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XEN-5310 TCG (XEN-TCG3880) with read-out Preliminary datasheet Features Binary gas composition measurement Vacuum measurement Analog (12 bit) & digital output Measurement with proven Thermal Conductivity Gauge XEN-TCG3880 Read-out with dedicated ASIC chip for biasing and measuring the sensor components Temperature and humidity compensated Temperature range: -20 ºC to +55 ºC Humidity range: 0-100% RH, non-condensing Start-up time: 1 second T90 sensing and T10 recovery time: 1 second Operation: 5 V @ 20 mA Digital output (RS232 @ 3.3 V) Dual Analog output Available in modular form with exchangeable TCG sensor in socket RS232 to USB converter board available. XEN-5310 sensor, approximately real size (58×25 mm) Applications Examples: - Measurement of helium, CO2, hydrogen concentration. - Detection of gas dispersion rate in jets and plumes. Description The XEN-5310 is an intelligent gas sensor for gas detection, based on the measurement of the thermal conductivity of the ambient gas. To compensate for the influence of temperature and humidity, these are measured separately and a correction is made for them in the micro-controller. Each device is factory calibrated, with the option of recalibration by the customer. Block Diagram TCGauge Digital IO ASIC Connector Analog out Micro-controller LED indications Pt100 RH sensor Voltage regulator Xensor Integration bv Distributieweg 28 2645 EJ Delfgauw The Netherlands copyright Xensor Integration Smart Sensor Devices Phone +31 (0)15-2578040 Founded 18 May 1988 ABN-AMRO 60 50 40 311 Fax +31 (0)15-2578050 Trade reg. 27227437 IBAN NL42ABNA060504031 1 Email [email protected] Site www.xensor.nl VAT NL 009122746 B01 12 October 2015 page 1 of 7 XEN-5310 TCG (XEN-TCG3880) with read-out Preliminary datasheet Preliminary Specifications (at 23 ˚C, 101 kPa, 50% RH) Item Typical General Sensitivity for traces of H2 Sensitivity for traces of He Sensitivity for traces of CO2 Sensitivity for vacuum Digital output Analog output LED Alarm Noise Offset drift Operating limits Temperature operating range Temperature changes Humidity operating range Humidity changes Pressure range Remarks -2.1 -1.1 +0.4 -4.7 %/% %/% %/% %/Pa 0.04 0.12 % %/yr Signal change for concentration in air Signal change for concentration in air Signal change for concentration in air For low pressures See list User specified User specified Of signal in air Of signal in air ºC ºC/min %RH %RH/min mbar mbar For full accuracy Maximum rate of change Non-condensing Maximum rate of change Full accuracy Reduced accuracy -20 to + 55 <1 0-100 <1 800-1200 200-800 Operation speed System start up time T90 response time T10 recovery time Data update rate 1 1 1 1 Electrical Current consumption Supply voltage Output signals Digital Analog signal: signal change Analog alarm: code Storage Temperature storage limits Humidity storage limits Unit Second Second Second Hz 20 5-8 mA V 0-3 0-3 V V 10-40 20-70 copyright Xensor Integration RS232 @ 3.3 V User Specified User Specified ºC %RH Xensor Integration bv Distributieweg 28 2645 EJ Delfgauw The Netherlands 100 mW @ 5 V Smart Sensor Devices Phone +31 (0)15-2578040 Founded 18 May 1988 ABN-AMRO 60 50 40 311 Fax +31 (0)15-2578050 Trade reg. 27227437 IBAN NL42ABNA060504031 1 Email [email protected] Site www.xensor.nl VAT NL 009122746 B01 12 October 2015 page 2 of 7 TCG (XEN-TCG3880) with read-out XEN-5310 Preliminary datasheet Functional description The XEN-5310 determines the concentration of a specified gas in air. This is done by measuring the thermal conductivity of the ambient air using a thermal conductivity gauge (TCG), and comparing this to the factory calibration measurement. To eliminate the influence of temperature and humidity, these are measured separately, and a compensation is made by the micro-controller. The remaining difference between the measured and calibrated value of the thermal conductivity is then a measure of the gas concentration. Range and poisoning Since the TCG is not poisoned by an overdose of gas, the operating range is 0-100% for noncorrosive and non-condensing gases. The analog outputs can be specified for their range and desired alarms. The digital output gives all concentrations, if calibration curves are available for the user-specified gas. The capacitive humidity sensor can be sensitive to poisoning by silicone vapors, so these have to be avoided. Selectivity The TCG-based device is non-selective in that it will give an output in the presence of any gas having a thermal conductivity different than air. The sensor is especially useful for the measurement of helium and hydrogen, which have thermal conductivities that are 6x resp. 7x as high as that of air at room temperature. Most other gases have much lower thermal