MSA 47K, 47K-PRP, 47K-HT-PRP Operation Manual

MSAsafety.com

Operation Manual

Series 47K Gas Detector [SIL 2]

Order No.: 10052472/14

Schlüsselstrasse 12
8645 Rapperswil-Jona
Switzerland

© MSA 2016. All rights reserved

For the Declaration of Conformity, please visit the product page on MSAsafety.com.

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MSA CONTENTS

Series 47K Gas Detector [SIL 2] 3

Contents

1. Safety Regulations .............................................................................................. 6

1.1. Correct Use ................................................................................................ 6

1.2. Liability Information .................................................................................... 6

1.3. Application, Advice and Restrictions .......................................................... 7

2. Description ........................................................................................................... 8

2.1. General ...................................................................................................... 8

2.2. Principle of Operation ................................................................................. 9

2.3. Technical Specification ............................................................................... 9

3. Installation .......................................................................................................... 11

3.1. Installation – Step by Step ........................................................................ 11

3.2. Unpacking ................................................................................................ 11

3.3. General Installation Instructions for Achieving EMC Compliance ............. 11

3.4. Recommended Torque and Terminal Sizes ............................................. 12

3.5. Electrical Connection to the Control Unit .................................................. 13

3.5.1 Junction Box Terminals ................................................................................. 13

3.5.2 Maximum Cable Length ................................................................................ 13

3.6. Electrical Connections .............................................................................. 14

4. Start-up ............................................................................................................... 14

5. Maintenance and Service .................................................................................. 15

5.1. Calibration ................................................................................................ 15

5.1.1 Zero Calibration ............................................................................................. 16

5.1.2 Span Calibration ............................................................................................ 16

5.1.3 Calibration with Accessories ......................................................................... 16

5.2. Sensor Replacement ................................................................................ 17

5.3. Series 47K-PRP and Series 47K-HT-PRP ............................................... 18

5.3.1 47K-HT-PRP .................................................................................................. 19

5.3.2 47K-PRP ........................................................................................................ 19

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CONTENTS MSA

4 Series 47K Gas Detector [SIL 2]

6. Accessories ....................................................................................................... 22

6.1. Calibration Cap ........................................................................................ 22

6.2. Weather Protection Cap ........................................................................... 22

6.3. Flow Through Adapter / Pump Adapter .................................................... 23

6.4. Duct Mount Flange ................................................................................... 24

6.5. Pipe Mounting Kit ..................................................................................... 25

6.5.1 Mounting Kit for Pipes with a Diameter of up to 50 mm ................................ 25

6.5.2 Mounting Kit for Pipes with a Diameter from 50 mm to 150 mm .................. 26

6.6. Remote Calibration Adaptor (CalGard) .................................................... 26

6.6.1 Installation ...................................................................................................... 27

6.6.2 Operation ....................................................................................................... 28

7. Markings, Certificates and Approvals ............................................................. 29

7.1. According to the Directive 2014/34/EU [ATEX] ........................................ 29

7.1.1 Series 47K-PRP, Series 47K-HT-PRP .......................................................... 29

7.1.2 Junction Box Typ S47K and X Series AL Junction Box ................................ 30

7.2. According to IECEx .................................................................................. 31

7.3. Special Conditions for SIL 2 According to TUV Certificate 968 /

EZ 392.00/09 ............................................................................................ 32



8. Ordering Information ......................................................................................... 34

8.1. Gas Detector (Sensor + Junction Box) ..................................................... 34

8.2. Gas Detector, Calibrated with Certified MSA Gas Controllers .................. 34

8.3. Sensor ...................................................................................................... 34

8.4. Junction Box ............................................................................................. 35

8.5. Accessories .............................................................................................. 35

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MSA CONTENTS

Series 47K Gas Detector [SIL 2] 5

9. Dimensions ........................................................................................................ 36

