sewerin VARIOTEC 480 EX User manual

20.04.2016 a – 106606 – en
VARIOTEC®480/460/450/400 EX
Operating instructions

Connector
Buzzer
USB port
ON/OFF key
Connection for
power supply
Signal light
Gas input
Function keys
Jog dial
Connector
Display
CH4
AL4
VOL%
CH4
0,1 1,0 010 100 10
0.90
Measurement value
Capacity
disposable battery/
rechargeable
battery
Selected
application
Bar display
Alarm
Unit
Gas type
Current assignment of
function keys F1 – F3
Supporting bracket
Fig. 1: VARIOTEC 480 EX device overview
Fig. 2: VARIOTEC 480 EX display
VARIOTEC®480/460/450/400 EX

General
Menu Fault
OK Carry out device inspection
Esc
Cancel Tab
(jump to next input eld)
Buzzer o󰀨
0
Set zero point
Take sample Purge
Save Stop measurement
Clear Information
Capacity disposable
battery/rechargeable
battery
Open stored comment
Open stored inspector
Applications
Inspection above ground Gas measuring
Measuring in bar holes Warning %LEL
Enclosed spaces Warning ExTox
House Ethane analysis
Display symbols

Information about this document
The warnings and notes in the document mean the following:
ADANGER!
Risk of personal injury. Results include serious injury or
death.
AWARNING!
Risk of personal injury. Can result in serious injury or
death.
ACAUTION!
Risk of personal injury. Can result in injury or a risk to
health.
CAUTION!
Risk of damage to property.
Note:
Tips and important information.
Enumerated lists (numbers, letters) are used for:
● Instructions that must be followed in a specic sequence
Bulleted lists (bullet points, dashes) are used for:
●Lists
●Instructions comprising only one action
Numbers enclosed by forward slashes /.../ refer to referenced doc-
uments.

I
Contents Page
1 General.....................................................................................1
1.1 Warranty ...................................................................................1
1.2 Purpose.....................................................................................2
1.3 Intended use .............................................................................3
1.4 General safety information ........................................................4
1.5 Allocation of tasks to applications .............................................5
2 Features ...................................................................................6
2.1 Visual and audible signals.........................................................6
2.2 Sensors .....................................................................................8
2.3 Explosion protection..................................................................9
2.3.1 Passive explosion protection..................................................9
2.3.2 Active explosion protection ..................................................10
3 Operation ............................................................................... 11
3.1 General information on operation............................................ 11
3.1.1 Keys and jog dial.................................................................. 11
3.1.2 Selecting/exiting menus and menu items.............................12
3.1.3 Switching the device on .......................................................12
3.1.4 Selecting/switching application ............................................14
3.1.5 Di󰀨erences between measuring mode and settings mode ..15
3.2 Measuring mode .....................................................................16
3.2.1 Accessing the menu (measuring mode menu structure)......17
3.2.2 Zero point .............................................................................18
3.2.3 Inspection above ground......................................................19
3.2.4 Measuring in bar holes.........................................................20
3.2.5 Ethane analysis ...................................................................21
3.2.5.1 General information on ethane analysis............................22
3.2.5.2 Purging the detector..........................................................24
3.2.5.3 Carrying out an ethane analysis........................................25
3.2.5.4 Evaluating an ethane analysis ..........................................26
3.2.6 Enclosed spaces ..................................................................29
3.2.7 House...................................................................................30
3.2.8 Gas measuring.....................................................................31
3.2.9 Warning %LEL ....................................................................32
3.2.10 Warning ExTox .....................................................................33
3.2.11 Settings ................................................................................35
3.2.12 Start/stop/save a measurement ...........................................35
3.2.13 Protocols ..............................................................................37

II
Contents Page
3.2.14 Device inspection .................................................................38
3.2.15 Gas type CxHy .....................................................................38
3.2.16 Device information ...............................................................39
3.3 Settings ...................................................................................39
3.3.1 Opening Settings..................................................................39
3.3.2 Settings menu structure .......................................................41
3.3.3 Adjustment ...........................................................................42
3.3.4 System .................................................................................44
3.3.5 Alarms ..................................................................................46
3.3.6 Date/time..............................................................................46
3.3.7 Memory ................................................................................46
4 Power supply.........................................................................48
4.1 Suitable disposable/rechargeable battery types .....................48
4.2 Operation with rechargeable batteries ....................................49
4.2.1 Charging...............................................................................49
4.2.2 Rechargeable battery maintenance .....................................50
4.3 Battery alarm...........................................................................51
4.4 Replacing disposable/rechargeable batteries .........................51
5 Maintenance ..........................................................................53
5.1 Device inspection ....................................................................53
5.1.1 General information on the device inspection ......................53
5.1.1.1 Scope................................................................................53
5.1.1.2 Frequency .........................................................................54
5.1.1.3 Documentation..................................................................55
5.1.1.4 Integrated device inspection .............................................55
5.1.1.5 Order.................................................................................56
5.1.1.6 Test gases for the device inspection .................................56
5.1.2 Carrying out the device inspection .......................................58
5.1.2.1 Accessing the device inspection .......................................58
5.1.2.2 Concluding the device inspection......................................59
5.1.3 Testing the general status ....................................................60
5.1.3.1 Housing.............................................................................61
5.1.3.2 Signals ..............................................................................61
5.1.3.3 Probe.................................................................................61
5.1.3.4 Filter ..................................................................................62
5.1.3.5 Pump.................................................................................62
5.1.4 Testing indication accuracy with supply of fresh air .............62
5.1.5 Testing indication accuracy with supply of test gas..............63

