Mipex MIPEX-04 User manual

Optosense LLC
USER MANUAL
Design department
MIPEX-04 ULTRA-LOW POWER INFRARED GAS SENSOR
ESAT.100000.00.02 UM
Revision 02
December 12th, 2016
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ULTRA-LOW POWER INFRARED GAS
SENSOR MIPEX-04
USER MANUAL
ESAT.100000.00.02 UM

Optosense LLC
USER MANUAL
Design department
MIPEX-04 ULTRA-LOW POWER INFRARED GAS SENSOR
ESAT.100000.00.02 UM
Revision 02
December 12th, 2016
Page 2 of 41
THE SOLE PROPERTY OF OPTOSENSE LLC. ANY REPRODUCTION WITHOUT THE WRITTEN PERMISSION OF OPTOSENSE LLC IS PROHIBITED.
INFORMATION CONTAINED IN THIS DOCUMENT IS THE SOLE PROPERTY OF OPTOSENSE
LLC. ANY REPRODUCTION IN PARTS OR AS A WHOLE WITHOUT THE WRITTEN
PERMISSION OF OPTOSENSE LLC IS PROHIBITED.
Document revisions
Rev.
Date
Common changes
02
December 12th, 2016
Formatting.
Temperature zero adjustment manual mode has been excluded
(see Appendix D.2).
Added information on displaying certain status word values in
concentration field while “INDSIG” mode is active (see Table 12).
Added information on concentration values exceeding
measurement range (see section 6.4).
Ordering codes for gas adapter and interface board have been
added.
Direct UART output has been added on Fig. 9.
Recommended sampling frequency by sending command <F> is
changed for troubleshooting from 0.1 Hz to 0.6 Hz (see Appendix
F).
01
March 11th, 2016
Released version.

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Table of contents
1. Introduction ...........................................................................................................................4
1.1. List of abbreviations......................................................................................................4
1.2. List of terms..................................................................................................................4
2. Description.............................................................................................................................5
3. Technical specifications .......................................................................................................6
4. Intrinsic safety.......................................................................................................................8
5. Handling precautions............................................................................................................9
6. Installation and service.......................................................................................................10
6.1. Preparation.................................................................................................................10
6.2. Mounting.....................................................................................................................10
6.3. Electrical conditions....................................................................................................10
6.4. Getting started............................................................................................................13
7. Storage and transporation..................................................................................................14
8. Warranty...............................................................................................................................15
9. Contacts...............................................................................................................................16
Appendix A. Sensor types and characteristics .....................................................................17
Appendix B. Connection diagram ..........................................................................................23
Appendix C. Sensor communication protocol ......................................................................26
Appendix C.1. General information .....................................................................................26
Appendix C.2. Communication protocol commands............................................................27
Appendix C.2.1. Commands for requesting measured data and diagnosing................27
Appendix C.2.2. Commands for controlling operating mode ........................................30
Appendix C.2.3. Commands for requesting factory settings and properties .................30
Appendix C.2.4. Commands for sensor configuring and span calibrating.....................31
Appendix D. Sensor configuration.........................................................................................34
Appendix D.1. Zeroing and span calibration........................................................................34
Appendix D.2. Temperature dependence of zero adjustment..............................................36
Appendix E. Dust filter attaching ...........................................................................................38
Appendix F. Troubleshooting.................................................................................................39

