : Nov. 23/07
LRE1019-1
SPERIAN
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
IEC60079-11
Spark
35-0761 Main Board BoM
Mass Fault on Capacitors
Issue Date: Nov. 17, 2008
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006
Thermal
X Calculation
Rev Level : A0
Details:
Consider all the capacitors on the main board as a collection of parallel capacitors that may be
combined into an equivalent capacitor, assuming they could be faulted either through creepage
of fallible components or traces.
Procedure:
Qnty
25
12
4
2
1
Capacitor Value
Equivalent Capacitance
0.1 uf, 10% => 0.11 uf
2.72 uf
1.0 uf, 16v 10% => 1.1 uf
13.2 uf
0.47 uf, 10% => 0.52 uf
2.08 uf
0.01 uf, 10% => 0.011 uf
0.022 uf
10 pf
0.00001 uf
Equivalent Capacitor
18.02 uf
Test Parameters/Results:
Assuming faults could be applied in this fashion that would paralle all these capacitors, and all
capacitors were at the high end of their rating tolerances, the equivalent value would be
approximately 18 uf.
Referring to Fig. A.3 (Ignition Curve for Capacitive Circuits) of the referenced standard, the circuit
test point is V = 4.95 Volts and C = 18 uf. Applying a safety factor of 1.5 as specified in Clause
10.1.4.2, the revised safety test point would be located at 7.45 V and 27 uf.
At 7.45 volts, the ignition capacitance is ~90 uf. Therefore, the circuit is at ~20% of the capacitance.
Similarly, at 27 uf, the IIC ignition voltage is at ~9.5 volts. Therefore the circuit is at ~50% of the
voltage.
Conclusions:
Report No. CA/QPS/ExTR08.0002/00
Page 85 of 107
Issue Date: Nov. 17, 2008
Considering the unlikely event that all the capacitors were at the high end of their tolerance
ranges and that they could all be faulted in the manner outlined, the combined effect would still
place the circuit at 50% or less from the Group IIC gas Ignition Curve. This is considered to be
acceptable and in compliance with the requirements of the standard.
Report No. CA/QPS/ExTR08.0002/00
Page 86 of 107
Issue Date: Nov. 17, 2008
Test No:
Page
Intrinsic Safety Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
LRE1019-1
SPERIAN
PhD6 Gas Detector
IEC 60079-0 & 60079-11,
UL913(6th)
x Spark
Thermal
62-692
Evaluation of L1 on Main Board
7
Date : Nov. 23/07
Rating :
Cal. Current :
Edition/Date :
x Calculation
Rev Level : 0109
Details:
The Main Board contains an inductor, L1 rated 4.7 uH, 650 mA. Evaluate the energy content
applying faults where possible.
Procedure:
Analyze the circuit for input ratings and identify any spacing faults. Check IS curves, if V and L
points are closer than ~80% to the curve, perform spark ignition test.
Test Parameters/Results:
Vpump from the battery pack = 4.95 Voc (with safety factor), limited by the 250 mA fuse to 250 x 1.7
= 425 mA. U20 can be faulted through pins 3 and 4, allowing L1 to be in series with infallible smd
film-type resistors R56 and R62. Nominal total resistance is 800K-ohm.
The max current is given by Vpump / Rtotal = 4.95 / 800K
= 6 uA
The ignition curve Fig. A.4 shows that the 4.7 uH , 6 uA point is significantly distant from the
ignition curves.
Conclusions:
This inductor is considered to be safe in this application.
Report No. CA/QPS/ExTR08.0002/00
Page 87 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
LRE1019-1
SPERIAN
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
IEC60079-11, UL913(6th)
Spark
Thermal
62-701 Charger Schematic
03-353b Charger Board
Charger Circuit Evaluation
Issue Date: Nov. 17, 2008
Test No:
Page
8
Date : Dec 5/07
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006
X Calculation
Rev Level : A0
B0
Details:
The charger board is intended to be used in non-hazardous areas to charge the battery pack of the
PhD6 device, and is then disconnected while the PhD6 is taken into the hazardous area. Consider
that a charger failure may damage the device circuitry so as to constitute a potential hazard when
the device is used in the hazardous area.