9.1. Gas Detector (Ex e Junction Box) ............................................................ 36

9.2. Gas Detector (Ex d Junction Box) ............................................................ 37

9.3. S47K Adapter Plate (Junction Box) .......................................................... 38

9.4. Wall Mounted Bracket, Sensor 47K-HT-PRP ........................................... 38

9.5. Junction Box ATEX 100 °C; Sensor 47K-HT-PRP ................................... 39

9.6. Pipe Mounting Kit ..................................................................................... 40

9.6.1 Mounting Kit for Pipes with a Diameter of up to 50 mm ................................ 40

9.6.2 Mounting Kit for Pipes with a Diameter from 50 mm to 150 mm .................. 41

9.7. Remote Calibration Adaptor ..................................................................... 42

10. Wiring Diagrams ................................................................................................ 43

10.1. MSA Control Unit SUPREMA ................................................................... 43

10.1.1 Series 47K-PRP/-HT-PRP [3-wire] ................................................................ 43

10.1.2 Series 47K-PRP/-HT-PRP [5-wire] ................................................................ 44

10.2. MSA Control Unit 9010 / 9020 Series ....................................................... 44

10.2.1 Series 47K-PRP/-HT-PRP [3-wire] Channel A ............................................. 44

10.2.2 Series 47K-PRP/-HT-PRP [3-wire] Channel B ............................................. 45

10.3. MSA Control Unit Gasgard XL ................................................................. 45

10.3.1 Series 47K-PRP [3-wire] ............................................................................... 45

10.3.2 Series 47K-HT-PRP ...................................................................................... 46

10.4. Wiring Diagram Sensor 47K-HT-PRP with Junction Box ATEX 100 °C ... 46

11. Appendix ............................................................................................................ 47

11.1. Discontinued Gas Detectors ..................................................................... 47

11.1.1 47K-ST ........................................................................................................... 47

11.1.2 47K-HT .......................................................................................................... 48

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SAFETY REGULATIONS MSA

6 Series 47K Gas Detector [SIL 2]

1. Safety Regulations

1.1. Correct Use

The MSA Gas Detector Series 47K is designed to continuously monitor the
atmosphere for the presence of potentially explosive gas or vapour in air in the
range 0 to 100% LEL.

It is designed for use as an integral part of an MSA fixed gas detection system for
the protection of industrial plant and workers.

It is imperative that this operating manual be read and observed when using the
system. In particular, the safety instructions, as well as the information for the use
and operation of the apparatus, must be carefully read and observed.
Furthermore, the national regulations applicable in the user's country must be
taken into account for a safe use.

Danger

This product is supporting life and health. Inappropriate use,
maintenance or servicing may affect the function of the device and
thereby seriously compromise the user’s life.

Before use, the product operability must be verified. The product must
not be used if the function test is unsuccessful, it is damaged, a
competent servicing/maintenance has not been made, genuine
MSA spare parts have not been used.

Alternative use, or use outside this specification will be considered as non­compliance. This also applies especially to unauthorised alterations to the
apparatus and to commissioning work that has not been carried out by MSA or
authorised persons.

1.2. Liability Information

MSA accepts no liability in cases where the product has been used
inappropriately or not as intended. The selection and use of the product are the
exclusive responsibility of the individual operator.

Product liability claims, warranties also as guarantees made by MSA with respect
to the product are voided, if it is not used, serviced or maintained in accordance
with the instructions in this manual.

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MSA SAFETY REGULATIONS

Series 47K Gas Detector [SIL 2] 7

1.3. Application, Advice and Restrictions

This Manual should be carefully read by those responsible for use and
maintenance of the gas detection and monitoring system.

 The series 47K catalytic sensor is suitable for the detection of gases or

vapours in air with a concentration below the Lower Explosive Limit [LEL].

 The series 47K catalytic sensor cannot measure concentrations of gases or

vapours in inert atmospheres or oxygen deficient atmospheres. The European
standard EN 60079-29-2 indicates an Oxygen concentration higher than
10 vol% is necessary for correct operation of catalytic sensors.

Attention
The certification does not permit use of the series 47K sensor in

oxygen enriched atmospheres.

 The series 47K catalytic sensors can be poisoned by high levels or long

exposure to certain substances present in the atmosphere being monitored.
When a catalytic sensor is installed in a place where those substances may
be present, to ensure the correct operation and measurement accuracy the
sensor should be calibrated more frequently.

 The sensitivity of the series 47K catalytic sensors is reduced by the presence

of silanes, silicates, silicones, tetraethyl lead, halogen compounds, sulphurous
compounds, organic-phosphorous compounds and compounds containing:
fluorine, chlorine, iodine or bromine, therefore the sensors must be
recalibrated after exposure to these substances.

