sewerin Ex-Tec OD 4, Ex-Tec GM 4 Operating Instructions Manual

Operating

Instructions

Measurable success by Sewerin equipment

Congratulations. You have chosen a quality instrument manufactured
by Hermann Sewerin GmbH.

Our equipment will provide you with the highest standards of perfor-

mance, safety and efciency. They correspond with the national and

international guide-lines.

Please read and understand the following operating instructions before
using the equipment; they will help you to use the instrument quickly and
competently. If you have any queries we are available to offer advice
and assistance at any time.

Yours

Hermann Sewerin GmbH

Robert-Bosch-Straße 3
33334 Gütersloh, Germany

Tel.: [phone]
Fax: [phone]

www.sewerin.com
[e-mail]

SEWERIN SARL

17, rue Ampère – BP 211
67727 HOERDT CEDEX, France
Tél. :[phone]
Fax :[phone]

www.sewerin.fr
[e-mail]

SEWERIN IBERIA S.L.

Centro de Negocios “Eisenhower”
Avenida Sur del Aeropuerto
de Barajas 28, Of. 2.1 y 2.2
28042 Madrid, España
Tel.: [phone]
Fax: [phone]

www.sewerin.es
[e-mail]

Sewerin Ltd

Hertfordshire
UK

Phone: [phone]

www.sewerin.co.uk
[e-mail]

Sewerin Sp.z o.o.

ul. Twórcza 79L/1

03-289 Warszawa, Polska
Tel.: [phone]
Faks: [phone]
Tel. kom. [phone]

www.sewerin.pl
[e-mail]

EX-TEC OD 4

®

0.0

THT

mg
m3

Sensor head

Attachment

Alarm lamp

LCD

Buzzer

Keypad

Charging contacts

Illustration EX-TEC OD 4

Illustration EX-TEC GM 4

Sensor head

Attachment

Alarm lamp

LCD

Buzzer

Keypad

Charging contacts

H2

Battery state

1500

EX-TEC GM 4

Activation

Alarm thresholds

1500

PPM

®

H2

PPM

Type of gas

Gas concentration
Unit

Trend bar

Operating Instructions

EX-TEC® OD 4/GM 4

20.04.2016 a – V1.XXX – 103955 – en

For your safety

This product may only be operated by appropriately-trained persons who
are familiar with the relevant operating manual.

It may only be used for its designated purpose, i.e. for industrial and com­mercial use.

Repair work may only be carried out by specialists or by persons who have
undergone appropriate training.

Any alterations or modications to the product require the prior approval of

Hermann Sewerin GmbH. In the event of unauthorised alterations to the
product the manufacturer accepts no liability for damage.

Only Hermann Sewerin GmbH accessories may be used with the pro­duct.

Only spare parts approved by us may be used for repairs.

Hermann Sewerin GmbH accepts no liability for damage resulting from
non-compliance with the foregoing. The guarantee and liability provisions
in the Hermann Sewerin GmbH terms of sale and supply are not extended
by the foregoing.

We reserve the right to make changes in the context of continued techni­cal development.

In addition to these instructions, please comply with generally applicable
safety and accident-prevention regulations.

Symbols used:

CAUTION:

Note:

This symbol warns of dangers that may threaten
the safety of the user or maty damage or destroy
the product.

This symbol ags information and hints extending

beyond the actual operation of the product .