Since the charger is designed with an incorporated zener barrier, this analysis will focus on the
non-hazardous side of this barrier. The assumption is that the barrier will protect the downstream
side from any destructive voltages or currents. Determine the maximum voltage, current and
power that can be delivered to the barrier to verify its adequacy. Since the ac adaptor is not
specified, it is considered to be fallible and capable of delivering up to 250 V to the charger via
the J6 jack and plug.
Procedure:
Calculate the Imax through F1, R9, L2, Q3, Q1, C4, C3 and L1. This will be the max current that
can flow. This current will evaluate the current limiting resistor R9
Test Parameters/Results:
We can fault the two FETs Q1 and Q3 due to pin-to-pin creepage distances, recognize that
capacitors C3 and C4 will short to ground on startup, but block current due to the RC time
constant in combination with R9. Similarly, L1 will initially block current.
The Zener strings will clamp the voltage at a nominal 6.6 volts, so the equivalent stabilized
circuit may be reduced to approximately the following:
Report No. CA/QPS/ExTR08.0002/00
Page 88 of 107
Issue Date: Nov. 17, 2008
I
V in
500 mA
3.1
F1
..
R9
3.3 V 5w
3.3 V 5w
3.3 V 5w
..
..
..
3.3 V 5w
3.3 V 5w
3.3 V 5w
..
..
..
V out
1/3 I
F1 = 500 mA – ceramic type – soldered to the pcb
If = 1.7 x fuse rating = 850 mA
R9 = 3.1 ohms, 5w 10% – ceramic Wire-Wound => 2.79 to 3.43 ohms
Vz = 3.3 V, 5w 10%
Total Vz = 2 x 3.3 = 6.6 v => 5.94 to 7.26 volts ( @ 10% tolerance)
At the maximum Vin of 250 v, R9 would initially see (250 – 5.94) / 2.79 = 87.5 A, but would be
quickly stopped as the fuse F1 opened and protected the components.
During Normal operation, the maximum current allowed by the fuse F1 is 1.7 times its nominal
value or 850 mA and the max power dissipated through R9 would be I2R = (0.85)2 x 3.43 =
2.47 w
At this rate, R9 is operating at ~ 50% of its power rating
The three zener strings would split the current and draw ~ 0.28 A through each zener. The power
dissipation in each zener is given by : Pz = Vz x Iz
= 3.61 x 0.28
= 1.01 watts or ~ 20% of its power rating
If a double fault is applied to the zeners (two legs opened), full current would flow through the
one remaining leg. At this current, the power dissipation in the zener would be :
Pz = Vz x Iz
= 3.61 x .85
= 3.06 watts or ~ 60% of its power rating
Evaluation of the creepage distances around the zeners found the smallest value to be 0.39 mm
while the Table 5 requirement for a 250 volt level of protection is 3.3 mm under a conformal
coating. This creates a no-count fault shorting the (pos) and (neg) bus traces, effectively placing
a short across the battery output lines.
Conclusions:
Under normal operation, the infallible current limiting resistor R9 operates at no more than 50%
Report No. CA/QPS/ExTR08.0002/00
Page 89 of 107
Issue Date: Nov. 17, 2008
of its rating, while the infallible string of redundant zeners operate at no more than 20% of their
ratings.
Under 2-fault conditions, all of the current would flow through one leg of the zener ladder, with
each zener operating at ~60% of its rating (66% allowed).
Under the abnormal condition when the Umax of 250 volts is impressed on the input, the no-count
fault shorting the zeners crowbars the output lines so that the downstream circuit is not exposed
to any voltage or current higher than the normal operational levels. In addition, the protective
fuse F1 and R9 operate as intended by opening the circuit and preventing any thermal issues.
The charger board is considered to meet the requirements of the standard.