III
Contents Page
5.2 Adjustment ..............................................................................65
5.2.1 Scope ...................................................................................65
5.2.2 Test gases for the adjustment ..............................................66
5.2.3 Special features of adjustment with gas mixture..................67
5.2.4 Preparation...........................................................................68
5.2.5 Performing the adjustment ...................................................68
5.2.5.1 Adjusting the zero point.....................................................68
5.2.5.2 Adjusting the sensitivity.....................................................69
5.2.6 Carrying out an oxygen adjustment .....................................70
5.2.6.1 Adjusting the zero point for oxygen...................................70
5.2.6.2 Adjusting the sensitivity for oxygen...................................72
5.3 Servicing .................................................................................72
6 Faults......................................................................................73
7 Appendix................................................................................74
7.1 Specications and permitted operating conditions..................74
7.2 Alarms .....................................................................................75
7.2.1 Features ...............................................................................75
7.2.2 Occupational exposure limits (OELs) and excess factors
(STEL and LTEL)..................................................................78
7.2.3 Alarm thresholds (factory settings).......................................78
7.2.4 Setting ranges for gas types ................................................79
7.3 Limit values for the device inspection .....................................79
7.4 Memory capacity .....................................................................80
7.5 Sensors ...................................................................................81
7.5.1 Gas-sensitive semiconductor (SC).......................................81
7.5.2 Catalytic combustion sensor (CC)........................................82
7.5.3 Thermal conductivity sensor (TC) ........................................82
7.5.4 Electrochemical sensors (EC)..............................................83
7.5.4.1 Oxygen O2........................................................................83
7.5.4.2 Carbon monoxide CO .......................................................83
7.6 Technical information ..............................................................84
7.6.1 Sensitivity of the catalytic combustion sensor......................84
7.6.2 Identication sticker (back of device) ...................................84
7.6.3 Cleaning ...............................................................................84
7.6.4 Electrostatic charge..............................................................85
7.7 Accessories and consumables................................................86
7.8 EU declaration of conformity ...................................................87

IV
Contents Page
7.9 Inspection protocol ..................................................................88
7.10 Advice on disposal ..................................................................90
7.11 Terminology and abbreviations ...............................................91
7.12 Referenced documents ...........................................................92
8 Index.......................................................................................93

1
1 General
1 General
1.1 Warranty
The following instructions must be complied with in order for any
warranty to be applicable regarding functionality and safe opera-
tion of this equipment. This product must only be commissioned
by qualied professionals who are familiar with the legal require-
ments (Germany: DVGW).
●Read these operating instructions prior to operating the product.
●Use the product only as intended.
●Repairs and maintenance must only be carried out by special-
ist technicians or other suitably trained personnel. Only spare
parts approved by Hermann Sewerin GmbH may be used when
performing repairs.
●Use only suitable battery types, otherwise the device will not
be explosion-proof.
● Changes or modications to this product may only be carried
out with the approval of Hermann Sewerin GmbH.
●Use only Hermann Sewerin GmbH accessories for the product.
Hermann Sewerin GmbH shall not be liable for damages resulting
from the non-observance of this information. The warranty con-
ditions of the General Terms and Conditions (AGB) of Hermann
Sewerin GmbH are not a󰀨ected by this information.
In addition to the warnings and other information in these Oper-
ating Instructions, always observe the generally applicable safety
and accident prevention regulations.
The manufacturer reserves the right to make technical changes.

2
1 General
1.2 Purpose
The VARIOTEC 480 EX and the models 460 EX, 450 EX and
400 EX are hand-held measuring devices which can be used for
all gas pipeline testing applications.
The devices are designed for professional industrial use and
require the necessary specialist knowledge for working in gas
pipelines. Example applications are described in /3/.
Models 480 EX and 460 EX can be optionally tted with a detector
for ethane analysis to help you safely distinguish between natural
gas and swamp gas.
All devices can also be individually tted with electrochemical
sensors.
Catalytic combustion sensors operate on the catalytic combustion
principle. Thermal conductivity sensors measure the specic con-
ductivity of gases. Electrochemical sensors operate on the elec-
trochemical cell principle. The gas-sensitive semiconductor reacts
to changes in conductivity brought about by reducible gases.
Note:
These operating instructions describe the VARIOTEC 480 EX with
all additional equipment (rmware version 1.XXX). All descriptions
refer to the device as delivered (factory settings) and apply to all
models. The manufacturer reserves the right to make changes.