Contents Page

1 EX-TEC OD 4/EX-TEC GM 4 system ......................................1

1.1 The EX-TEC OD 4 system ........................................................1

1.1.1 Before starting work ...............................................................1

1.1.2 The need for gas odorisation .................................................1

1.1.3 Measurement principle ........................................................... 1

1.1.4 Boundary conditions for measurement and sampling .............. 2

1.1.5 EX-TEC OD 4 ............................................................................3

1.1.6 Test certicates ......................................................................4

1.2 EX-TEC GM 4 system ............................................................... 5

1.2.1 Test certicates ......................................................................5

2 Safety .......................................................................................6

2.1 Safety instructions ..................................................................... 6

3 Measuring operation ............................................................... 8

3.1 Switching on .............................................................................. 8

3.2 Operating modes ..................................................................... 11

3.3 Alarms .....................................................................................16

3.4 Illumination and operating-hours display ................................. 18

3.5 Battery alarm ........................................................................... 18

3.6 Switching off ............................................................................19

4 Charging and battery operation ........................................... 20

4.1 Charging and charge maintenance when using NiMH batteries ... 20

4.2 Self-dischargeand battery care ...............................................22

4.3 Battery operation ..................................................................... 23

4.4 Instruments showing serial number 062 00 ............................24

5 Testing the instrument .......................................................... 25

5.1 Testing/upkeep ........................................................................25

5.2 Test set ....................................................................................27

5.2.1 EX-TEC GM 4 ......................................................................27

5.2.2 EX-TEC OD 4 ....................................................................... 28

5.3 Test gases ...............................................................................29

5.4 Testing the pump, zero point and display accuracy ................30

I

Contents Page

6 Info menu ...............................................................................33

6.1 Menu structure ........................................................................33

6.2 Overview .................................................................................34

7 Adjustment menu .................................................................. 36

7.1 Menu structure ........................................................................36

7.2 Sensor adjustment ..................................................................36

7.2.1 Setting the H2-sensor ...........................................................36

7.2.2 Setting the O2 sensor ...........................................................37

7.3 Setting the test gas concentration ........................................... 38

7.4 Inspection conrmation ...........................................................40

7.5 Leaving the adjustment menu ................................................. 40

8 System menu ......................................................................... 41

8.1 Menu structure ........................................................................41

8.2 Setting the date and time ........................................................42

8.3 Setting the inspection intervall ................................................43

8.4 Setting the inspection block ....................................................46

8.5 Setting the PIN ........................................................................47

8.6 Setting the alarm thresholds ...................................................48

8.7 Setting the user name .............................................................51

8.8 Setting the language ...............................................................53

8.9 Leaving the system menu .......................................................53

9 Hardware menu .....................................................................54

9.1 Menu structure ........................................................................54

9.1.1 EX-TEC GM 4 ......................................................................54

9.1.2 EX-TEC OD 4 .......................................................................55

9.2 Setting the battery type ...........................................................56

9.3 Setting the illumination time and contrast ...............................57

9.4 Autostart ..................................................................................58

9.5 Range .....................................................................................59

9.6 Changing the sensor ...............................................................59

9.6.1 Gas ....................................................................................... 60

9.6.2 Sensor installation ................................................................ 60

9.7 Setting pump operation ...........................................................61

9.8 Carrying out an LCD test ......................................................... 61

II

Contents Page

9.9 Restoring the factory settings .................................................. 62

9.10 Leaving the hardware menu ....................................................63

10 Memory menu ........................................................................ 64

10.1 Menu structure ........................................................................64

10.2 Clearing memory .....................................................................64

10.3 Setting the memory interval ....................................................65

10.4 Leaving the memory menu ......................................................65

11 Technical aspects..................................................................66

11.1 Technical notes .......................................................................66

11.2 Technical data .........................................................................68

11.3 Error messages ....................................................................... 79

11.4 Consumables .......................................................................... 80

11.5 Hints on Disposal .................................................................... 81

12 Delivery variants and accessories ......................................82

12.1 Delivery variants ......................................................................82

12.2 Accessories .............................................................................84

13 Appendix ................................................................................90

13.1 EU-declaration of conformity ...................................................90

13.2 Inspection protocol ..................................................................91

13.3 EX-TEC OD 4/GM 4 operating instructions in brief ................. 92

III

1 EX-TEC OD 4/EX-TEC GM 4 system

1 EX-TEC OD 4/EX-TEC GM 4 system

The EX-TEC OD 4 is a combined warning and measuring instru-
ment for determining odorant concentration. It is available with
either a THT or a TBM sensor.

The EX-TEC GM 4 is a warning and measuring instrument that
detects oxygen and various toxic gases.

1.1 The EX-TEC OD 4 system

1.1.1 Before starting work

Adequate gas odorisation is an important criterion for safe network

operation. Please take careful note of the following information.