 The series 47K sensor opening [sintered disc] must be protected against

water, dust and mechanical damage. During painting operations in the area
where the sensor is installed, avoid traces of paint on the sensor opening. The
paint must not interfere with the diffusion process.

 Note that the sensor opening [sintered disc] must always face downwards.
 After having exceeded the full scale value an increased display of measured

values can appear temporarily. During this period no calibration must be
performed.

The only method of verifying the correct operation of the sensor is to carry out a
span check using a known concentration of calibration gas in air.

For response curves contact your national MSA office.

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DESCRIPTION MSA

8 Series 47K Gas Detector [SIL 2]

2. Description

2.1. General

The MSA Gas Detector Series 47K is designed to continuously monitor the
atmosphere for the presence of potentially explosive gas or vapour in air in the
range 0 to 100% LEL.

It is designed for use as an integral part of an MSA fixed gas detection system for
the protection of industrial plant and workers.

 Typical areas where the MSA Series 47K Gas Detector can be used include:
 The chemical and petrochemical industry
 The paint and solvent-processing industry
 The gas-processing industry
 The steel-processing industry
 Municipal areas
 The Production, Warehousing, Distribution, Shipping and processing of gases

and vapours

The MSA Series 47K Gas Detector consists of the Series 47K catalytic sensor
and the junction box that contains the terminal board.

There are two versions of the junction box available:

 Flameproof [Ex d] with ¾” NPT cable gland thread
 Increased safety [Ex e] with metric M25 cable gland thread

The following Sensor Versions are available:

 Series 47K-PRP: Poison Resistant Pellistor [100% LEL]
 Series 47K-HT-PRP: High Temperature Poison Resistant Pellistor

[100 % UEG]

All versions are available in Stainless Steel 316.

Four accessories are available to allow easy calibration and to adapt the gas
detector to various applications:

 Calibration cap
 Flow through adapter
 Duct mount flange
 Weather protection cap with remote calibration capability

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MSA DESCRIPTION

Series 47K Gas Detector [SIL 2] 9

2.2. Principle of Operation

The MSA 47K series of sensors operate on the principle of catalytic combustion.
The sensing element consists of a pair of filaments [“pellistors”] connected to a
pair of precision resistors to form a Wheatstone bridge.

One of the filaments, the detector, is coated with a catalyst, whilst the other, the
compensator is used as a reference to achieve the best stability.

The gas or vapour diffuses through a porous Stainless Steel sintered disc, which
acts as a flashback arrestor. When gas comes into contact with the surface of the
detector filament, it is oxidised. The heat generated by the reaction increases the
temperature of the detector, which results in a change of the detector electrical
resistance, and hence an unbalance of the Wheatstone bridge. The result is an
output signal directly proportional to the concentration of the flammable gas or
vapour. The signal is processed by an MSA controller designed to display the gas
concentration, actuate alarms and provide a suitable output signal to activate
subordinated external measurement data acquisition systems.

2.3. Technical Specification

The Series 47K combustible gas sensors are designed to meet the rigorous
requirements of ATEX Directive 2014/34/EU for fixed gas detection installations.

Sensor

Power consumption 1 Watt, typically

Linear dynamic range Standard & PRP & HT-Sensor: 0–100% LEL

Response time t50 ≤10 sec for propane + methane

t

90

≤20 sec for propane + methane
For other gases or vapours the response time
may be longer.

Typical sensitivity PRP- sensor methane: 12 mV/vol%;

propane: 16 mV/vol%;

HT-PRP- sensor methane: 12 mV/vol%;

propane: 16 mV/vol%;

Operating configuration Wheatstone Bridge circuit
Operating mode Constant current

Sensor current 310 mA for 47K-PRP,

280 mA for 47K-HT-PRP

V

max

10 V

Operating life time 3 Years, in clean air, typically

Storage life time 5 Years, in MSA container, typically

Storage temperature range -20 °C to +40 °C**

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DESCRIPTION MSA

10 Series 47K Gas Detector [SIL 2]

Operating temperature range PRP- sensor

Extended range *)

-25 °C to +55 °C

-40 °C to +55 °C

HT-PRP sensor -40 °C to +160 °C

Operating humidity range 5% to 95% RH non-condensing

Operating pressure range

800–1200 hPa

Air velocity Air velocity 0–6 m/s

[with duct mount flange: 0.5–20 m/s]

Poison resistance

PRP sensor and HT-PRP sensor:
10 ppm HMDS for 40 min.
[max. signal loss 5% of reading]

Dimension Ø 36 x 56 mm

Weight < 230 g

Material

St. St. 316

Accessory thread M36 x 1.5 mm

Sensor to junction box ¾” NPT or M25 x 1.5 mm

*) Extended range: The sensor extended temperature range is greater than the maximum specified in

EN 60079-29-1. It is therefore strongly recommended that if used above +55 °C or below -25 °C the
sensor is calibrated at the operating temperature.

