8 Index .......................................................................................93
IV
1 General
1.1 Warranty
The following instructions must be complied with in order for any
warranty to be applicable regarding functionality and safe operation of this equipment. This product must only be commissioned
by qualied professionals who are familiar with the legal requirements (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 modications 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 aected by this information.
In addition to the warnings and other information in these Operating Instructions, always observe the generally applicable safety
and accident prevention regulations.
The manufacturer reserves the right to make technical changes.
1 General
1
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 specic conductivity of gases. Electrochemical sensors operate on the electrochemical 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.
2
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 CH
● Oxygen O
● 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 rechargeable 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.
/ propane C3H8 / butane C4H
4
2
1 General
10
3
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 equipment when using the device close to (mobile) radio equipment.
Note:
Follow the advice regarding explosion protection (see Sec-
tion 2.3).
4
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/).
1 General
Gas measuring
● Measuring the gas concentration
Inspection above
ground
– Ground
– Gas line
commissioning or decommissioning gas systems
– Purge to verify gas purity or absence of gas, for example, when
– Possible leakage points
● Distinguishing between natural gas and swamp gasEthane analysis
Warning ExTox
Warning %LEL
area monitoring
● Warning against explosive gas concentrations through work
Measuring in bar
holes
– Determine gas dispersion (detection limit)
– Classify leaks
– Locate a probable gas escape (repair point)
monitoring
● Warning against explosive and toxic gases through work area
– Prevent possible dangers
● Measuring the gas concentrationEnclosed spaces
House
● Locating the source of gas
● Finding leaks at internal connections
LocationActivityApplication
Gas lines, gas systems,
…
Buried gas lines● Measuring minimal gas concentrations above:
Gas lines, gas systems,
… in houses, enclosed
spaces and shafts
In the ground● Measuring the gas concentration to:
In enclosed spaces
and shafts with an in-
creased potential of gas
dispersal
In the house● Measuring very low gas concentrations
5
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:
Application480 EX 460 EX 450 EX 400 EX
Inspection above ground×××
Measuring in bar holes
O
2
Enclosed spaces××
House××
Gas measuring×××
Warning %LEL××
Warning ExTox
CO
O
2
Ethane analysis○○
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.
×
○
×
○
○
× standard○ Optional
×
○
×
○
×
○
○
6
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 remains 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-
ied limit values (alarm thresholds) the device gives a warning. It
emits both audible and visual signals, which are distinctly dierent
from the operating signal.
WARNING! Danger of death due to hazardous gas
A
There is detailed information on alarms in Section 7.2.
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.
7
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)
ApplicationGasMeasuring rangeSensors
Inspection above
ground
Measuring in bar
holes
CH
CH
1 ppm – 10 % vol.SC, TC
4
0.0 – 100 % vol.TC
4
Enclosed spacesCH
HouseCH
CO0 – 500 ppmEC
Gas measuringCH
Warning %LEL and
Warning ExTox
CH
O
CO0 – 500 ppmEC
Ethane analysisCH
C
C3H
1 ppm – 100 % vol. SC, TC
4
1 ppm – 100 % vol. SC, TC
4
0.0 – 100 % vol.TC
4
0 – 100 % LELCC
4
0 – 25 % vol.EC
2
---Gas chroma-
4
tograph, SC,
2H6
8
TC
8
2.3 Explosion protection
2.3.1 Passive explosion protection
The device is assigned to the following explosion-proof groups:
2 Features
Explosion-proof
group
II2G Ex d e ib IIB T4 Gb – Methane CH
II2G Ex d e ib IIC T4 Gb – Methane CH
For the following atmospheres
– Propane C3H
– Butane C4H
4
8
10
– Carbon monoxide CO
– Propane C3H
– Butane C4H
4
8
10
When using
Device
without
carrying
bag TG8
Device with
carrying
bag TG8
– Carbon monoxide CO
– Hydrogen H
2
EC type-examination certicate: TÜV 07 ATEX 553353 X
DANGER! Risk of explosion due to sparks
A
● 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.
9
2 Features
2.3.2 Active explosion protection
The functional safety test applies to:
Applications:Warning %LEL
Gas types:Measuring range:
– Methane CH
– Propane C
4
3H8
Gases:Measuring range:As per:
– Oxygen O
2
– Carbon monoxide CO0 – 500 ppm CO/5/
Tested accessories: – Test set SPE VOL
Type examination
Warning ExTox
0 – 100 % LEL
0 – 100 % LEL
0 – 25 % O
2
– Flexible hand probe, 1 m
– Floating probe 2 m, 6 m
/7/
10
Testing institute:DEKRA EXAM GmbH
Certicates: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)
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.