1.1.2 The need for gas odorisation

Natural gas is odourless. So that even the smallest leaks in indoor
installations or elsewhere in a gas-distribution network can be

immediately detected, the gas is odorised: a strong-smelling sub­stance is added to it. The substances used are organic sulphur
compounds and acrylates. The most widespread currently being
tetrahydrothiophene (THT) and tertiary butyl mercaptan (TBM).

DVGW worksheet G 280 sets the minimum values for odorant
concentration at 10 mg of THT / m3 and 3.8 mg of TBM / m3. This

worksheet also requires the operator of a distribution network to
check and document the odorant concentration at least once a
year.

1.1.3 Measurement principle

The EX-TEC OD 4 contains an electrochemical sensor that reacts
to the smallest traces of sulphur compounds. This produces elec-

trical signals, which are then processed by the integral electronic

system. The intensity of the signal varies directly with the strength

of the concentration.

1

1 EX-TEC OD 4/EX-TEC GM 4 system

The sensor is lled with a liquid (electrolyte), which makes it very
sensitive to high temperatures. The maximum storage tempera­ture of 40 °C must therefore not be exceeded. Electrochemical

processes constantly take place inside the measurement cell,
requiring the EX-TEC OD 4 to be permanently supplied with bat­tery power at an adequate voltage. For this reason the integral
batteries must not be permitted to reach a state of deep discharge.

When the instrument is not in use it should therefore be stored
in charge-maintenance operation (see section 4.1: Charging and
charge maintenance when using NiMH batteries).

1.1.4 Boundary conditions for measurement and sampling

As well as all sulphur compounds, the electrochemical measure­ment cell also reacts very strongly to moisture. Even though this

is rarely important when carrying out measurements in a gas­distribution network, operators should not blow through sampling
hoses to clear them.

When sampling it is essential to ensure that there are no connect­ing pieces made of rubber or synthetic substances between the
EX-TEC OD 4 and the connection to the gas main unless these

consist of inert materials (e.g. Viton or nylon).
A further factor that affects the measurement of sulphur com-

pounds with the EX-TEC OD 4 is the ow rate through the mea-
surement chamber, which must always exceed 20 l/h. Only the

connection hoses supplied with the instrument should therefore
be used for sampling.

2

1.1.5 EX-TEC OD 4

The following sensors are available:

1 EX-TEC OD 4/EX-TEC GM 4 system

The EX-TEC OD 4 is a hand-held
instrument for the measurement

of tetrahydrothiophene (THT) or
tertiary butyl mercaptan (TBM). It

is available in pump and diffusion
versions.

Sensor

THT
TBM

range principle

0 –100 mg/m
0 –100 mg/m

3

3

electrochemical

electrochemical

3

1 EX-TEC OD 4/EX-TEC GM 4 system

1.1.6 Testcerticates

Passive explosion protection

The EX-TEC OD 4 has been tested for explosion protection in
accordance with European norms (CENELEC):

EC prototype test certicate: TÜV 01 ATEX 1657
Identication: II2G Ex e ib IIB T4 Gb
Testing institution: TÜV NORD CERT GmbH,

Hannover

4

1.2 EX-TEC GM 4 system

The EX-TEC GM 4 is a gas-measurement and warning instru-
ment. It is available in pump and diffusion versions. A different

sensor is used for each gas.

The following electrochemical sensors are available:

Sensor range

Carbon monoxide CO 0 – 500 ppm

Hydrogen H2 0 – 1.0 vol.%

Hydrogen sulphide H2S 0 – 100 ppm

Hydrogen sulphide H2S 0 – 2000 ppm

Ammonia NH3 0 – 100 ppm

Oxygen O2 0 – 25 vol.%

Hydrogen chloride HCI

1.2.1 Testcerticates

Passive explosion protection

The EX-TEC GM 4 has been tested for explosion protection in
accordance with European norms (CENELEC):

1 EX-TEC OD 4/EX-TEC GM 4 system

0 – 30 ppm

EC prototype test certicate: TÜV 01 ATEX 1657
Identication 1: II2G Ex e ib IIB T4 Gb

basic instrument without
leather case for all gases
except hydrogen H

2

Identication 2: II2G Ex e ib IIC T4 Gb

basic instrument with leather
case for all gases including
hydrogen H

2

Testing institution: TÜV NORD CERT GmbH,

Hannover

5

2 Safety

2 Safety

2.1 Safety instructions

CAUTION!