**) The storage temperature range is also valid for spare parts and accessories

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MSA INSTALLATION

Series 47K Gas Detector [SIL 2] 11

3. Installation

3.1. Installation – Step by Step

(1) Unpack and inspect the device or its components.
(2) Check the suitability of the installation site and the cabling requirements.

(3) Install the sensors and connect the wiring to the MSA control unit.
(4) The installation of the sensor must be performed according to standard

EN 60079-14 or according to applicable national standards.

Warning
Follow the installation instructions for hazardous areas!

(5) After installation is complete, perform the start-up procedure as instructed in

the relevant MSA controller manual.

3.2. Unpacking

Perform the following steps on receipt of the shipment:
(1) Carefully unpack the device or its components, observing all of the

instructions printed on or accompanying the packaging.

(2) Also inspect the contents of the delivery to determine if any transport

damage has occurred and verify that everything listed in the shipping papers
has been received.

3.3. General Installation Instructions for Achieving EMC Compliance

 For connection to the power supply system a fault-free ground or fault-free

equipotential bonding must be provided.

 An appropriate supply voltage free of feedback to the external source in

accordance with the EMC Directives (2014/30/EU) must be used.

 If the devices are supplied from a direct voltage [dc] source, the supply cable

must be screened.

 Screened cable is to be used to connect the sensor signal.
 Screened cable must have at least 80% coverage by the screening.
 Sensor cables must be installed physically separate from power supply

cables.

 Screened cables must be installed in one piece. If it should prove necessary

to extend a cable by way of a terminal box, the terminal box must be
screened, and the connections in the box must be kept as short as possible.

 Unscreened cables and cables from which the insulation has been stripped

must be as short as possible and must be terminated without loops.

 If additional high-voltage surge protection measures are required an

appropriate high-voltage protection filter, approved by MSA, must be installed
in the sensor cable.

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INSTALLATION MSA

12 Series 47K Gas Detector [SIL 2]



Strict adherence to the specifications and regulations applicable to installation,
start-up, operation, and maintenance is required.

 Follow the installation instructions for hazardous areas.
 The specified environmental conditions must be adhered to.
 Position the height of the MSA Gas detector Series 47K according to the

density of gas or vapour to be measured.

 The proper installation location must be chosen to ensure that the sintered

disc of the MSA Gas detector Series 47K is kept dry and dust-free.

 The sintered disc must always face downwards.
 The MSA Gas detector Series 47K must never be covered with paint, grease

or similar.

 These substances prevent diffusion, of the atmosphere to be monitored, to the

sensing elements.

3.4. Recommended Torque and Terminal Sizes

Cable gland size

Connection

thread

Pressing screw Terminal sizes

M25 x 1,5 3,0 Nm 2,0 Nm 7–12/10–17* mm

* To be able to use size M25 x 1,5 for terminal sizes 10–17 mm, remove the small sealing ring.

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MSA INSTALLATION

Series 47K Gas Detector [SIL 2] 13

3.5. Electrical Connection to the Control Unit

3.5.1 Junction Box Terminals

Screw terminals: cross section 0,5–2,5 mm

2

Spring terminal: cross section 0,5–1,5 mm

2

3.5.2 Maximum Cable Length

The maximum cable length depends on the maximum permissible load, the cross
section of the conductor and the conductor material.

The maximum permissible load [loop resistance] is 36 ohms for the MSA Control
units SUPREMA [for MSA Control unit 9010/9020 refer to the control unit
manual].

Maximum cable length: L =

R x k x A

2

L = cable length in metres [loop]
R = maximum permissible load in ohms
A = cross sectional area of conductor in mm

2

k = conductivity of copper at 20 °C [1/Resistivity]

Example: R = 36 ohms, A = 0.75 mm², k = 56 m ohms

-1

mm-2

L = 36 x 56 x 0.75/2 = 756 m

Wire Cross
Section

Maximum Load

[max. cable resistance]

Maximum
Length

Remarks

0.75 mm² 36 Ohm 750 m

Screened cable
is required.