3
1 General
1.3 Intended use
This device is intended for professional residential and commercial
use, in small rms and commercial operations and in industry. The
appropriate specialist knowledge is required to operate the device.
The device may only be used to measure the following gases
(depending on the device model and additional equipment):
●Methane CH4/ propane C3H8/ butane C4H10
●Oxygen O2
●Carbon monoxide CO
The device must not be used for:
●Gas analysis of technical processes
●Monitoring liquids
The device can be used up to a temperature of 40 ºC. However,
high temperatures reduce the lifetime of the sensors and re-
chargeable batteries.
If a device with an electrochemical sensor is exposed to gas
concentrations above the measuring range limit, this can reduce
the lifetime of the sensor.

4
1 General
1.4 General safety information
●The device has been tested to ensure that it is explosion-proof
in accordance with European standards (CENELEC).
●The device must only be switched on with fresh air.
●Do not use this device in oxygen-enriched atmospheres, oth-
erwise it will not be explosion-proof.
● Only probe hoses with a hydrophobic lter may be used.
Exception:
If the probe has a built-in hydrophobic lter, the hose does not
require any other lters.
●The device must only be tested and adjusted with test gases
in well ventilated rooms or in the open air. Test gases must be
handled in a professional manner.
●Always carry out a device inspection after the device has suf-
fered an impact (for example, if dropped accidentally) (see
Section 5.1).
● Always carry out a device inspection (see Section 5.1) after
the device has been exposed to gas concentrations above the
measuring range limit of the LEL range.
●The device complies with the limits of the EMC directive. Always
observe the information in the manuals of (mobile) radio equip-
ment when using the device close to (mobile) radio equipment.
Note:
Follow the advice regarding explosion protection (see Sec-
tion 2.3).

5
1 General
1.5 Allocation of tasks to applications
Refer to the table below to help you select the appropriate appli-
cation for a given activity (according to /3/).
Location Activity Application Gas lines, gas systems, …
●Measuring the gas concentration
– Purge to verify gas purity or absence of gas, for example, when
commissioning or decommissioning gas systems
Gas measuring
Buried gas lines ●Measuring minimal gas concentrations above:
– Ground – Gas line – Possible leakage points
Inspection above ground
●Distinguishing between natural gas and swamp gas Ethane analysis
Gas lines, gas systems, … in houses, enclosed spaces and shafts
●Warning against explosive gas concentrations through work
area monitoring
Warning %LEL
●Warning against explosive and toxic gases through work area
monitoring
Warning ExTox
In the ground ●Measuring the gas concentration to:
– Determine gas dispersion (detection limit) – Classify leaks – Locate a probable gas escape (repair point) – Prevent possible dangers
Measuring in bar holes
In enclosed spaces and shafts with an in- creased potential of gas dispersal
●Measuring the gas concentration Enclosed spaces
In the house ●Measuring very low gas concentrations
●Locating the source of gas ●Finding leaks at internal connections
House

6
2 Features
2 Features
The device comes in four models:
VARIOTEC 480 EX
VARIOTEC 460 EX
VARIOTEC 450 EX
VARIOTEC 400 EX
The models are suitable for the following applications:
Application 480 EX 460 EX 450 EX 400 EX
Inspection above ground × × ×
Measuring in bar holes
O2
×
○
×
○
×
○
Enclosed spaces × ×
House × ×
Gas measuring × × ×
Warning %LEL × ×
Warning ExTox
CO
O2
×
○
○
×
○
○
Ethane analysis ○ ○
× standard ○ Optional
2.1 Visual and audible signals
The device features two alarms:
● Signal light on top of device (visual signal)
● Buzzer on side of device (audible signal)
The signals indicate alarms and faults. The device also emits
signals when it is switched on and o󰀨.

7
2 Features
If this symbol appears on the display, the audible signal
can be switched o󰀨.
When an audible signal has been switched o󰀨 it cannot
be switched back on while the concentration level re-
mains above the alarm threshold.
This symbol appears at the top left of the display as soon
as the audible signal has been switched o󰀨. It disappears
automatically if the level falls below the alarm threshold.
Operating signal
When using the Warning %LEL and Warning ExTox applications,
the device emits a visual and audible signal at regular intervals.
This indicates that the device is working properly.
Alarm
The device can monitor several gases at the same time. If the
measured gas concentration of one or more gases exceeds spec-
ied limit values (alarm thresholds) the device gives a warning. It
emits both audible and visual signals, which are distinctly di󰀨erent
from the operating signal.
AWARNING! Danger of death due to hazardous gas
concentrations
The alarms AL1, AL2 and AL3 always indicate danger.
Alarm AL4 indicates the possibility of danger.
●Take all necessary measures for your own safety and
the safety of others immediately.
There is detailed information on alarms in Section 7.2.