Always use original SEWERIN accessories with the

EX-TEC OD 4/GM 4!

CAUTION!

Observe the permissible operating temperature

range of minus 10 °C to plus 40 °C!

(with some sensors the temperature range may be

wider - see section 11.2: Technical data)!

CAUTION!

The EX-TEC OD 4/GM 4 must not be recharged or
its battery compartment opened in areas exposed

to the danger of explosion!

CAUTION!

Test gases may only be used in well-ventilated

spaces!

CAUTION!

The EX-TEC OD 4/GM 4 satises the limits of the

EMV regulation. When using it near (mobile) radio

equipment please also observe the instructions in

the manuals for that equipment!

6

CAUTION!

Please note that when the EX-TEC OD 4/GM 4 is
in measuring operation the gas sample is released
into the ambient air through its outlet.
Special care must be taken to ensure that this does
not produce an explosive or toxic gas mixture, espe-

cially during use in conned spaces. It may therefore

be necessary to use a gas-warning device to monitor
the ambient air.

CAUTION!

The EX-TEC GM 4 with the hydrogen sulphide H2S
sensor (0 – 2000 ppm) is a pure measuring instru-

ment: the „warning“ operating mode is not available.

Please note that the human sense of smell fails at

concentrations of 100 ppm of H2S and above. Con­centrations of over 500 ppm of H2S lead to very seri-

ous damage to health, uncoordinated movements,
unconsciousness, respiratory failure and death. It is
thus essential to ensure that the lower toxic limit of

10 ppm in the ambient air is not exceeded!

2 Safety

CAUTION!

When using the H2 sensor the HG4 must be in its
leather case (to provide explosion protection)!

7

3 Measuring operation

V1.001

EX-TEC GM4

H2

3 Measuring operation

3.1 Switching on

Note:

This operating manual describes the functions
of software version 1.XXX. Other versions may

involve changes.In this event please consult any
page insertions.

z always switch the instrument

on in „fresh air“

z hold the on/off key down for

about 3 seconds

z the optical and acoustic control

signals (items 1 and 7) operate

for about 3 seconds

z the LC display illumination

automatically switches on

z pump instruments: the inte-

gral pump runs at constant
power

Opening screen

z display of:

- version number (V1.001)

- instrument type (GM 4)

- sensor type (H2)

8

27.11.2000
12:37

Stadtwerke GT
Heinz Muster
Abt. TDLL 24.4

Date/time

z display of:

- date (27.11.2000)

- time (12:37)

- user name

z properly-set values are impor-

tant for the documentation of
your readings

3 Measuring operation

Sensor install.

12.06.2002

durability

24 Monate

H2

0...1,00 Vol%

z you can correct any variances

(cf. section 8.2: Setting the
date/time)

Instrument settings

The EX-TEC OD 4/GM 4 defaults
to a set operating mode at switch­on, which you can change (cf.

section 9.4: Autostart). The

operating mode is factory-set to

„Measurement“:

z display of:

- battery-charge level

- gas (here: H2)

- operating mode

(here: measurement)

- range

(here: 0 – 1.00 vol.%)

Other possible settings can be

found in section 9.4: Autostart.

z display of the day the sensor

was tted

z display of expected sensor

life

Symbols

z available operating hours are

displayed (5 hours = 5 bars)

symbol: battery

z measurement is under way

(symbol eggtimer)

z all alarm thresholds are acti-

vated

symbol: alarm threshold

9

3 Measuring operation

Next scheduled inspection

(display optional)

z if you have set an inspec-

tion interval, the next sched­uled inspection date (e.g.

11.03.2004) is displayed for

about 3 seconds (cf. section

8.3: Setting the inspection
interval))

z depending on the current and

inspection dates, the intermit­tent or continuous alarm may

also be triggered (items 1
and 7)

z clearing the alarm with the

on/off key or waiting for 15

seconds switches to mea­suring operation

Note:

If the EX-TEC OD 4/GM 4 now automatically
switches off, the inspection date has passed with

the inspection block switched on (cf. section 8.0:
System menu).

The instrument does not revert to measuring opera-

tion until an inspection has been carried out and

conrmed.