conductivities than helium, with neon at 2x the thermal conductivity of air as the highest of the others. So, other gases give much smaller signal changes. Methane has a thermal conductivity of about 40% higher than that of air, and CO2 (carbon di-oxide) nearly 40% lower. These gases can still be measured using the XEN-5310. However, CO (carbonmonoxide), for example, has about the same thermal conductivity as air, so this gas is very difficult to detect with a thermal conductivity measurement. Safety Note: the XEN-5310 is not CE approved. Note: the XEN-5310 is not approved and equipped for hydrogen leak detection in safety applications. Options The XEN-5310 has several options, see also the selection Table at the end. Calibration First of all the calibration can be chosen. This means that the analog and digital output signals can be calibrated for the concentration of a specific gas in, for instance, air. The standard options are helium (in air) and hydrogen (in nitrogen). The digital output signal is always full range, -5% to 105%, with 5% undershoot and overshoot to allow for tiny variations in the zero and gain. The analog output signals can be chosen. Other standard options are a general output and a vacuum output. Custom options are gases such as CO2, CH4, argon and other gases. Apart from the digital output signal, a number of other signals are available as digital output. For the analog output, a second output is available for safety alarms. At this time, no specific safety checks are made in the XEN-5310. This is available as special, custom option. Data rate Standard the data or measurement rate of the XEN-5310 is 1 Hz, one measurement per second. This will allow for safety checks to be made if so desired (no standard safety checks are made in the XEN-5310). An increased data rate of 2 Hz still gives all the measurement data, but no safety checks can be made any more. The highest data rate available is 4 Hz, every 250 ms measurement data are available. However, no humidity measurement is made, and no correction is made for changes in humidity. This can Xensor Integration bv Distributieweg 28 2645 EJ Delfgauw The Netherlands copyright Xensor Integration Smart Sensor Devices Phone +31 (0)15-2578040 Founded 18 May 1988 ABN-AMRO 60 50 40 311 Fax +31 (0)15-2578050 Trade reg. 27227437 IBAN NL42ABNA060504031 1 Email [email protected] Site www.xensor.nl VAT NL 009122746 B01 12 October 2015 page 3 of 7 TCG (XEN-TCG3880) with read-out XEN-5310 Preliminary datasheet degrade the accuracy of the output signal, especially at higher temperatures, where the absolute humidity can be increased (at room temperature, the absolute humidity is maximally about 3 kPa against 100 kPa atmospheric pressure). However, for helium and hydrogen measurements in the percentage range at room temperature, this is not very critical, and the increase measurement rate can be very important. The supply voltage is also not monitored anymore. Sensor type Standard the XEN-5310 is equipped with a XEN-TCG3880-P2-W-R sensor. That means, a standard thermal conductivity gauge, with a Pt100 temperature sensor on board (P2), with a roof over the sensor chip to shield it from flow effects (R), and with a cap having a 5 mm hole, covered by a screen filter welded to the TO-5 header (W) for mechanical protection and flow shielding. This sensor has a t90 time constant of 1 s. For fast measurement applications, in combination with the high data rate, it can be interesting to mount a special, ultra-fast sensor. This does not have the welded cap, and is made to exchange gas with the ambient very fast. The code is XEN-TCG3880-P2-RR-U. Extra roofing (RR) is applied to give this sensor a reduced flow sensitivity. At 1 l/min in a 4.5 mm inner diameter pipe no significant flow effects were found, but a t90 of the order of 50 ms was measured for hydrogen and helium. Of course, at lower flow velocities a somewhat higher time constant may be expected. Because of the vulnerability of this sensor, this option includes a socket to insert the sensor on the XEN-5310 board (standard, the sensor is soldered to the board). Other options Other options include a housing, and flow adapters. The flow adapter is especially interesting when using the ultrafast sensor, which is unprotected. This sensor will fit in the flow adapter, which is fastened to the XEN-5310 with screws. The adapter gives a 4.5 mm diameter flow channel, with the option to screw in M5 flow-circuit parts. Software The XEN-5310, if in combination with the XEN-85000 USB read-out board comes with LabView software to read out digitally. The read-out includes signals such as sensor output voltage, transfer, heater current and voltage, output signal, supply voltage, humidity and temperature. Xensor Integration bv