Honeywell Sensepoint HT User manual

Sensepoint HT
Combustible Gas Sensor
Quick Start Guide
SENSEPOINT HT
COMBUSTIBLE GAS SENSOR
MAN0622 Issue 01 January 03
2106M0523 The Sensepoint High Temperature (HT) Combustible Gas Sensor is a sealed
disposable sensor for the detection of flammable gases. It must be fitted into a
suitably approved Exe or Exd high temperature junction box (e.g. Feel Flameproof
Enclosures) fitted with an approved cable gland for external wiring (e.g. Peppers
Cable Glands, Series A3LF or CR3 CROLOCK Series).
The sensor features a Filter Housing that retains a stainless steel mesh filter. It
employs a catalytic pellistor sensor device which is used as part of a bridge
measuring circuit.
Sensepoint HT is certified for hazardous areas to EN50014/EN50018 and is
protected against water and dust ingress to IP66/67. The sensor is available in
M20, M25 and 3/4 NPT thread versions. The sensor accepts accessories from a
specified range (see Accessories & Spare Parts).
Information notices
The types of information notices used throughout this handbook are as
follows:
WARNINGS
Indicates hazardous or unsafe practice that could result in severe
injury or death to personnel.
Caution: Indicates hazardous or unsafe practice which could
result in minor injury to personnel, or product or
property damage.
Note Provides useful/helpful/additional information.
If more information outside the scope of this technical handbook is
required please contact Honeywell Analytics.
Associated Documents
Sensepoint Gas Sensors Technical Handbook Part No: 2106M0502
1. INTRODUCTION
1 2
11 12 13 14
8. SPECIFICATIONS 9. ACCESSORIES & SPARE PARTS7. CERTIFICATION
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section.
Operating temperature range: -40°C to +150°C.
Operating humidity range: 20% to 90% RH continuous.
10% to 99% RH intermittent - non
condensing.
Operating pressure range: 75 to 110 k Pa.
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.)Am002ta(egdirbV5.3otV9.2:egnaregatloV
Power consumption: 700mW.
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Calibration flow rate: Recommended between 1 and
1.5 l/min.
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become inactive after extensive
exposure to silicones,
halogenated hydrocarbons,
heavy metals or sulphur
compounds.
Expected operating life: 5 years.
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Weather Protection.
htiwseilpmocrosnesehT:EC
relevant CE directives.
ATEX Certification: II 2G EEx d II C T3
Tamb -40oC to +150oC
Baseefa02ATEX0242X
rebmuNtraPnoitpircseD
Complete replacement sensor:
0132B6012noisrev02M•
1132B6012noisrev52M•
2132B6012noisrevTPN4/3•
8100-F-08700retlifleetssselniatS
8300-C-08700gnisuoHretliF
High Temperature Junction Box 2052D0001
High Temperature Weather Protection 00780-A-0076
Quick Start Guide
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A company of the Zellweger Luwa Group
total environmental solutions
This publication is not intended to form the basis of a contract, and the company reserves the right
to amend the design and specification of the instruments without notice.
The following BASEEFA certification information is imprinted on adjacent
faces in two separate blocks on the hexagonal part of the sensor body.
CE mark
- conforms to all
applicable European
directives
Manufacturer’s
trademark & address
Identification number
of ATEX notified body
Product name
Year of manufacture/
serial number
Certification number
Explosion protection
mark and equipment
group & category
Certified ambient
temperature range
Certification
code
Caution
6. FAULT FINDING
2. SAFETY
WARNINGS
1. This unit is intended for use at a normal, or reduced, levels of
atmospheric oxygen and pressure only, i.e. less than 21% oxygen
and less than 1.1 bar. Oxygen deficient atmospheres (less than
10%V/V) may suppress the sensor output.
2. Refer to local or national regulations relative to installation at the
site. For Europe see EN50073 and EN60079-14.
3. Operators should be fully aware of the action to be taken if the gas
concentration exceeds the alarm level.
4. Installation should consider not only the best placing for gas leakage
related to potential leak points, gas characteristics and ventilation,
but also where the potential of mechanical damage is minimized or
avoided.
5. Only assessed for ATEX for ignition hazards.
CAUTIONS
1. Atmospheres above 100% LEL may suppress the sensor reading.
2. Do not modify or alter the sensor construction as essential safety
requirements may be invalidated.
3. Install using suitably approved and certified Exe or Exd high temperature
junction box, connectors and glands.
4. Dispose of in accordance with local disposal regulations.
Materials used - Stainless Steel.