10

3.2 Operating modes

WARNING

z Warning of high gas concentration in buildings and the work-

ing environment

z Testing enclosed spaces

H2

1500

PPM

3 Measuring operation

z all alarm thresholds are acti-

vated

NB:

z the current gas concentration

is displayed:

- as a gure
(e.g.: 1500 PPM H2)

- as a trend bar

z every 5 seconds an operating

signal - both acoustic (item 7)
and optical (item 1) - is emitted
to conrm that the instrument

in functioning in the warning
operating mode. If this ope­rating signal is not emitted,
you cannot be sure that the
gas concentration is being
properly monitored and must
leave the endangered area
without delay.

11

3 Measuring operation

H2

PPM

1500

MEASUREMENT

EX-TEC GM 4:

z Testing the gas concentration in buildings
z Measuring gas concentrations in pipes and elsewhere

z Searching for leaks in pipes in buildings

z Checking joints, e.g. weld seams

z Carrying out building tests

z Checking enclosed spaces

EX-TEC OD 4:

z Determining the odorant concentration in natural gas
z Measuring the odorant concentration in the air in odorising

plants

z Before sampling observe the sufcient ush of intake

z the current gas concentration

is displayed:

- as a gure
(e.g.: 1500 PPM H2)

- as a trend bar

12

Sampling hoses

To ensure that the sample always passes through the

EX-TEC OD 4 at an adequate rate, there are different sampling

hoses for each of the possible pressure ranges. These are colour­coded as follows:

Colour Pressure range Part-Nr.

black 20 – 50 mbar OD04-Z0100
blue 50 – 125 mbar OD04-Z0200
green 125 – 400 mbar OD04-Z0300
yellow 400 – 1000 mbar OD04-Z0400
red 1 – 2 bar OD04-Z0500
(further on request)

Measurements are only reliable if the original Sewerin-supplied

hoses are used.

Switching operating modet

H2

0...1,00 Vol%

H2

0...1,00 VOL%
AL1 0,4 VOL%
AL2 0,8 VOL%

pin point:

0001

pin point: 0001

02.07.02 13:58
1500 PPM

3 Measuring operation

z holding down one of the cursor

keys for about 2 seconds

brings you to operating mode
selection

z use the cursor keys to select

one of the items:

Zero point

in the currently selected mea-

surement range zero-point

correction can be carried out

if necessary (temporary zero-

point adjustment within certain

limits)

Warning

selects the WARNING ope­rating mode

Measurement

selects the MEASUREMENT
operating mode

1500

â

â

H2

PPM

Saving

The gas concentration meas­ured can be saved and
assigned to a measurement

location. After the number of

the measurement location
has been entered, the mea­surement location, date, time
and reading are displayed

together once again. These

data can subsequently be read
out and analysed with the PC
analysis software (available

separately).

13

3 Measuring operation

z then press the on/off key to

conrm your selection

Note:

If the selection is not conrmed with the on/off key,
the instrument reverts to its previous operating mode

after about 10 seconds!

14

3 Measuring operation

Starting measurement (only possible on the EX-TEC OD 4 in
the „Measurement“ operating mode)

z A measurement can also be started by briey pressing the

on/off key.

z Indication when measurement is under way: eggtimer

symbol.

z Measurement is halted on the expiry of the measurement dura-

tion (about 3.5 minutes) or when the reading has stabilised.

z When measurement is complete the reading can be assigned

to a measurement location and saved.

z These data can subsequently be read out and analysed with

the PC analysis software (available separately).

z If no measurement location is entered within 10 seconds, the

measurement is lost.