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USER MANUAL
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1. INTRODUCTION
This user manual (UM) is intended to describe design and operation of small-sized gas
sensor MIPEX-04-X-XX-3.1 (hereinafter MIPEX-04 or sensor). UM contains basic technical data,
recommendations and other information necessary for proper operation, maintenance and storage
of sensor.
Sensor is intended for automatic continuous measurement of hydrocarbons concentration in
atmosphere of hazardous areas. Sensor can be used as a part of gas-analyzing equipment groups
I and II according to IEC 60079-0 in the explosion-hazardous zones classes 0, 1, 2 according to
IEC 60079-10-1, and Class I, Division 1, Group A, B, C, D according to UL Std. 913, CAN/CSA
Std. C22.2 No.157-92.
Any command stated in this UM as <X>, where X stands for a command text consisted of
any number of characters, must be read and/or sent without the symbols “<” and “>”.
Optosense LLC reserves the right to make changes to this manual, excluding
intrinsically safe sensor parameters.
1.1. List of abbreviations
LEL stands for Lower Explosive Limit;
LED stands for Light Emitting Diode;
CGM stands for Control Gas Mixture;
NDIR stands for Non-Dispersive Infra-Red;
UART stands for Universal Asynchronous Receiver/Transmitter.
CRC stands for Cyclic Redundancy Check.
IP stands for Ingress Protection.
PCB stands for Printed Circuit Board.
1.2. List of terms
Target gas is a gas, which sensor is intended to detect and measure its concentration.
Calibration gas refers to CGM containing that gas, used for sensor calibration.
Any command stated in this UM as <X>, where X stands for a command text consisted of
any number of characters, must be read and/or sent without the symbols “<” and “>”.

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2. DESCRIPTION
Sensor has several modifications for specific needs. They differ by photodiode and LED
types, calibration gases, measuring ranges etc. (see Appendix A).
Sensor is a smart integrated system and includes mirror optical system, photodiode and
LED, signal amplifiers, microcontroller, current driver of the infrared LED, UART interface signal
generator and forming voltage supply unit. Sensor microcontroller performs storage of unique
sensor calibration constants, processing of measurement results and concentration of measured
gas, and information exchange.
Sensor operating principle is based on NDIR technology, i.e. on selective infrared radiation
absorption by gas molecules.
Infrared radiation from LED permeates through a measuring diffusion-type gas cell and
arrives on signal and reference photodetectors, one of which detects radiation only in the
wavelength range of infrared radiation absorbed by gases, while the other one detects radiation
only in the wavelength range of 3.5…3.7 μm. Gas flowing through the cell absorbs the radiation of
the operating wavelength (s) and does not affect the radiation of the reference wavelength (ref).
Amplitude Usof the photodetector operating signal varies with the concentration of the target gas in
accordance with the following equation:


 󰇛󰇟󰇛󰇜 󰇛󰇜󰇠   󰇜
where:
󰇛󰇜 –absorption coefficient at the predetermined wavelength;
L–optical length of the cell;
–measured concentration of gas;
Us,Uref –signal amplitude at photodetector.
Differential dual wavelength method allows eliminating of water vapor, optical elements
contamination and other non-selective hindrances influence.
Target gases available for MIPEX-04 are listed in Table 1.
Table 1. Target gases for MIPEX-04 sensors
Target gas
Analytical tasks
description
Optical elements
code (see
Appendix A)
Spectral
characteristic
maximum
Notes
CH4
Analyzing a gas mixture
containing methane as
the main component.
1
3.31 m
For the optical
elements sensitivity to
other hydrocarbons
see Fig. 4.
C3H8
Analyzing a gas mixture
containing heavy
hydrocarbons. The
presence of methane is
negligible.
2
3.40 m
For the optical
elements sensitivity to
other hydrocarbons
see Fig. 5.