The following table provides a list of possible faults related to the sensor
together with possible causes and remedies.
ydemeR/esuaCtluaF
Sensor reads non zero Gas could be present, ensure
all the time there is no combustible gas in the
atmosphere.
Sensor reads non zero Adjust the control system zero
when no gas is present setting.
Sensor reads low when Adjust the control system span
gas is applied setting.
Sensor reads high when Adjust the control system span
gas is applied setting.
Sensor reads zero when 1. Check the wiring.
gas is applied 2. Check that the protective disc
has been removed from the
filter housing.
3. Check that the filter is not
dirty/obstructed.
4. Replace the sensor if
poisoning is suspected.
Issue 1 12/2005
H_MAN0622Z_ 2106M0523_EMEA
07-07
© 2007 Honeywell Analytics
11187
Find out more
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Please Note:
While every effort has been made to ensure
accuracy in this publication, no responsibility can
be accepted for errors or omissions. Data may
change, as well as legislation, and you are strongly
advised to obtain copies of the most recently
issued regulations, standards, and guidelines.
This publication is not intended to form the basis
of a contract.

3
5. MAINTENANCE
4 5
CALIBRATION
Table 2 Meter Settings
* Calibration * Rating of Gas to be Detected
Gas 8* 7* 6* 5* 4* 3* 2* 1*
8* 50 62 76 95 - - - -
7* 40 50 61 76 96 - - -
6* 33 41 50 62 78 98 - -
5* 26 33 40 50 63 79 100 -
4* 21 26 32 40 50 63 80 -
3* - 21 26 32 40 50 64 81
2* - - - 25 31 39 50 64
1* - - - - 25 31 39 50
Note: These settings must only be used with a calibration gas
concentration of 50% LEL. All data at standard temperature and
pressure.
Example
1. The target gas to be detected is Butane.
The calibration gas available is Methane (50% LEL).
2. Look up the star rating for each gas from Table 1:
Butane = 4* Methane = 6*
3. Check the meter settings for 50% LEL calibration gas from Table 2.
The reading is 78%.
4. The control card should therefore be set to 78%.
This gives an accurate reading for Butane, using 50% LEL Methane
as a calibration gas.
Table 3 Meter Multiplication Factors
Unit calibrated Unit used to detect
to detect 8* 7* 6* 5* 4* 3* 2* 1*
8* 1.00 1.24 1.52 1.89 2.37 2.98 3.78 4.83
7* 0.81 1.00 1.23 1.53 1.92 2.40 3.05 3.90
6* 0.66 0.81 1.00 1.24 1.56 1.96 2.49 3.17
5* 0.53 0.66 0.80 1.00 1.25 1.58 2.00 2.55
4* 0.42 0.52 0.64 0.80 1.00 1.26 1.60 2.03
3* 0.34 0.42 0.51 0.64 0.80 1.00 1.27 1.62
2* 0.26 0.33 0.40 0.50 0.63 0.79 1.00 1.28
1* 0.21 0.26 0.32 0.39 0.49 0.62 0.78 1.00
CALIBRATION
The Sensepoint HT Combustible Gas Sensor must be fitted into a
suitably approved Exe or Exd high temperature junction box fitted with
an approved cable gland for external wiring. The sensor requires a
200mA current supply, nominal 3V, derived from a suitable control card.
Only a qualified installation engineer should install the sensor.
Install the sensor in a location free from direct heat sources and fit it so
that it either points downwards or horizontally. It is not recommended
that the sensor points upwards. See the Sensepoint Gas Sensors
Technical Handbook for installation in forced air conditions.
1. Isolate all associated power supplies and ensure that they remain
OFF during the installation procedure. Ensure a gas free
atmosphere.
2. Install the high temperature junction box.
See the manufacturer’s instructions.
3. Remove the junction box lid.
4. Fit the Sensepoint HT sensor to the junction box.
Ensure that the junction box thread and the sensor thread are
compatible. Push the sensor wires through the cable entry in the
junction box and screw the sensor body firmly home into the entry.
Lock the sensor in place with a suitable lock-nut.
5. Connect the sensor wiring to the junction box terminal strip.
See the subsequent wiring diagram. Use multicore cable, three wire
minimum, of conductor size 2.5mm2max.
6. Fit a suitable gland to the box, secure the control system cable
and connect the field wiring to the terminal strip.
See the subsequent wiring diagram.
7. Refit the junction box lid.
8. Unscrew the filter housing from the sensor body and remove
the filter from the filter housing.
Discard the filter housing with protective disc. The filter housing
material cannot withstand high temperatures.
3. INSTALLATION
Sensors should be calibrated at concentrations representative of those
to be measured. It is always recommended that Sensepoint HT is
calibrated with the target gas it is to detect. If this is not possible, then
cross calibration can be used.