Report No. CA/QPS/ExTR08.0002/00
Page 90 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
Test No:
Page
09
Date : Dec. 10/07
LRE1019-1
SPERIAN
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
IEC60079-11, UL913(6th)
Issue Date: Nov. 17, 2008
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006
Spark
Thermal
62-699 Rechargeable Battery pack
35-0771 BoM
03-355 PCB
Creepage and Spacings
X Calculation
Rev Level : A0
A0
B0
Details:
Evaluate the circuit board for creepage and spacings. Measure the trace dimensions to determine
the T-Rating.
Procedure:
Using the Gerber files provided and the Gerber Viewing Software provided by the manufacturer
to measure dimensions. Software is ViewMate version 9.8.25
Validate the dimensions using calibrated calipers and/or loupe.
Test Parameters/Results:
The Charger Board was evaluated elsewhere and it was determined that its onboard zener
barriers would prevent any abnormal voltages or currents from being transmitted to this battery
pack. Therefore, the highest voltage appearing at the battery pack charge terminals will be 6.6
Vdc.
Table 5 of IEC60079-11 specifies Clearance and Creepage of 1.5 mm for circuit boards
operating at 10 volts or less and 0.5 mm Creepage under conformal coating.
The minimum creepage measured on the PCB was 1.5 mm between the positive and negative
pads.
The trace pads are set back from the board edge by a minimum of 0.55 mm on each side. The
total wraparound creepage is 2 x 0.55 mm + 1.65 mm thick = 2.75 mm
The minimum trace width of the F1 circuit is 0.079 mm between the connector and the fuse
itself. Since the fuse rating is 0.25 amps, the max fuse current will be 1.7 times this value for
Report No. CA/QPS/ExTR08.0002/00
Page 91 of 107
Issue Date: Nov. 17, 2008
0.425 amps. From Table 4 of the standard, a track width of 0.075 mm and carrying less that 0.5
amps is allowed a T Rating of T6.
Conclusions:
Creepage and Clearance distances are within acceptable dimensions for the intended application,
so they can not be used as sources of applied faults.
The minimum trace width on the fuse F1 line determines the Temperature Code to be T6.
Report No. CA/QPS/ExTR08.0002/00
Page 92 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
LRE1019-1
SPERIAN
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
UL913(6th) / IEC60079-11
X Thermal
Spark
62-699 Rechargeable Battery pack
35-0771 BoM
03-355 PCB
Thermal and Power
Issue Date: Nov. 17, 2008
Test No:
Page
10
Date : Jan 10/08
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006
X Calculation
Rev Level : A0
A0
B0
Details:
Determination of the Isc for the Lithium-Ion battery given that the creepage distance between the
case and battery terminal was in the order of 0.5 mm, much less than the required 1.5mm. High
short circuit currents will raise surface temperatures that may affect the temperature code.
Procedure:
It was recognized that Lithium-Ion batteries are manufactured with internal PTC (positive
temperature coefficient) devices that limit the short circuit current to levels on the order of 4 to 6
amps; much lower than that available from alkaline batteries. It was also noted that the battery
has been tested by UL and maximum currents and temperatures recorded. This information is on
file at SGS, but relevant portions are shown below.
UL File MH12210 , Project 94NK28453 dated Feb. 8, 1995, and updated on Oct 6, 2006.
This file covered a series of Panasonic batteries of which the CGR18650 family was one. These
were evaluated to UL1642 Standard for Lithium Batteries, Fourth Edition.
Ratings: 4700 mA maximum
4.3 volts max
Test results of short circuiting the batteries showed the maximum surface temperature to be 90C
for tests done in a 60C ambient. According to the UL report, there was no deformation to the
case and there was no leakage of the electrolyte.
Conclusions:
Since the UL report indicates short circuit currents and temperatures lower than that measured
for the alkaline batteries, which have been spark tested and considered acceptable, these
Lithium-Ion batteries are also considered to comply with the requirements of UL913(6th ed).
Report No. CA/QPS/ExTR08.0002/00
Page 93 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
LRE1019-1
SPERIAN
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
IEC60079-11, UL913(6th ed)
X Thermal
Spark
62-699 Rechargeable Battery pack
35-0773 BoM
03-355 PCB
Current Limiting Resistors and Fuses
Issue Date: Nov. 17, 2008
Test No:
Page
11
Date : Jan 10/08
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006
X Calculation
Rev Level : A0
A0
B0
Details:
This battery pack is similar to the Alkaline battery pack except for the addition of a charging
circuit. The resistors and fuses used are the same as in Tests 5 & 6, except the Voc is nominally
4.3 volts rather 4.5 as for the alkaline batteries.