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3. TECHNICAL SPECIFICATIONS
Table 2. General specifications (for available options see Appendix A)
Gas sampling method
Diffusion
Operating principle
Non-Dispersive Infra-Red (NDIR)
Target gas1
CH4
C3H8
Operating,
storage and
transportation
conditions:
Relative humidity, %
up to 98
Atmospheric pressure, kPa
80…120
Temperature2, °C
-40...+60
Temperature range, °C
-10…+40
-40…+60
-20…+50
Overall dimensions, mm
52×24×18
Warm-up time, sec
≤ 120
Weight, g
11
Housing material
Polycarbonate Lexan™
Lifetime expectancy3(not less than), years
7
IP rating
20 (without dust filter)
54 (if a dust filter provided by Optosense LLC is
applied, see Appendix E)
Table 3. Measurement specifications
Typical measurement range, % vol.
0…2.5
0…5
0…100
Basic variability (+20…+25 °C)4
± 0.1% vol. or ± 5% of readings (whichever is greater) for CH4
± 0.05% vol. or ± 5% of readings (whichever is greater) for
C3H8
Response time (T90), sec
12 (without dust filter)
22 (if a dust filter provided by Optosense LLC is applied, see
Appendix E)
1
See Appendix A for details.
2
Term “operating temperature” refers to ambient temperature at which sensor operates and its
intrinsic safety is ensured, but sensor accuracy stated in Table 3 is provided only in specified temperature
range (see Table 5 and Table 6).
3
To provide metrological properties during sensor lifetime, span calibration should be performed
periodically (see Ошибка! Источник ссылки не найден.).
4
For variability in whole operating temperature range for any sensor modification refer to Table 6.

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Table 4. Electrical specifications, marking and standards compliance
Operating supply voltage, VDC
+2.8…+5.0
Max supply voltage, VDC
+5.5
Communication interface
UART
Average current, μA
35
Marking and standards compliance
Sensor is not certified.
It is designed in accordance with various international
standards.
IEC/EN 60079-0, IEC/EN 60079-11:
Explosion protection level –“ia”;
Hazardous area class (Electrical equipment group) –“I”
and “IIC”;
Temperature class –“T6”.
UL913, CAN/CSA-C22.2 No. 157-92:
Class I, Division 1, Group A, B, C, D.

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4. INTRINSIC SAFETY
Sensor’s intrinsic safety is provided by:
limiting the parameters of its electrical circuits to intrinsically safe values in accordance
with EN 60079-11;
providing the required electrical clearances and creepage paths in accordance with EN
60079-11.
Combined intrinsically safe sensor circuits parameters:
IECEx/ATEX: Ui= 5.5 V, Ii= 200 mA, Pi= 0.13 W, Ci= 26 µF, Li= 0 mH.
CAN/CSA: Vmax = 5.5 V, Imax = 200 mA, Pmax = 0.13 W, Ci= 26 µF, Li= 0 mH.
It is allowed to connect sensor only to intrinsically safe circuits with the rated direct current
output voltage (U0) within the range of +2.8…+5.5 V and with the output power (P0) range of
0.02…0.13 W in accordance with IEC 60079-0, IEC 60079-11 and whose parameters conform
MIPEX-04 intrinsic safety values pointed above. Current provided by power supply unit must be 20
mA ≤I0≤200 mA.

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5. HANDLING PRECAUTIONS
Do not use damaged sensor. It must be repaired only by personnel authorized by
manufacturer.
Keep sensor out of contact with aggressive substances e.g. acidic environments, which
can react with metals, as well as solvents, which may affect polymeric materials.
Diffusion holes of sensor should be protected against ingress of dust and sprayed
materials.
Sensor is not intended to measure hydrocarbons contained in fluids.
It is not allowed to use brazing furnace, infrared or convection ovens for soldering
sensor contacts to end-user equipment. Soldering conditions stated in 6.2 must not be
violated. Spot soldering only.
Maximum pressure on sensor top surface must not exceed 1 MPa.
It is not allowed to apply pressure on sensor side surface.
Sensor updates information about concentration every 1.32 ±0.04 seconds. Sending
any command more often than one time per 2 second (0.5 Hz) may reduce sensor
accuracy and increase its current consumption.
Correct measurement is provided when ambient temperature changes not faster than
0.6 °C/min.
Sensor may accumulate an electrostatic charge on its housing. Thus, there is risk of
electrostatic discharge. Clean only using a damp cloth. Note this during installation and
use of sensor in the end-user equipment.
Covering diffusion holes of sensor increases its response time (T90).
When operating sensor, observe conditions stated in Table 2 and Table 4.
Inspection and maintenance should be carried out by suitably trained personnel in
accordance with the applicable code of practice (e.g. EN 60079-17).
Persons, who have studied this UM, must be briefed on safety precautions when
operating electrical equipment intended for use in explosive areas in due course.
When dealing with cylinder containing gas mixture under pressure, it is necessary to
follow the safety regulations. Dumping of CGM into the work area is not allowed.
There is no risk of pollution and negative impact on human health. Sensor does not
contain any harmful substances that may be released during its normal operation.
It is strictly prohibited to remove label from sensor or to damage marking information in
any way.

