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ExTR Reference No. US/ETL/ExTR12.0007/00 (100677772CRT-001b)

ExTR Reference Number...............: US/ETL/ExTR12.007/00

ExTR Free Reference Number......: 100677772CRT-001b

Compiled by + signature (ExTL).....: Robert Reason

Mentored by + signature (ExTL)…. : Michael Spector

Reviewed by + signature (ExTL)....: Kevin Wolf

Date of issue..................................: 2012-05-11

Ex Testing Laboratory (ExTL)........: INTERTEK

Address..........................................: 3933 US Route 11; Cortland, NY, 13045; USA

Applicant’s name............................: Crowcon Detection Instruments Ltd

Address..........................................: 2 Blacklands Way, Abingdon Business Park

Abingdon,Oxon, OX14 1DY, United Kingdom

Standard........................................: IEC 60079-11:2006, 5th Edition

Test procedure...............................: IECEx System

Test Report Form Number.............: ExTR60079-11_5B-1 (released 2010-08)

Instructions for Intended Use of Ex Test Report:An Ex Test Report provides a clause-by-clause documentation of the initial evaluation and testing that verified compliance of an item or product with an IEC Ex standard. This Ex Test Report is part of an ExTR package that may include other Ex Test Report, Addendum and National Differences documents, along with a single ExTR Cover. An Ex Test Report is to be compiled and reviewed by the ExTL. The Issuing ExCB indicates final approval of the Ex Test Report as part of the overall ExTR package on the associated ExTR Cover.

Copyright © 2010 International Electrotechnical Commission System for Certification to Standards Relating to Equipment for use in Explosive Atmospheres (IECEx System), Geneva, Switzerland. All rights reserved.This blank publication may be reproduced in whole or in part for non-commercial purposes as long as the IECEx System is acknowledged as copyright owner and source of the material. The IECEx system takes no responsibility for, and will not assume liability for, damages resulting from the reader's interpretation of the reproduced material due to its placement and context.

Possible test case verdicts:- test case does not apply to the test item.....................:N / A

- test item does meet the requirement...........................:Pass

General remarks:The test results presented in this Ex Test Report relate only to the item or product tested.

"(see Attachment #)" refers to additional information appended to this document. "(see appended table)" refers to a table appended to this document. Throughout this document, a point is used as the decimal separator.

The technical content of this Ex Test Report shall not be reproduced except in full without the written approval of the Issuing ExCB and ExTL.

TRF No. ExTR60079-11_5B-1 of 29

IECEx TEST REPORT IEC 60079-11

Explosive atmospheres – Part 11: Equipment protection by intrinsic safety "i"


IEC 60079-11

Clause Requirement – Test Result – Remark Verdict

1 SCOPE

2 NORMATIVE REFERENCES

3 DEFINITIONS

4 GROUPING AND CLASSIFICATION

5 LEVELS OF PROTECTION AND IGNITION COMPLIANCE

5.1 General Refer to Appendix A.1 for details. PASS

5.2, 5.3, 5.4

Level of protection Refer to Appendix A.1 for details. PASS

5.5 Spark ignition compliance Refer to Appendix A.2 for details. PASS

5.6 Thermal ignition compliance

5.6.1 General Meets T4 (See Appendix A.3 Below) PASS

5.6.2 Temperature for small components

Meets T4 (See Appendix A.3 Below) PASS

5.6.3 Wiring within apparatus No Wires N / A

5.6.4 Tracks on printed circuit boards PCBs Awarded T4 As A Result Of Maximum Possible Power Dissipation In Any Component Or PCB Track = 0.62W < 1.25W (T4 @ +50°C) [Refer to Appendix A.3 Below]

PASS

Passed temp test on PCB track across battery: 57.5°C MAX MEASURED [Refer to Appendix B.3 Below]