ControlActionFunction
ON/OFF keyPress● Switches the device on
● Switches the device o
Function keys
F1, F2, F3
Jog dialTurn● Selects functions, settings,
Press● Variable
● As indicated on the display at
the bottom of the screen
● Function keys may also have
no function assigned in some
cases
measurement data, etc.
● Modies values
Press● Opens the next program lev-
el (e.g. menu item, function,
measurement data, selectable
values)
● Accepts values
3 Operation
11
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.
ProcessTest purpose
Buzzer emits audible
signal.
Signal light gives visual
signal.
Display is inverted.Are there pixels missing from the
12
Is the audible signal working?
Is the visual signal working?
display?
3 Operation
The start screen appears on the display.
Display:
– Device type: VARIOTEC 480 EX
®
VARIOTEC 480 EX
– User:
Frank Smith
Frank Smith
City Council
Leakage Delivery
V1.200
Fig. 3: Start screen
22.04.2013
13:02
City Council
Leakage Delivery
– Firmware version: V1.200
– Date and time
– Capacity disposable battery/
rechargeable battery
The start screen for the application set under Autostart then
appears (see Section 3.3.4).
Display:
– Gas type: CH
4
– Application as symbol (top left)
and text:
Inspection above ground
– Measuring range:
0 ppm ... 10 % vol.
Fig. 4: Start screen for inspec-
tion above ground application
– Alarm threshold:
AL4, 3 ppm
– Symbol for next application that
can be selected via function
key F3: Measuring in bar holes
The device switches to measuring mode. The device warms
up. The reading ashes.
While the device is warming up, the prompt Add fresh air! is
displayed as a reminder.
2. Make sure the device is actually drawing in fresh air. Change
its location if necessary.
3. Wait until the reading stops ashing.
The device is ready for use.
13
3 Operation
0
1010010
Fig. 5: Inspection above ground measuring mode
A
3.1.4 Selecting/switching application
A
0,1
1,0
PPM
CH4
0
WARNING! Danger of death due to incorrectly adjusted or faulty devices
Gas warning instruments must be inspected before use
at regular intervals.
● Carry out a device inspection every day before starting
work.
WARNING! Danger of death due to incorrectly adjusted or faulty devices
If the device is used as a gas warning instrument (Warning %LEL and Warning ExTox applications), it must be
regularly inspected before use.
● Carry out a device inspection every day before starting
work.
Display:
– Current reading: zero when
device is switched on with fresh
air
14
Note:
You may only switch applications when the device is drawing in
fresh air.
The current application is indicated by the symbol at the top left
of the display. The symbol at the bottom right shows the next application that can be selected via function key F3. The Settings
3 Operation
under System (see Section 3.3.4) are used to specify which ap-
plication is rst activated when you switch the device on.
● Press Menu. Select the menu item for the application you
want to use.
OR
a) Press function key F3. The device switches to the next ap-
plication.
b) Repeat until the symbol for the application you want to use
appears at the top left.
3.1.5 Dierences between measuring mode and settings mode
The device is operated in two modes:
● Measuring mode (see Section 3.2)
Measurements are taken in measuring mode. All functions
needed to take readings can be accessed from one menu.
● Settings (see Section 3.3)
The device settings can be changed in settings mode. Information about the device can also be retrieved. Measurements
cannot be taken in settings mode.
Settings are accessed via the menu in measuring mode. The
settings are access-protected by a PIN code.
A
WARNING!
Danger of death due to lack of alarm signal
The device only issues alarms in measuring mode. As
soon you access the menu, alarms are no longer triggered.
● Only change the settings outside of explosive areas and
away from toxic or low-oxygen atmospheres.
15
3 Operation
3.2 Measuring mode
When switched on, the device is in measuring mode. The current
measurement values are always shown in measurement mode
(Fig. 5). Depending on the application, measurements will have
to be saved or started and then stopped (see Section 3.2.12).
WARNING!
A
Danger of death due to operating signal failure
When the device is used as a gas warning device (Warning %LEL and Warning ExTox applications), an operat-
ing signal must always sound in measuring mode. If the
operating signal fails, the device is not safe to use.
● Stop using the device immediately.
● Move away from explosive areas or toxic or low-oxygen
atmospheres immediately.
16
3 Operation
Zero point
Inspection above ground
Measuring in bar holes
Ethane analysis
Enclosed spaces
House
Gas measuring
Warning %LEL
Warning ExTox
Settings
Start measurement
Protocol
Purge
Device inspection
Gas type CxHy
Device information
Exit
3.2.1 Accessing the menu (measuring mode menu structure)
In measuring mode F1 can be used to access the menu.