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6. INSTALLATION AND SERVICE
MIPEX-04 may accumulate an electrostatic charge on its housing. Thus,
there is risk of electrostatic discharge. Clean only using a damp cloth. Note
this during installation and use of sensor in the end-user equipment.
Sensor must be mounted with its contacts soldered to mating PCB pads.
Using of brazing furnace for this purpose is not allowed. Soldering conditions
stated in 6.2 must not be violated. Spot soldering only.
Maximum pressure load on sensor top surface must not exceed 1 MPa.
It is not allowed to apply pressure on sensor side surface.
Span calibration is necessary during initial installation to gas analyzers and
during preparation for the yearly tests. Manual zeroing must be performed
after prolonged storage without power supply, after transportation as well as
after dust filter is applied (see Appendix D.1).
It is required to perform span calibration at least once in 2.5 years.
6.1. Preparation
If sensor has been kept in transport containers at temperatures below zero centigrade,
leave it at 10…35 °C for at least an hour.
Remove the packaging. Make sure there are no mechanical injuries on sensor surfaces.
6.2. Mounting
Sensor should be mounted with its contacts soldered to mating PCB pads. Spot soldering
only. Maximum soldering temperature is 350 °C; maximum soldering time is 3 s.
Recommended mating board configuration and sensor pinout are shown in Appendix A.
End-user equipment design has to provide that sensor is free of excessive pressure on its
housing, ingress of dust, dirt and condensed moisture, as these factors may affect the accuracy of
measurement. It is recommended to use dust filter (available as an option; see Appendix E). Filter
has to be checked regularly and replaced when fouling is significant.
6.3. Electrical conditions
During first 0.01 seconds after power up, sensor consumes up to 18 mA (see
Fig. 1).
During operation MIPEX-04 has pulsed power consumption. Pulse repetition
period is about 320 ms, maximum surge current is 4 mA. Average power
consumption is 35 μA (see Fig. 2 and Fig. 3).
Sending any command more often than one time per 2 second (0.5 Hz) may
reduce sensor accuracy and increase its current consumption.
Use intrinsically safe circuit connections represented in Appendix B.
Sensor power supply has to follow requirements of IEC 60079-0 and IEC 60079-11, with
rated output range of intrinsically safe DC voltage U0of +2.8…+5.0 V, with rated power range P0of
0.02…0.13 W. Current provided by power supply unit must be 20 mA ≤I0≤200 mA.

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Sensor transmits information about measured concentration via UART interface. Sensor
supports embedded self-testing while operating and is designed for continuous 24/7 operation.
End-user equipment UART transceiver should meet the requirements of standards
IEC 60079-0, IEC 60079-11.
Sensor UART transceiver communication properties are:
High logic level for transmitting line TxD is +2.1 V;
High logic level for receiving line RxD is in range of +2.1…+2.3 V;
Low logic level is in range of +0.1…+0.6 V;
Maximum output current of UART is not more than 2.1 mA.
Fig. 1. Typical sensor voltage drop after power up (load resistance R = 100 Ohm)
-0.3
-0.1
0.1
0.3
0.5
0.7
0.9
1.1
1.3
1.5
1.7
1.9
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Voltage U, V
Time T, s