0.0

0.0

store

Yes

No

16.5

pin point: ----

5.4.2002 8:50

16.5

14.5

THT

mg
m3

THT

mg
m3

mg
m3

mg
m3

THT

mg
m3

Possibilities to start measuring:

1) choose menu and start measuring

2) press on-key shortly

Cancel measuring:

1) press on-key shortly

2) choose menu and stop measuring

pin point:

0

012

pin point: 0012

5.4.2002 8:50

mg

16.5

m3

Time-out: 60 seconds

Time-out: 10 seconds

Measuring value remains
for 20 seconds

15

3 Measuring operation

H2

AL1

VOL%

0,4

3.3 Alarms

In the WARNING operating mode the EX-TEC OD4/GM 4 has

various alarm thresholds:

EX-TEC OD 4

Example: TBM
AL1 alarm threshold 1 = 10 mg/m
AL2 alarm threshold 2 = 20 mg/m3

EX-TEC GM 4

Example: H2 (factory setting)
AL1 alarm threshold 1 = 4000 ppm
AL2 alarm threshold 2 = 8000 ppm

3

AL1 alarm (example: H2)

z if this alarm threshold is

exceeded, the result is:

- optical alarm (item 1)

- acoustic alarm (item 7) at
2 Hz

- LCD (item 2) lights up

- AL1 appears in the LCD

z the 2 Hz intermittent tone is

quite different from the ope­rating signal

z the acoustic AL1 alarm can

be cleared by briey pressing

the on/off key, but the optical

alarm (item 1) continues

z if the concentration falls below

this alarm threshold, the opti­cal and acoustic alarms (items

1 and 7) switch off

16

3 Measuring operation

H2

AL2

VOL%

0,8

AL2-alarm (example: H2)

z if this alarm threshold is

exceeded, the result is:

- optical alarm (item 1)

- acoustic alarm (item 7) at

5 Hz

- LCD (item 2) lights up

- AL2 appears in the LCD

z the rapid intermittent tone at

5 Hz is quite different from the

operating signal

z the AL2 alarm cannot be

cleared

z if the concentration falls below

this alarm threshold, the alarm

becomes an AL1 alarm, which

can be cleared

17

3 Measuring operation

0

3.4 Illumination and operating-hours display

z pressing any key switches the

LCD illumination on

z ou can also adjust the illumina-

tion time individually (cf. sec-

tion 9: Hardware menu)

z when the illumination comes

on the remaining operating
hours (e.g. 5 hours) are dis­played

z this display (battery symbol

and bars) and the illumination

switch off automatically after

about 10 seconds

z the battery symbol appears in

the LC display and the ope­rating signal sounds at twice
its normal rate

z you now have at least another

15 minutes' operating time

available

z after that the instrument must

be charged (cf. section 4:

Charging and battery opera-

tion)

1500

3.5 Battery alarm

H2

PPM

H2

PPM

18

3.6 Switching off

3 Measuring operation

z hold down the on/off key for

about 3 seconds

z the optical and acoustical

control signals (items 1 and

7) are activated for about 3

seconds

z remaining operating hours are

displayed in the form of the
battery symbol and bars (e.g.

5 hours = 5 bars)

19

4 Charging and battery operation

4 Charging and battery operation

CAUTION!

The EX-TEC OD 4/GM 4 must not be recharged or
its battery compartment opened in an area exposed
to the danger of explosion

4.1 Charging and charge maintenance when using NiMH batteries

Batteries should be approximately at room temperature for charging.

Charging

After 12 hours‘ charging the instrument has about 20 hours of oper-
ation with the pump running or about 50 hours of operation in diffu­sion operation.

The docking station HG4 is required for charging. It can be used
either in the workshop or in the emergency vehicle.

The docking station has the fol­lowing connections on its side:

z AC/DC adapter M4 for

100 – 240 V~

z Vehicle cable M4 12 V= mount-

ing

z Vehicle cable M4 12 V=

mobile

z Vehicle cable M4 24 V= mount-

ing

z You can operate up to 5 dock-

ing stations with one 100 – 240
V~ AC/DC adapter M4

z With more than 5 stations the

charg. volt.
too low

charg. volt.
too high

charging voltage is insufcient.
An error message is displayed

to that effect

z if you connect the docking sta-

tion directly to a 24-V network in

the vehicle, the voltage will be
too high for proper charging

20

4 Charging and battery operation

04

Place the EX-TEC OD 4/GM 4 in the docking station and a display

on the following lines appears:

z the instrument now has 5

operating hours left (= 5 bars)

and needs another 4 hours to
reach full charge

z if it is fully charged, all the bars

appear and the digital display
disappears

Charge maintenance

Once the instrument is fully charged, it switches automatically to
charge maintenance. It can be left in the docking station until the
next time it is needed.

21