This battery was tested by UL under File MH12210, Project 94NK28453 dated Feb. 8, 1995 and
confirmed that the Panasonic CGR18650D battery complies with the requirements of UL1642
Standard for Lithium Batteries (4th edition). The Voc is reported as 4.3 V.
Procedure:
Compare calculations to the results of Tests 5 & 6
Test Parameters/Results:
The resistance and fuse ratings are identical, but the Voc is lower on this board than on the
alkaline board evaluated in Tests 5 & 6. Therefore the currents and power dissipations will also
be lower.
Conclusions:
Since the calculations in Test 5 & 6 showed those components to be acceptable, and the power
dissipation on this rechargeable board are therefore lower, the current limiting resistors and fuses
on this board are considered acceptable.
Report No. CA/QPS/ExTR08.0002/00
Page 94 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
LRE1019-1
SPERIAN
Issue Date: Nov. 17, 2008
Test No:
Page
12
Date : Nov. 23/07
PhD6 Gas Detector
Rating : IIC ia
Hydrogen (21 +/- 2) %
Cal. Current : 30 – 30.5 mA
th
IEC60079-0 & -11, UL913(6 ed)
Edition/Date : 2006
7.7 & 10.7
X Spark
X Calculation
Thermal
62-692 Main Board
Rev Level : A0
Piezoelectric Component
Details:
Apparatus containing piezoelectric devices that may be accessible in use need to be tested for
any generated energy upon impact. This test will measure the energy generated when the gas
detector is impacted to ensure it is below the allowable 50uJ level.
Procedure:
Inspection of the gas detector enclosure construction showed that the two piezo alarms were
physically positioned in a location that could not be accessed directly or indirectly by an external
impact.
Conclusions:
Since the piezo alarms are not accessible while the PhD6 is in use, this test is not considered to
be required.
Report No. CA/QPS/ExTR08.0002/00
Page 95 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
Issue Date: Nov. 17, 2008
Test No:
Page
13
Date : April 1 / 08
LRE1019-1
SPERIAN
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
IEC60079-11, UL913(6th ed)
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006
x Calculation
Spark
Thermal
Li-Ion Battery pack
Rev Level : A0
Clearance on Battery Protection Circuit board
Details:
While both IEC60079-11 and UL913 allow approved (IEC61960 and UL1642 respectively) Li-Ion
batteries to be used in intrinsically safe equipment, any additional battery protection circuits must be
evaluated for intrinsic safety.
Procedure:
Remove the outer heat shrink wrapper form the battery and measure the spacings between the
battery terminations and the board traces..
Test Parameters/Results:
The applicant’s Panasonic battery has an additional circuit beneath the plastic shrink wrap. This
circuit is designed to limit charge / discharge currents and limit under and over voltages. The
original design that was submitted had creepage spacings that did not meet the requirements. An
alternate supplier of the batteries included a different circuit that had improved spacings and layout.
The board traces were measured to be between 0.5 and 0.7 mm which were insufficient for unencapsulated boards. This drawing shows that the 0.5 and 0.2 mm gaps can be added, but the
spacing between the black lead pad and its neighbour are dependant on insulation peel-back and
workmanship in soldering. This spacing was therefore considered as a countable fault.
0.5 mm
0.2 mm
Fallible
fdff spacing
This board was then encapsulated as shown below,
Report No. CA/QPS/ExTR08.0002/00
Page 96 of 107
Issue Date: Nov. 17, 2008
The external sleeve on the battery was removed to allow the board to be lifted off the battery surface
and allow the encapsulant to flow completely around the circuit board.
Conclusions:
This combination of battery and board meets the 0.5 mm spacing requirements and is considered to
be in compliance with the requirements of the standards.