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Fig. 2. Typical voltage drop within a single operating period (3.3 V Input; R = 100 Ohm)
Fig. 3. Typical voltage drop within a single operating period and while data transferring
(3.3 V input; R = 100 Ohm)
-0.05
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0 0.005 0.01 0.015 0.02 0.025
Voltage U, V
Time T, s
-0.1
-0.05
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0 0.005 0.01 0.015 0.02 0.025
Voltage U, V
Time T, s

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6.4. Getting started
If “INDSIG” mode is active, during first 40 seconds after the power is up sensor
does not return the measured concentration value (the value is displayed as “-
1”, hex: “8001”, see Table 12).
When the measurement range is exceeded, concentration value is displayed
as “32767” (hex: “7FFF”).
Sensor updates information about concentration every 1.32 ±0.04 seconds
(depends on ambient temperature and whether UART is active or not).
Correct measurement is provided when ambient temperature changes not
faster than 0.6 °C/min.
Switching on/off sensor is performed automatically upon feeding/disconnecting power
supply.
After sensor is installed into end-user equipment check its status by sending command
<DATAE2> via UART interface:
for <DATAE2> command description see Appendix C.2.1;
for response description and recommendations see Table 10.
Sensor span calibration and zeroing should be performed next. Methods of sensor span
calibration and zeroing are given in Appendix D.1.

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7. STORAGE AND TRANSPORATION
Transportation can be done by all means of transportation in covered vehicles as well as in a
heated pressurized plane compartments in accordance with the rules of cargoes transportation
actual for the respective type of transportation.
Sensor in manufacturer’s package should be kept in supplier’s and customer’s storages
under storage conditions specified in Table 2. Ambient atmosphere should be free of any harmful
impurities, which can cause corrosion.

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8. WARRANTY
Manufacturer guarantees sensor compliance with specifications and requirements stated in
this UM if customer follows operating, transportation and storage terms.
During warranty period, manufacturer replaces or repairs for free all products, which do not
work because of production fault.
Warranty period is 24 months since product is shipped to customer. Shipment date is
registered in the ESAT.100000.00.XX PS manufacturer’s certificate.
Manufacturer is not responsible for sensor fault and discontinues warranty in following cases:
if the rules and conditions of operation, transportation and storage stated in this UM and
in Data Sheet for sensor were violated;
if sensor has marks of unauthorized repair attempts;
if any mechanical damage occurs and/or if any damage is caused by exposure to
extremely high or low temperatures, corrosion, oxidation, ingression of any foreign
objects, materials, liquids, insects;
if sensor was damaged by using connection circuit, which not complies with
requirements stated in this UM;
if damage is caused by force majeure, accident, intentional or careless actions of the
customer or third parties;
if damage (or fault) is caused by installing, editing or damaging sensor firmware and/or
by making changes to the firmware settings using service codes;
if damage (or fault) is caused by the fact of power and signal cables does not meet the
standard or technical regulations and/or by electromagnetic interferences exceeding
permissible according to EN 60079-29-1.
Replacement or repairs of faulty sensor does not extend initial warranty period.
Manufacturer is not responsible for any possible damage directly or indirectly caused by
sensor to people and property in case it is a result of improper usage, storage and transportation
or due to intentional or careless actions of the customer and/or third parties.
Risks and costs of transportation and packaging as well as other contingencies concerning
product return to manufacturer are carried out by the customer.

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9. CONTACTS
MIPEX TECHNOLOGY / Оptosense LLC
27AD, Engelsa prospekt, St. Petersburg, 194156, Russia
Tel/fax: [phone]
web: http://www.mipex-tech.com
e-mail: [e-mail]
support: [e-mail]

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APPENDIX A. SENSOR TYPES AND CHARACTERISTICS
MIPEX-04-B-RX-3.1
Interface options:
1. UART
Housing type:
3. “Plastic”
Application:
R–calibration gas and range*
X–temperature class and accuracy**
Target gas**:
1. CH4(methane)
2. C3H8(propane, CmHn–hydrocarbons)
MIPEX model number
*See Table 5 for details.
** See Table 6 for details.