8
2 Features
2.2 Sensors
The device features four types of sensor:
● Gas-sensitive semiconductor (SC)
● Catalytic combustion sensor (CC)
● Thermal conductivity sensor (TC)
● Electrochemical sensor (EC)
Application Gas Measuring range Sensors
Inspection above
ground
CH41 ppm – 10 % vol. SC, TC
Measuring in bar
holes
CH40.0 – 100 % vol. TC
Enclosed spaces CH41 ppm – 100 % vol. SC, TC
House CH41 ppm – 100 % vol. SC, TC
CO 0 – 500 ppm EC
Gas measuring CH40.0 – 100 % vol. TC
Warning %LEL and
Warning ExTox
CH40 – 100 % LEL CC
O20 – 25 % vol. EC
CO 0 – 500 ppm EC
Ethane analysis CH4--- Gas chroma-
tograph, SC,
TC
C2H6
C3H8

9
2 Features
2.3 Explosion protection
2.3.1 Passive explosion protection
The device is assigned to the following explosion-proof groups:
Explosion-proof
group
For the following atmos-
pheres
When us-
ing
II2G Ex d e ib IIB T4 Gb – Methane CH4
– Propane C3H8
– Butane C4H10
– Carbon monoxide CO
Device
without
carrying
bag TG8
II2G Ex d e ib IIC T4 Gb – Methane CH4
– Propane C3H8
– Butane C4H10
– Carbon monoxide CO
– Hydrogen H2
Device with
carrying
bag TG8
EC type-examination certicate: TÜV 07 ATEX 553353 X
ADANGER! Risk of explosion due to sparks
●Only open the battery compartment outside of explo-
sive areas.
●Only charge the device outside of explosive areas.
●Only use the USB port outside of explosive areas.
●Use only suitable battery types.
●When working with hydrogen, always use the carrying
bag TG8 for the device.

10
2 Features
2.3.2 Active explosion protection
The functional safety test applies to:
Applications: Warning %LEL
Warning ExTox
Gas types: Measuring range:
– Methane CH40 – 100 % LEL
– Propane C3H80 – 100 % LEL
Gases: Measuring range: As per:
– Oxygen O20 – 25 % O2/7/
– Carbon monoxide CO 0 – 500 ppm CO /5/
Tested accessories: – Test set SPE VOL
– Flexible hand probe, 1 m
– Floating probe 2 m, 6 m
Type examination
Testing institute: DEKRA EXAM GmbH
Certicates: PFG 08 G 002 X N1
BVS 09 ATEX G 001 X N1
The following points were not part of the type examination:
● Saving measurement data (see Section 3.2.12)
●Saving protocols from the integrated device inspection (see
Section 5.1.1.4)
●Disposable alkaline batteries for the power supply (see Sec-
tion 4.1)

11
3 Operation
3 Operation
3.1 General information on operation
3.1.1 Keys and jog dial
The ON/OFF key is the only control on the device that does not
change its function.
When switched on, the device is operated using the jog dial and
function keys to navigate the display.
Control Action Function
ON/OFF key Press ●Switches the device on
● Switches the device o󰀨
Function keys
F1, F2, F3
Press ●Variable
●As indicated on the display at
the bottom of the screen
●Function keys may also have
no function assigned in some
cases
Jog dial Turn ●Selects functions, settings,
measurement data, etc.
● Modies values
Press ●Opens the next program lev-
el (e.g. menu item, function,
measurement data, selectable
values)
●Accepts values

12
3 Operation
3.1.2 Selecting/exiting menus and menu items
Functions, applications and settings etc. are selected via the
main menu (for short: Menu). This menu has submenus and
menu items. Refer to Section 3.2.1 for information on accessing
the menu.
Selecting submenus/menu items
Submenus and menu items are selected and opened using the
jog dial and/or function keys.
In measuring mode the name of the selected application is in-
dicated by the symbol at the top left of the display. You can nd
detailed information on how to select or switch applications in
Section 3.1.4.
Exiting menus/menu items
There are generally two ways to exit open menus/menu items
and go back up a level:
●Press Esc
●Select Exit menu item
3.1.3 Switching the device on
Note:
Always switch the device on with fresh air.
1. Press the ON/OFF key. The device switches on.
The switching on process involves an internal check.
Process Test purpose
Buzzer emits audible
signal.
Is the audible signal working?
Signal light gives visual
signal.
Is the visual signal working?
Display is inverted. Are there pixels missing from the
display?