Report No. CA/QPS/ExTR08.0002/00
Page 97 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
IEC60079-11 / UL913(6th ed)
Spark
Test No:
Page
14
Date : April 1 / 08
LRE1019-1
SPERIAN
x
Issue Date: Nov. 17, 2008
x
Thermal
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006 / 2002
Calculation
Rev Level : A0
Pump Evaluation
Details:
The gas manifold pump is a mechanical device that will have potentials for electrical spark and
thermal ignition. The pump has been evaluated by UL for a previous application.
Procedure:
Using the test results obtained from the UL report and the schematic from 62-700, determine the
energy stored in the pump coil.
Test Parameters/Results:
From BoM 35-0770, the pump is identified as a T Squared Pumps model 03.08.019C. UL Test
Report, File E109447 evaluated model 03.08.019A. The suffixes denote different construction and
considered not relevant to an electrical evaluation.
The UL report states:
From 10 samples, the average DC resistance was found to be 12.6 ohms and the inductance at 1000
hz was found to be approximately 0.487 mH. Using the nominal circuit voltage of 3 volts and a 1.5
factor on the current, the energy calculated as being stored in the coil was given by :
E=½xLxI2
= ½ x 0.487 x ((3/12.6) x (1.5))2
= 30.8 uH
Plotting this locus on the Inductance / Voltage curve places it well under the allowable current curve
of 10 amps.
Conclusions:
Based on the UL test results, the maximum energy capable of being stored in the pump coil is
sufficiently low that it is considered to be safe in this application.
Report No. CA/QPS/ExTR08.0002/00
Page 98 of 107
Issue Date: Nov. 17, 2008
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test:
Test No:
Page
15
Date : April 1 / 08
LRE1019-1
SPERIAN
PhD6 Gas Detector
Hydrogen (21 +/- 2) %
IEC60079-11 / UL913(6th ed)
Spark
Rating : IIC ia
Cal. Current : 30 – 30.5 mA
Edition/Date : 2006 / 2002
Thermal
Calculation
Rev Level :
Drop Test
Details:
The requirements state that the device shall be dropped onto a concrete floor from a height of 1
meter, both with and without batteries.
Procedure:
For this device, run four sets of tests: with batteries, without batteries and battery packs only:
For each series, drop 5 times as a free-fall, then 5 times onto different sides or corners.
For the tests with batteries, verify that the units functions after the tests. After testing the battery
packs, install them into the unit and test for functionality.
Test Parameters/Results:
With
Batteries
Without
Batteries
Alkaline
Pack
Li-Ion
Pack
1
2
FREE FALL
3
4
5
6
7
ORIENTED FALL
8
9
10
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
pass
Conclusions:
The units were turned ON before the tests and operation verified. During one test, the unit reset, but
otherwise continued to operate properly. After the drop tests, there were no failures of the units. The
battery packs remained intact and after insertion into the gas detector, appeared to function properly.
Note: only the operation of the gas detector was monitored – there was no evaluation as to accuracy or proper measurement
functionality.
These results are considered satisfactory.
Report No. CA/QPS/ExTR08.0002/00
Page 99 of 107
Intrinsic Safety - Fault Analysis
Project No :
Customer :
Device :
Test Gas :
Referenced Std :
Clause :
Type of Analysis:
Ref Dwg. :
Type of Test :
Issue Date: Nov. 17, 2008
Test No:
Page
16
Date : Oct 16, 2008
LRE1019-1
SPERIAN
PhD6 Gas Detector
Rating : IIC ia
Hydrogen (21 +/- 2) %
Cal. Current :
IEC60079-11 / UL913
Edition/Date : 2006 / 2002
10.5.3 (60079-11) / 17 (UL913)
X Thermal
Spark
62-699 Li-Ion Battery pack
Rev Level : A0
Battery Short Circuit & Temperature
Details:
Perform short circuit tests on the Li-Ion battery to determine maximum surface temperature. Test 10
samples with internal PTC intact and 10 samples with the internal PTC removed or shorted (these
samples are provided by the manufacturer). Any external current limiting circuits are to be shorted
or bypassed for the test.