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Table 5. Metrological properties of sensor (RX-code)
Part number
Target gas5
Calibration
gas
Measurement
range, % vol.
Temperature
range, °C
RX-code
MIPEX-04-1-00-3.1
CH4
CH4
0…2.5
-10…+40
00
MIPEX-04-1-10-3.1
0…5
10
MIPEX-04-1-20-3.1
0…100
20
MIPEX-04-1-01-3.1
0…2.5
-40…+60
01
MIPEX-04-1-11-3.1
0…5
11
MIPEX-04-1-21-3.1
0…100
21
MIPEX-04-1-02-3.1
0…2.5
-20…+50
02
MIPEX-04-1-12-3.1
0…5
12
MIPEX-04-1-22-3.1
0…100
22
MIPEX-04-1-61-3.1
C3H8
0…1.5
-40…+60
61
MIPEX-04-1-71-3.1
0…2.5
71
MIPEX-04-1-62-3.1
0…1.5
-20…+50
62
MIPEX-04-1-72-3.1
0…2.5
72
MIPEX-04-2-61-3.1
C3H8
C3H8
0…1.5
-40…+60
61
MIPEX-04-2-71-3.1
0…2.5
71
MIPEX-04-2-62-3.1
0…1.5
-20…+50
62
MIPEX-04-2-72-3.1
0…2.5
72
5
Typical sensor sensitivity to other hydrocarbons is shown on Fig. 4 and Fig. 5.

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Table 6. Basic sensor readings variability
6
Calibration
gas
Readings variability within a
temperature range
Additional variability
due to pressure
Additional variability
due to humidity
CH4
±0.1% vol. or ±5% of indication
(whichever is greater) within the
range of +20…+25 °C
±0.2% vol. or ±30% of
indication (whichever
is greater) at 100 kPa
(test: 80 kPa, 100 kPa,
120 kPa)
±0.2% vol. or ±15% of
indication at 40 °C
(test: 20% RH, 50%
RH, 90% RH)
±0.2% vol. or ±10% of indication
(whichever is greater) within the
range of -10…+20 °C and
+25…+40 °C
±0.4% vol. or ±20% of indication
(whichever is greater) within the
range of
-40…-10 °C and +40…+60 °C
C3H8
±0.05% vol. or ±5% of indication
(whichever is greater) within the
range of
+20…+25 °C
±0.1% vol. or ±30% of
indication (whichever
is greater) at 100 kPa
(test: 80 kPa, 100 kPa,
120 kPa)
±0.1% vol. or ±15% of
indication (whichever
is greater) at 40 °C
(test: 20% RH, 50%
RH, 90% RH)
±0.1% vol. or ±10% of indication
(whichever is greater) within the
range of
-10…+20 °C and +25…+40 °C
±0.2% vol. or ±20% of indication
(whichever is greater) within the
range of -40…-10 °C and +40…+60
°C
6
Table shows basic variability of MIPEX-04 readings. For each sensor modification, readings
variability stated in Table 6 is provided within a temperature range determined by a sensor RX code (see
Table 5).

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Fig. 4. Typical sensitivity of MIPEX-04-1-XX-3.1 (target and calibration gas is CH4) to other
hydrocarbons
Fig. 5. Typical sensitivity of MIPEX-04-2-XX-3.1 (target and calibration gas is C3H8) to other
hydrocarbons
0
50
100
150
200
250
020 40 60 80 100 120
Sensor readings % LEL
Gas mixture concentration, % LEL
CH4
C3H8
C2H6
C4H10
C6H14
C2H4
0
20
40
60
80
100
120
140
020 40 60 80 100 120
Sensor readings, % LEL
Gas mixture concentration, % LEL
C3H8
C4H10
C5H12
C6H14
CH4