Mipex MIPEX-02 1 Series User manual

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
Revision 2.0 27 August 2015
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SMALL-SIZE EXPLOSIVE GAS MEASURING
SENSOR MIPEX-02-Х-X-X.1 X
USER MANUAL
ESAT.413347.005 UM

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
Revision 2.0 27 August 2015
Page. 2 of 38
THE SOLE PROPERTY OF OPTOSENSE LLC. ANY REPRODUCTION WITHOUT THE WRITTEN PERMISSION OF OPTOSENSE LLC IS PROHIBITED.
THE INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF
OPTOSENSE LLC. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE
WRITTEN PERMISSION OF OPTOSENSE LLC IS PROHIBITED.
Document revisions
Rev.
Date
Common changes
1.34
16 July 2014
Released version
2.0
27 August 2015
Formatting.
Typical sensor sensitivity for different hydrocarbons.
Description of RX code.
Dust filter specification.

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
Revision 2.0 27 August 2015
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Table of Contents
INTRODUCTION ............................................................................................................................4
1. DESCRIPTION........................................................................................................................5
2. TECHNICAL SPECIFICATIONS.............................................................................................6
3. INTRINSIC SAFETY...............................................................................................................8
4. PRECAUTIONS......................................................................................................................9
5. INSTALLATION AND SERVICES ........................................................................................10
6. STORAGE AND TRANSPORTATION..................................................................................12
7. WARRANTY.........................................................................................................................13
8. CONTACTS..........................................................................................................................14
APPENDIX A. SENSOR TYPES AND CHARACTERISTICS................................................15
APPENDIX B. CONNECTION DIAGRAM.............................................................................21
APPENDIX C. UART COMMUNICATION PROTOCOL........................................................24
C.1. General information...........................................................................................................24
C.2. Work modes......................................................................................................................24
C.3. Protocol commands...........................................................................................................24
C.3.1. Operating commands ........................................................................................24
C.3.2. Request commands of factory settings and properties.......................................28
C.3.3. Sensor setting and calibration commands .........................................................30
C.4. Firmware update ...............................................................................................................32
C.5. Troubleshooting ................................................................................................................33
APPENDIX D. SENSOR ZEROING AND CALIBRATION.....................................................34
D.1. Zeroing..............................................................................................................................34
D.1.1. Autozero............................................................................................................34
D.1.2. Manual zeroing in whole temperature range......................................................35
D.1.3. Manual zeroing in different points of temperature range....................................35
D.2. Scaling..............................................................................................................................35
APPENDIX E. DUST FILTERS.................................................................................................38
List of abbreviations:
CGM –Control Gas Mixture;
EMI - Electromagnetic Interference;
LEL –Lower Explosive Limit;
NDIR - Non-Dispersive Infra-Red;
UART - Universal Asynchronous Receiver/Transmitter.

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
Revision 2.0 27 August 2015
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INTRODUCTION
MIPEX-02-Х-Х-X.1 X (hereinafter, sensor or MIPEX-02) is the gas sensor, which is intended
for automatic continuous measurement of concentration of hydrocarbons in explosive areas and
carbon dioxide. The sensor is used for gas detection in atmosphere.
Sensor can be used as part of gas-analyzing equipment of groups I and II according to IEC
60079-0 in the explosion-hazardous zones of classes 0, 1, 2 according to IEC 60079-10-1, and
Class I, Division 1 according to UL Std. 913, CAN/CSA Std. C22.2 No.157-92.
Optosense LLC reserves the right to update and change current user manual in parts
excluding intrinsic safety parameters and accompanied information specified below.

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
Revision 2.0 27 August 2015
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1. DESCRIPTION
The principle of sensor operation is based on NDIR technology.
Infrared radiation of the LED passed through the measuring gas diffusion cell and reaches
the two of photodetectors, one of which detects radiation in the wavelength range of 3.25 to
3.45 m only, while the other one detects radiation in the wavelength range of 3.45 to 3.7 m. The
analyzed gas that is present in the measuring cell absorbs radiation of the operating wavelength
(o) and does not affect radiation of the reference operating wavelength (r). The amplitude Io of
the light-sensitive cell operating signal changes upon changing concentration in accordance with
equation:
Io/Ir = ехр {-[К(o) –К (r)]СL};
(1)
where:
К ()–coefficient of absorption at a given wavelength;
L –optical length of cell;
С–measured concentration of gas;
Io, Ir –amplitude of signals at light-sensitive cell.
The concentration of gas is:
С = -Ln (Io/Ir)/(L [K (o) –К (r)]);
(2)
Using differential dual wavelength method allows eliminating influence of water vapor,
contamination of optical elements and other non-selective hindrances affecting both channels
similarly.
The sensor structure contains an optical cell with a mirror system, infrared light-emitting
diode (LED), LED driver, receivers of Signal and Reference channels, analog amplifiers,
microcontroller and supply voltages unit.
The microcontroller of the sensor performs:
- storage of unique calibration constants;
- calculation of gas concentration based on measured results;
- communication via UART output interface.