Distributieweg 28 2645 EJ Delfgauw The Netherlands copyright Xensor Integration Smart Sensor Devices Phone +31 (0)15-2578040 Founded 18 May 1988 ABN-AMRO 60 50 40 311 Fax +31 (0)15-2578050 Trade reg. 27227437 IBAN NL42ABNA060504031 1 Email [email protected] Site www.xensor.nl VAT NL 009122746 B01 12 October 2015 page 4 of 7 TCG (XEN-TCG3880) with read-out XEN-5310 Preliminary datasheet Instructions for Use Proper ventilation Above all other measures, the user must take care that the sensing element is properly ventilated so that the gas to be measured can access the sensing element through diffusion into the cap via the hole in the cap. Blocking this hole, or proper ventilation of the instrument in general will make the device non-functional, while still it will indicate proper values. This must be avoided at all times. Although some checks can be made, non-ventilation of the whole instrument cannot be detected and there is therefore no warning against such a situation. Condensing and water dropping onto the sensors Precaution must be taken against condensing of water vapor in the sensor or water drops falling onto the sensors, as this may lead to (irreversible) malfunctioning. Preferably the sensor is installed in such a way that the opening of the thermal conductivity gauge is downwards, to avoid contamination by water drop, dust or other matter falling onto the gauge and the humidity sensor. However, the sensor will function properly in any orientation. Humidity sensor influence and care More specific caution should be taken when subjecting the humidity sensor to extreme values of temperature and humidity. When subjected to temperatures below zero or humidities around zero, the humidity sensor may take some time to recover. It is therefore not advised to use the XEN5310 at these extremes and then suddenly expose the XEN-5310 to high temperatures (above room temperature) and humidities, this can temporarily lead to falsely indicated concentrations. Exposure to very high humidities over the 90% RH may lead to some drift of the sensor, and thus to drift of the XEN-5310 at the high end of the temperature range. In general inaccuracies of the humidity sensor will be more serious at temperatures above room temperature, since the absolute humidity almost doubles every 10 ºC, while the effect of humidity is proportional to the absolute humidity (in kPa). At room temperature of around 25 ºC the maximum water vapor content in air is about 3 kPa or 3%, and this may lead to a signal change of the order of 0.6%. At 55 ºC, the upper limit of the XEN-5310, the maximum water vapor pressure is about 15 kPa. Proper correction for humidity is therefore necessary, in particular for the higher end of the temperature range. Flow and sudden changes in the ambient Sudden temperature shocks and humidity shocks may lead to spurious signals in the sensor output. Also sudden movement of the sensor and strong air flow directly onto the sensor may lead to spurious signals. This does not normally lead to an alarm situation, except for extreme shocks. Periodic calibration In normal circumstances, a total drift of the sensor offset of well below 2000 ppm per year is typical, when measuring under identical circumstances (same temperature, humidity and pressure), and no calibration is required until such time as the deviation becomes significant (i.e., 5000 ppm signal change when pure air is supplied). It is advised to periodically check the functioning of the thermal conductivity gauge. In practice, it will suffice to determine the sensor output in a normal situation where the absence of a deviation from the normal air composition is established, and where no significant temperature and humidity changes or gradients are present. This would also be apparent from the indicated signal-level, which should be stable. In that case a (near-)zero signal change should be indicated. If suddenly a significant change of more than 2000 ppm typically is observed while the operation circumstances have not changed, the temperature sensor and humidity sensor should be checked for proper operation, and possibly a recalibration should be carried out. Xensor Integration bv Distributieweg 28 2645 EJ Delfgauw The Netherlands copyright Xensor Integration Smart Sensor Devices Phone +31 (0)15-2578040 Founded 18 May 1988 ABN-AMRO 60 50 40 311 Fax +31 (0)15-2578050 Trade reg. 27227437 IBAN NL42ABNA060504031 1 Email [email protected] Site www.xensor.nl VAT NL 009122746 B01 12 October 2015 page 5 of 7 XEN-5310 TCG (XEN-TCG3880) with read-out Preliminary datasheet Electrical characteristics The XEN-5310 sensor requires a nominal supply of 5-8 V and about 20 mA at room temperature. This supply voltage is converted to the internal operating supply of 3.3 V. The minimum and maximum