For calibration in fast flow conditions see the Sensepoint Gas Sensors
Technical Handbook.
Prior to calibration, allow the sensor to warm up for approximately
10 minutes. Re-calibration should only be attempted by qualified service
personnel.
1. Zero the control system with no gas present on the sensor.
If combustible gas is suspected to be in the vicinity of Sensepoint HT
flow clean air over the sensor using a flow housing (see below).
2. Fit a flow housing and connect a cylinder of either air, for a zero,
or a known concentration of gas in air, at approximately the
alarm point (e.g. 50% LEL), to the flow housing.
3. Pass the gas through the flow housing at a flow rate of
approximately 1 litre to 1.5 litre/min.
4. Allow the sensor to stabilise.
5. When gassing with air, adjust the control card to indicate zero.
6. For span, the control card should be adjusted to indicate the
concentration of the target gas being applied.
Remove the flow housing and the gas supply.
Cross Calibration Procedure
When calibrating the Sensepoint HT sensor with a gas which is different
to the gas/vapour to be detected, the following cross calibration procedure
should be followed.
Table 1 lists gases according to the reaction they produce at the detector.
An eight star (8*) gas produces the highest output while a one star (1*)
gas produces the lowest output. (These are not applicable at ppm
levels.)
4. CALIBRATION
7 8 9 10
6
INSTALLATION
CALIBRATION
To calibrate the Sensepoint HT sensor carry out the following procedure:
1. Obtain the star rating for both the test gas and the gas to be
detected from Table 1 .
2. Use the values in Table 2 to obtain the required meter setting
when a 50% LEL test gas is applied to the detector.
If a sensor is to be used to detect a gas other than that for which it
was calibrated, the required correction factor may be obtained from
Table 3 . The meter reading should be multiplied by this number in
order to obtain the true gas concentration.
Important Notes:
1. Since combustible sensors require oxygen for correct operation,
a mixture of gas in air should be used for calibration purposes.
2. Assuming an average sensor performance, the sensitivity
information in Tables 1 to 3is normally accurate to ± 20%.
Table 1 Star Rating of Gases
Gas Star Rating Gas Star Rating
Acetone 4* Hexane 3*
Ammonia 7* Hydrogen 6*
Benzene 3* Methane 6*
Butane 4* Octane 3*
Diethyl ether 4* Propan-2-ol 4*
Ethane 6* Propane 5*
Ethanol 5* Styrene 2*
Ethyl acetate 3* Tetra hydrafuran 4*
Ethylene 5* Xylene 2*
Sensitive (S)
Non-Sensitive (NS)
Common
Earth
Brown
Blue
White
Green
dleifmetsyslortnoCgniriwrosneS
wiring
Note: In addition to the sensor's integral earth conductor, earth
equipotential bonding may be maintained via the sensor rear
mounting thread if required.
9. If the sensor is installed:
• indoors - discard the filter.
• outdoors - fit the previously removed filter (if required) to
the High Temperature Weather Protection accessory
(Part No: 00780-A-0076) and fit the accessory to the sensor.
Fit the seal supplied with the Weather Protection accessory to
the sensor body. Screw the accessory firmly onto the sensor until
it seats against the sensor body hexagon.
10. Power-up the system and check for correct operation.
INSTALLATION
High Temperature
Junction Box
Exe/Exd gland
Threads available:
M20, M25, 3/4 NPT
38mm across flats
Sensepoint
Combustible
Gas Sensor 0-100%LEL
Filter
Filter Housing
High
Temperature
Certification data (on
adjacent faces)
58mm
42mm
125mm
Only a qualified installation engineer should service the sensor. Ensure
power is off before carrying out any maintenance procedures.
The only maintenance required is sensor replacement and filter changing
(if fitted to an accessory). To replace the complete sensor refer to the
Sensepoint Gas Sensors Technical Handbook. To replace the filter
carry out the following procedure:
1. Remove the High Temperature Weather Protection accessory.
2. Remove the old filter and replace with a fresh filter.
3. Replace the Weather Protection accessory.
Ensure the Weather Protection seal is in place. Screw the accessory
firmly onto the sensor until it seats against the sensor body hexagon.

Thank you for reading this data sheet.
For pricing or for further information, please contact us at our UK Office, using the details
below.
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P.O. Box 2124, Chelmsford, Essex, CM1 3UP, Engl nd.
Tel: [phone]
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Em il: s [email protected].uk
Please note - Product designs and specifications are sub ect to change without notice. The user is responsible for determining the
suitability of this product.