Test Parameters:
QPS #
622
703
1219
1218
458
917
893
10
1205
Description
Multi-meter
Battery Short Circuit jig
Amp clamp
Tektronix amplifier
Scope
Shunt
Knife switch
Data logger
DC Multi-Ohm meter
Report No. CA/QPS/ExTR08.0002/00
Page 100 of 107
Issue Date: Nov. 17, 2008
Panasonic 18650D with PTC intact
Results normalized to 40C
Battery
#1
#2
#3
#4
#5
#6
#7
#8
#9
#10
Voc
4.17
4.17
4.18
4.17
4.19
4.17
4.18
4.15
4.19
4.18
Tmax
81.8
76.0
77.4
69.6
67.8
75.0
72.6
77.2
73.1
78.4
Imax / Isteady-state
65 / 1.5
69.8 / 1.4
64 / 1.6
66 / 1.5
69.5 / 1.65
64 / 4.65
66 / 1.7
67.5 / 1.75
62.8 / 1.6
62.8 / 1.8
Panasonic 18650D with PTC bypassed (IEC60079-11 and UL913(7th ed) requirement only)
Results normalized to 40C
Battery
#1
#2
#3
#4
#5
#6
#7
#8
#9
#10
Voc
4.14
4.14
4.14
4.14
4.13
4.12
4.11
4.16
4.16
4.14
Tmax
120.4
134.0
138.2
140.8
141.3
138.3
157.6
135.8
140.2
143.2
Imax / Isteady-state
85 / 25
81 / 15
83 / 16
91 / 16
(not recorded) / 15
93 / 15
85.5 / 15
80.5 / 15
75 / 15
73.5 / 15
Results & Conclusions:
For UL913(6th ed) evaluation, there is no requirement for testing without the PTC. Therefore,
since the results of the first test are lower than the results obtained for the alkaline batteries, the
temperature Code is not affected by the Li-Ion batteries.
For UL913(7th ed) and IEC60079-11, the second test with the PTC bypassed resulted in a
maximum temperature of 157.6C in a 40C ambient, or 167.6C in a 50C ambient. The Temp
Code is therefore T3C (160) in a 40C ambient or T3A (180) in a 50C ambient. The Zone system
does not recognize these subdivisions, so for use in a Zone system, the Temp Code will be T3
(200) for 50C ambients.
There was no evidence of leakage or damage to any of the batteries. These batteries are
considered acceptable.
Report No. CA/QPS/ExTR08.0002/00
Issue Date: Nov. 17, 2008
Page 101 of 107
Test No:
Page
Dust Tightness Test
Standard:
(a) UL 913(6th ed) (b) IEC 60529 (2001)
Raw Data Number
QSD/RD/UL913
Hazloc test number
(a) Clause 30 (b) Clause 13
Submitter
Sperian
Report No.
LRE1019-2
Manufacturer
Sperian
Device
Hand Held Gas Detector
Page
Model No
PhD6
Date
Sample Tag
Clause
ENT 2982
QPS ID No.
QPS 192
------QPS 486
Title
1
of
Oct 29, 2008
Dust Tight Enclosure
Result
PASS
Equipment
Dust Chamber & Usage Log
Flow Meter
Range Used
N/A
N/A
Vacuum Pressure Pump
Water Gage Dwyer
Talcum powder WW 271 1000
Square Mesh 50 microns
Number of times Dust used
N/A
N/A
N/A
N/A
13 times (max 20 allowed)
FAIL
TEST CONDITIONS – UL913
N/A
17
Report No. CA/QPS/ExTR08.0002/00
Ambient
Sample Temp
25 ºC
25 C
Calculations:
a) Required amount of powder in the Chamber
(Q)
Volume of Dust Chamber QPS 192 = 1.15m³
The amount of talcum powder necessary is: 2 Kg per
cubic meter (0.125 lb/Ft³) Q = 2 x 1.15 = 2.3 Kg of
powder
Issue Date: Nov. 17, 2008
Page 102 of 107
Refer to horizontal test procedure UL 913 Clause
30
For tests classified under category “b” clause 30.2
UL 913, the enclosure is to be placed in a dust
chamber where dust (talcum powder) is to be
circulated around it. The test is to be conducted in a
period of 8 hours and no vacuum system is
necessary.
b) for Category 30.2b
8 hours of test is necessary for items under test
Test No..