1.5 mm² 36 Ohm 1,500 m

For detailed information refer to the relevant MSA controller manual.

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START-UP MSA

14 Series 47K Gas Detector [SIL 2]

3.6. Electrical Connections

Warning

Installation should only be carried out by suitably qualified personnel.

 During installation all relevant codes of practice and National wiring

regulations should be complied with especially in places where there is a risk
of explosion and fire. [Classified areas]

 Refer to the MSA controller instruction manual for the sensor connection

details.

 Where an earth connection to the junction box/sensor is required use the

earth terminal provided on the outside of the junction box.

The sensor connections are shown in Section 10, Wiring diagrams.

4. Start-up

Warning

Installation should only be carried out by suitably qualified personnel.

Before applying power ensure that all installation steps have been correctly
carried out and the cable connections and controller configuration are correct.

Caution

Ensure that the sensor current is correctly set to 310 mA for the
47K-PRP and 280 mA for the 47K-HT-PRP.

Allow a warm-up time of at least 30 minutes before calibrating the gas sensor.
Perform an initial calibration following the instructions in Section 5.1 “Calibration”

and the manual for the relevant MSA controller.

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MSA MAINTENANCE AND SERVICE

Series 47K Gas Detector [SIL 2] 15

5. Maintenance and Service

There are no serviceable or adjustable parts within the sensor assembly and any
attempt to dismantle the assembly or access it will invalidate the sensor
approvals and manufacturers guarantee.

Maintenance and service may only be performed by authorised and suitably
qualified personnel.

Caution

To guarantee the nonambiguity of the series 47K catalytic sensor
operation ensure [e.g. by check with hand-held test instruments] each
time before turning on the sensors that the atmosphere to be
monitored by the sensors is free of combustible gases.

Maintenance must be performed according to standards EN 60079-17 [gas] and
EN 61241-14 [dust] or according to applicable national standards.

5.1. Calibration

According to EN 60079-29-2 the combustible gas detectors must be checked at
regular intervals to ensure that it is functioning properly in accordance with the
applicable international, national, industry-specific or company regulations.

The sensitivity and zero point of the sensor must be adjusted as necessary [every
6 months at the latest] in accordance with the operating instructions for the type
of sensor and controller it is connected to.

Sensors that are no longer able to generate the minimum signal must be replaced
[see relevant controller manual].

Allow a warm-up time of at least 30 minutes for the sensor to stabilise, before
calibration is performed.

Calibrating the Gas Detectors 47K-HT-PRP

These gas detectors must be calibrated at their ambient working temperature
using the flow through adaptor [please refer to 5.1.3 Calibration with accessories].

The specified temperature range of the 47K-HT-PRP gas detectors is -40 °C to
+160 °C and the bridge operating current is 280 mA.

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MAINTENANCE AND SERVICE MSA

16 Series 47K Gas Detector [SIL 2]

5.1.1 Zero Calibration

 Apply zero gas to the sensor using the appropriate calibration adapter.
 Wait for approximately 2 minutes or until the sensor reading has stabilised.
 Adjust the controller until the correct reading is obtained.

Gas flow rate : 1.0 l/min

Zero gas : synthetic air or component-free ambient air

5.1.2 Span Calibration

See also Section 5.3.

 Apply span calibration gas to the sensor using the appropriate calibration

adapter.

 After the reading has stabilised adjust the controller until the correct reading is

obtained.

 Remove calibration adapter.

Gas flow rate : 1.0 l/min
Stabilisation time : depending on gas type between 2 and 4 min

Caution

Use span gas with a concentration of approximately 50% of the
measuring range. In no case should the span gas concentration be
less than 25% of the full scale value of the measuring range.

If possible, the span gas [the gas used to calibrate the sensor] and the
measurement gas [the gas to be monitored] should be identical. If this
is not the case and a reference gas is used, the response factor of the
gas used must be known.

5.1.3 Calibration with Accessories

Calibration of Gas detectors used with duct mount flange, flow through adapter or
weather protection cap should be carried out as described above using the
particular gas inlets of the accessories.

Gas flow rate : 1.0 l/m