supply voltages are 4 V and 12 V, the sensor will stop operating when a voltage of less than approximately 3.5 V is supplied. Such low power supply voltages are not recommended, as the operation of the sensor is no longer complete (for instance, the sensor can no longer display the analog signal up to 3 V). A power supply of more than 12 V will lead to increased power consumption, and self-heating of the PCB. It is recommended to have the supply voltage close to 5 V, any excess voltage will be converted into heat dissipation, possibly causing thermal drift of the sensor. Trouble Shooting In case of trouble: First try to get the sensor to work again by disconnecting and connecting the power supply. If the sensor is out of the operating offset range in the absence of gases other than air, recalibrate if possible. If the sensor will still not operate properly then contact the manufacturer: call +31 15 2578040 or email [email protected]. Physical dimensions and connections The XEN-5310 is standard supplied with an 8-terminal 2-row micro-fit connector, with on the bottom row the power supply and the analog output signals. On the top row the RS-232 signal lines and an additional ground connection are situated. If so desired, the sensor can also be supplied with a 4-terminal single row connector, omitting the RS-232 connection. Furthermore, if so desired a 3-wire connection is possible with only a single analog output, where a modulation on the analog signal output will be installed instead of on the analog alarm output. Physical geometry of the PCB, top view and view from connector side: 58.4 mm 9 mm 3.2 mm mounting holes connector capacitor 20.3 mm 38.7 mm TCG 10 mm 25.4 mm 14 mm Connections of the 2-row 8-pin AMP connector, view from outside of board: Tx Gnd Rx Out1 Gnd Out0 Vdd Printed Circuit Board thickness 1.6 mm, components on both sides. All components are less than 3 mm high, except for the connector, TCG and buffer capacitance. Xensor Integration bv Distributieweg 28 2645 EJ Delfgauw The Netherlands copyright Xensor Integration Smart Sensor Devices Phone +31 (0)15-2578040 Founded 18 May 1988 ABN-AMRO 60 50 40 311 Fax +31 (0)15-2578050 Trade reg. 27227437 IBAN NL42ABNA060504031 1 Email [email protected] Site www.xensor.nl VAT NL 009122746 B01 12 October 2015 page 6 of 7 TCG (XEN-TCG3880) with read-out XEN-5310 Preliminary datasheet Order Information and Accessories Standard version The order code for the XEN-5310 sensor with standard options: XEN-5310-He-2Hz-100%. Cable pack 1 is included: cable connector + separate contacts not assembled. Options for the XEN-5310 sensor Option Select Code Content Availability Calibration He H2 General Vacuum Custom He H2 Gen Vac Custom Digital output for helium in Air Digital output for hydrogen in nitrogen Digital output for transfer deviation Digital output for nitrogen pressure Digital output for other gases (CO2, CH4, etc) Standard Standard Standard Standard On request Data Rate 1 Hz 2 Hz 4 Hz 1Hz 2Hz 4Hz Full functionality No safety No humidity correction, no safety Standard Standard Standard Sensor Type Standard Ultrafast U Standard (1 s) sensor, soldered Exposed, ultrafast (50 ms) sensor and socket Standard On request Analog output Full range H2 leak Other 100% 4% ?% -5 to 105%, no alarm 0-4%, alarm 1% Customer specified Standard On request On request Other options Inquire Customer-specific alterations On request Accessories for the XEN-5310 sensor, available separately XEN-85000 PCB with FTDI interface chip to connect up to 4 XEN-5310 to a PC via USB. Cable pack 2 Custom specified cable for XEN-5310. Cable pack 4 Cable of 50 cm, with AMP connectors 2x4 rows on both sides, for connection of the sensor to the FTDI PCB. Disclaimer: No responsibility is taken for the consequences of improper functioning of the sensor. Conditions: Use of sensors for industrial applications is subjected to patent rights. Xensor Integration assumes no liability arising from violation of these rights Warranty: Xensor Integration warrants its products against defects in materials and workmanship for 12 months from date of shipment. Products not subject to misuse will be replaced or repaired. The foregoing is in lieu of all other expressed or implied warranties. Xensor Integration reserves the right to make changes to any product herein and assumes no liability arising out of the application or use of any product or circuit described or referenced herein. Xensor Integration bv Distributieweg 28 2645 EJ Delfgauw The Netherlands copyright Xensor Integration Smart Sensor Devices Phone +31 (0)15-2578040 Founded 18 May 1988 ABN-AMRO 60 50 40 311 Fax +31 (0)15-2578050 Trade reg. 27227437 IBAN NL42ABNA060504031 1 Email [email protected] Site www.xensor.nl VAT NL 009122746 B01 12 October 2015 page 7 of 7