Pictures are to be taken and stored on the LAN
File location: LRE1019-2 Photos folder
Data logger results are to be stored on the LAN
File location:
N/A
TEST RESULTS
PASS
1
Comments
FAIL
N/A
At the end of testing no visible dust shall be
detected inside the enclosure.
This device does not “breathe” during operation so procedure (b) was followed with no vacuum for 8
hours. The test chamber and dust were configured as required above.
Report No. CA/QPS/ExTR08.0002/00
Ambient
Sample Temp
25 ºC
25 C
Issue Date: Nov. 17, 2008
Page 103 of 107
TEST CONDITIONS – IEC60529
Refer to test procedure Clause 13.4 and 13.6
Under 13.5, for IP rating of 5, dust may be
acceptable inside the enclosure if it does not
interfere with correct operation or impair safety.
For tests classified under category 2, clause 13.4, the
enclosure is to be placed in a dust chamber where
dust (talcum powder) is to be circulated around it.
The test is to be conducted in a period of 8 hours and
no vacuum system is necessary.
Under 13.6, for IP rating of 6, no dust is allowed
inside the enclosure.
Pictures are to be taken and stored on the LAN
File location: LRE1019-2 Photos folder
Data logger results are to be stored on the LAN
File location:
N/A
Test No..
TEST RESULTS
PASS
1
Comments
FAIL
N/A
At the end of the test, no dust was visible inside
the enclosure, giving it an IP rating of 6 for the
first characteristic numeral.
This device does not “breathe” during operation so procedure of 13.4 was followed with no vacuum for 8
hours. The test chamber and dust were configured as required above. From Clause 13.6.1, the enclosure is
deemed to be category 1
Accumulation after 8 hours
Post-Test before opening
Report No. CA/QPS/ExTR08.0002/00
Page 104 of 107
Issue Date: Nov. 17, 2008
Two halves separated
Edge seams are clean
Edge seams are clean
Battery pack viewed from the inside
Report No. CA/QPS/ExTR08.0002/00
Page 105 of 107
Sensor sockets are clean
Issue Date: Nov. 17, 2008
Report No. CA/QPS/ExTR08.0002/00
Page 106 of 107
Issue Date: Nov. 17, 2008
Test No:
Page
Capacitance Test
Clause
26.15
Title
QPS ID No.
Equipment
Isolated plate (earthgrounded plate).
LCR Meter & Leads
Range Used
1113
1124 & 1125
18
Measurement of
Capacitance
Calibration Due
N/A
N/A
C-R
Nov 21, 2008
CALIBRATION PROCEDURE REQUIRED
No special calibration procedure required
Hazloc laboratory startup and calibration procedure
Other
TEST CONDITIONS
Test within standard YES
NO
Ambient
Ambient
Ambient
20.0 C
30 %
101 KpA
Temperature
Humidity
Pressure
Have sample(s) been conditioned as per Clause 26.15.1 in IEC 60079-0 General (Fourth
Edition – 2004-01)
YES
NO
Gas Group
Maximum Capacitance Allowed
Group I
(9.8 ± 0.5)% Methane
50 pF
Group IIA
(4.6 ± 0.3)% Propane
50 pF
Group IIB
(8 ± 0.5)% Ethylene
15 pF
(14 ± 1)% Acetylene / (31 ± 1)%
5 pF
Group IIC
Hydrogen
TEST RESULTS
PASS
FAIL
N/A
Location
AB
0.005 nF
Report No. CA/QPS/ExTR08.0002/00
AC
0.0025 nF
AD
0.001 nF
AF
0.005 nF
CD
0.0007 nF
BE
0.0017 nF
AG
0.002 nF
Page 107 of 107
Issue Date: Nov. 17, 2008
COMMENTS / OBSERVATIONS
Measurements were taken between exposed metal screws as noted. AB means measured between screw A
and screw B.
A
F
B
C
E
G
D