Fig. 6: Menu with submenus (menu items)
Once you have started a measurement, Start measurement in
the menu becomes Stop measurement. In some applications
this menu item is called Save measurement.
You can nd detailed information on starting, stopping and saving
measurements in Section 3.2.12.
Protocol does not appear in the menu until you save a protocol
for the rst time.
Purging only appears in the menu in the ethane analysis application.
Gas type CxHy only appears in the menu if the device is equipped
for at least one further gas type apart from methane CH4.
17
3 Operation
3.2.2 Zero point
The zero point can be set manually in the Zero point menu item.
This is only necessary if the displayed fresh air measurement is
not zero after the end of the warm-up period.
GasContent in fresh air Correct zero point on device
0 % vol.0.0 % vol.
CH
4
CO0 ppm0 ppm
O
20.9 % vol.20.9 % vol.
2
The manual zero point setting is not saved. The zero point can be
corrected by adjustment as often as zero point deviations occur
(see Section 5.2).
Requirements for correct setting of the zero point
● Device has been switched on with fresh air.
● Device continues to draw in fresh air.
Setting zero point (manual zero point setting)
1. Press Menu.
2. Select Zero point menu item. The values are automatically
adjusted. The device returns to measuring mode.
18
The Setting zero point function can also be accessed using
the relevant symbol in the Inspection above ground, Enclosed
spaces and House applications.
3.2.3 Inspection above ground
This menu item allows you to change the measuring mode to
Inspection above ground .
Range of use
– Measuring minimal gas concentrations above the ground, the
gas pipe or possible leakage points
Symbol
Unit
– ppm (parts per million)
– % vol.
Measuring range
Gas-sensitive semiconductor 0 to 10,000 ppm
Thermal conductivity sensor 1 to 10 % vol.
3 Operation
Measurement data display
0
1010010
0,1
1,0
– Digit, e.g.
0.90 % vol. CH
– Bar graph with quasi-logarith-
mic scale
AL4
0.90
Fig. 7: Inspection above ground measuring mode
VOL%
CH4
4
19
3 Operation
3.2.4 Measuring in bar holes
This menu item allows you to change the measuring mode to
Measuring in bar holes.
Range of use
– Measuring gas dispersal in the ground
– Locating the possible leakage point and classifying the leak
Symbol
Unit
– % vol.
Measuring range
Thermal conductivity sensor 0.0 to 100 % vol.
20
Electrochemical sensor
(oxygen O
)
2
0.0 to 25.0 % vol.
Measurement data display
– Digit, e.g.
20.9 % vol. O
0.60 % vol. CH
– Bar display with quasilogarith-
mic scale (for CH4)
Fig. 8: Measuring in bar holes measuring mode
2
4
3.2.5 Ethane analysis
Selecting Ethane analysis from the menu opens an overview
of the detectable gases. The device automatically returns to
measuring mode.
Note:
The ethane analysis cannot be started with the Ethane analysis
menu item.
Information about carrying out the ethane analysis can be found
in Section 3.2.5.3.
Range of use
– Distinguishing between natural gas and swamp gas
Symbol
Unit
3 Operation
– ppm (parts per million)
– % vol.
Measuring range
Thermal conductivity sensor 0.0 to 100 % vol.
Electrochemical sensor
(oxygen O
)
2
Gas chromatograph/
0.0 to 25.0 % vol.
1 ppm to 1.2 % vol.
gas-sensitive semiconductor
21
3 Operation
Measurement data display
– Digit, e.g.
20.9 % vol. O
9.0 % vol. CXH
– Bar display with quasilogarith-
mic scale (for CxHy)
Fig. 9: Ethane analysis measuring mode
3.2.5.1 General information on ethane analysis
Ethane analysis is used to demonstrate the presence of natural
gas and to distinguish between natural gas and swamp gas.
This analysis utilises the fact that natural gas contains ethane,
but swamp gas does not. Thus, if ethane is detected, it can be
concluded that natural gas is present.
Note:
Ask the network operator about the composition of natural gas.
Request an analysis certicate.
2
Y
22
Ethane can denitely be detected in natural gas at a minimum
concentration of 1 % vol. If the concentration of ethane in natural
gas is less than 0.5 % vol., the gas cannot be detected. If the
concentration falls between these two values, the analysis can
be carried out, but the result must be assessed subsequently.
During the ethane analysis, the gas sample is always analysed
for the presence of the following three gases:
● Methane CH
● Ethane C2H
● Propane C3H
4
6
8
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