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
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2. TECHNICAL SPECIFICATIONS
Table 1. Technical specification (available options see Appendix A).
General
Gas sampling method:
Diffusion
Operating principle:
Non-Dispersive Infra-Red (NDIR)
Target gas
CH4
CH4/CH4+С2Н6
C3H8
CO2
Operating,
storage and
transportation
conditions:
Relative humidity, %
up to 98
Atmospheric
pressure, kPa
80-120
Operating
temperature*, °C
-55... +60
Temperature range*, °C
-10… +40
-40… +60
-20… +50
Overall dimensions, mm
ø20х16.5 without pins (standard and plastic versions)
ø22х16.5 without pins (fast response versions)
Pins length, mm
4,6
5.75
Weight, g
16,6
15,5
5,5
Housing
Stainless steel (standard and fast response versions)
Plastic
MTBF, years
10
Ingress protection (IP) rating
20 (without dust filter)
54 (with dust filter)
Measurement
Measurement range, % Vol
0-1.5
0-2.5
0-5
0-100
Accuracy (UART data)
Up to 0.05% Vol or 5% of indication for CO2 and C3H8
Up to 0.1% Vol or 5% of indication for CH4
Response time (T90), s
10
20
30
60

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
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Electrical
Supply Voltage Range:
+3.0…+5.0 VDC
Output signal
digital UART
Power consumption, mW
<5
Warm-up time (not more), min
2
Degree of personal protection against
electrical shock caused by the sensor
meets the requirement of class III GOST 12.2.007.0
Marking and standards
compliance
Ex ia I U/Ex ia IIC U. acc. to ГОСТ РМЭК 60079-0,
ГОСТ РМЭК 60079-11, ТР ТС 012/2011
Ex ia I Ma/Ex ia IIC Ga. acc. to IEC60079-0, IEC60079-
11, IEC60079-26. -55⁰≤ Ta ≤ +60 ⁰C
IM 1/II 1 G Ex ia I Ma / Ex ia IIC Ga. acc. to EN60079-0,
EN60079-11, EN60079-26. -55⁰≤ Ta ≤ +60 ⁰C
* Term operation temperature means the ambient temperature where the sensor can be used
safely, but the sensor accuracy supported only in temperature range (see Table 3 and Table 5).

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
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3. INTRINSIC SAFETY
Combined intrinsically safe parameters of sensor circuits are as follows:
IECEx/ATEX: Ui = 5.0V, Ii = 450mA, Pi = 0.25W, Ci = 38.8µF, Li = 0 mH.
CAN/CSA: Vmax = 5.0V, Imax = 450mA, Pmax = 0.25W, Ci = 38.8µF, Li = 0 mH.
It is allowed to connect the sensor only to intrinsically safe circuits with the rated direct
current output voltage (U0) within the range of not less than 3 V and not more than 5 V, with the
output power (P0) - not less than 0.02 W and not more than 0.25 W.
The gas-analyzing equipment, which is used with MIPEX-02, must meet the requirements of
IEC60079–0, IEC60079–11, IEC 60079-14 and have parameters conforming the MIPEX-02
intrinsic safety pointed above.

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
Revision 2.0 27 August 2015
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4. PRECAUTIONS
Inspection and maintenance of the sensor should be carried out by suitably trained
personnel in accordance with the applicable code of practice (e.g. EN 60079-17).
Any person who have studied this UM, have been briefed on safety precautions when
operating electrical equipment intended for operation in the explosion-hazardous zones in
the established order, is admitted to operate the sensor.
Do not use damaged sensor. Unauthorized repair of the sensor is not allowed.
It is strongly prohibited to discharge the control gas mixture (CGM) to the atmosphere
during the sensor calibration.
Do not allow the contact of the sensor with aggressive substances e.g. acidic liquids or
gases that might attack metals, or solvents that might affect polymeric materials.
The sensor does not contain any poisons and other harmful substances that might be
released from the sensor during its operation. Risk to humans and environment does not
exist.

OPTOSENSE LLC
Design Department
USER MANUAL
SMALL-SIZE EXPLOSIVE GAS MEASURING SENSOR MIPEX-02-Х-X-X.1 X
File name: ESAT.413347.006 UM v.2.0.docx
Revision 2.0 27 August 2015
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5. INSTALLATION AND SERVICES
5.1 Preparation
5.1.1 If the sensor has been kept in the transportation package at temperature lower than
00C, hold it at temperature of 10–35 0C for at least one hour.
5.1.2 Remove the packing. Check presence of the certification marking, ensure absence
of mechanical injuries.
5.2 Installation
Use intrinsic safety connection (see Appendix B for details).
5.2.1 Use the following recommended sockets for the sensor connection or similar:
Cambion 450-3729-01-06-00;
Harwin H3183-05;
Harwin H3182 (for the MIPEX-02-X-X-X.1 A modification).
Sensor pinout is shown in Fig. 1 of Appendix A.
5.2.2 Provide intrinsically safe power supply to the sensor from power sources featuring
nominal range of output DC voltage of not less than 3 V and not more than 5 V,
output power (P0) –not less than 0.02 W and not more than 0.25 W in accordance
with requirements of standards IEC 60079–0:2004, IEC 60079–11:2006.
5.2.3 The transceiver of UART interface should meet the requirements of standards
IEC 60079–0, IEC 60079–11.
Communication parameters of UART- transceiver are following:
- HIGH logic level for transmit line TxD is 2.8V;
- HIGH logic level for receive line RxD should be in range between 2.8V and 3.3 V;
Models MIPEX-02-X-X-3.1 X are potential electrostatic charging hazard –
clean them with a damp cloth only. Take it into account during installation
and operation of the sensor in end-user equipment.
The MIPEX-02-X-X-1.1 X and MIPEX-02-X-X-2.1 X models of the
equipment were tested and found to hold 17.4pF maximum capacitance.
Connection should be made via PCB sockets. Soldering to the pins will
seriously damage the sensor.
Excessive force on sensor housing is not allowed. For the metal housing -
no more than 2 MPa applied to reflecting cover center or on at any point of
middle part side surface and no more 100 MPa applied to boundary of
reflecting cover. For the plastic housing - no more than 20 kPa applied to
reflecting cover center or on at any point of side surface and no more 2
MPa applied to boundary of reflecting cover.
Metrological properties are not supported in ambient temperature gradient
faster than 0.6 ⁰C/min.
Set manual zeroing procedure after continues storage or transportation.