PASS

5.7 Simple apparatus No Simple Apparatus N / A

6 APPARATUS CONSTRUCTION

6.1 Enclosures Enclosure Visually Meets IP20 PASS

6.1.1 Apparatus complying with Table 5 Adequate Separations Provided [Refer to Appendix B.1 Below]

PASS

6.1.2 Apparatus complying with Annex F Annex F Not Used N / A

6.2 Facilities for connection of external circuits

No External Connections N / A

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IEC 60079-11


6.2.1 Terminals No External Connections N / A

6.2.2 Plugs and sockets No External Connections N / A

6.2.3 Determination of maximum external inductance to resistance ratio (Lo/Ro) for resistance limited power source

Not a Power Source N / A

6.2.4 Permanently connected cable No Cable N / A

6.3 Separation distances

6.3.1 Separation of conductive parts Adequate Separations Provided [Refer to Appendix B.1 Below]

PASS

6.3.1.1 Distances according to Table 5 Adequate Separations Provided [Refer to Appendix B.1 Below]

PASS

6.3.1.2 Distances according to Annex F Annex F Not Used N / A

6.3.2 Voltage between conductive parts Adequate Separations Provided [Refer to Appendix B.1 Below]

PASS

6.3.3 Clearance Adequate Separations Provided [Refer to Appendix B.1 Below]

PASS

6.3.4 Separation distances through casting compound

No Casting Compound N / A

6.3.5 Separation distances through solid insulation

Adequate Separations Provided [Refer to Appendix B.1 Below]

PASS

6.3.6 Composite separations No Composite Separations N / A

6.3.7 Creepage distance Adequate Separations Provided [Refer to Appendix B.1 Below]

PASS

6.3.8 Distance under coating No PCB Coating N / A

6.3.9 Requirements for assembled printed circuit boards

No PCB Coating N / A

6.3.10 Separation by earth screens Portable Battery Powered N / A

6.3.11 Internal wiring No wires N / A

6.3.12 Dielectric strength requirement Not Required/Applicable N / A

6.3.13 Relays No Relays N / A

6.4 Protection Against Polarity Reversal

Non-Replaceable Battery Cell PASS

6.5 Earth conductors, connections and terminals

Portable Battery Powered N / A

6.6 Encapsulation No Encapsulation N / A

7 COMPONENTS ON WHICH INTRINSIC SAFETY DEPENDS

7.1 Rating of components Except for Protective Components, all other components assumed to be no-count-fallible

N / A

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IEC 60079-11


7.2 Connectors for internal connections, plug-in cards and components

No Plug-Ins N / A

7.3 Fuses No Fuses N / A

7.4 Primary and secondary cells and batteries

7.4.1 General UL Recognized Lithium Battery Cell PASS

7.4.2 Electrolyte leakage and ventilation No Electrolyte Leakage Observed During/Following Short Circuit Test [Refer to Appendix B.6 Below]

PASS

7.4.3 Cell voltages Values Per UL 60079-0 Used: 3.9Vpeak|3.6Vnom

PASS

7.4.4 Internal resistance of cell or battery

Cell Resistance Not Used N / A

7.4.5 Batteries in apparatus protected by other means of protection

No Associated Apparatus N / A

7.4.6 Batteries used and replaced in explosive gas atmospheres

No replaceable current-limiting devices N / A

7.4.7 Batteries used but not replaced in explosive gas atmospheres

Non-replaceable Battery Cell N / A

7.4.8 External contacts for charging batteries

No charging contacts N / A

7.4.9 Battery construction Battery Passed Spark Ignition And Temperature Testing [Refer to Appendix B.6 Below]

PASS

7.5 Semiconductors7.5.1 Transient effects No Transients – Battery Powered N / A7.5.2 Shunt voltage limiters See 8.6 Below PASS7.5.3 Series current limiters None N / A

7.6 Failure of components, connections and separations

All applicable faults considered/applied PASS

7.7 Piezo-electric Passed piezo testing [Refer to Appendix B.5 Below]

PASS

7.8 Electrochemical cells for the detection of gases

Gas Detectors Considered For Spark Ignition Contribution Based on Most Severe Parameters (See Appendix A Below)

PASS

8 INFALLIBLE COMPONENTS, INFALLIBLE ASSEMBLIES OF COMPONENTS AND INFALLIBLE CONNECTIONS ON WHICH INTRINSIC SAFETY DEPENDS

8.1 Mains transformers No Transformers N / A

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IEC 60079-11


8.1.1 Protective measures No Transformers N / A

8.1.2 Transformer construction No Transformers N / A

8.1.3 Transformer type tests No Transformers N / A

8.1.4 Routine test of mains transformers No Transformers N / A

8.2 Transformers other than mains transformers

No Transformers N / A

8.3 Infallible windings No Transformers N / A

8.3.1 Damping windings No Transformers N / A

8.3.2 Inductors made by insulated conductors


8.4 Current-limiting resistors Adequate SMD Current-Limiting Resistors Provided (See Appendix A.4 Below)

PASS

8.5 Blocking capacitors No Blocking Capacitors N / A

8.6 Shunt safety assemblies

8.6.1 General Adequately Rated Zener Diode Shunt Assembly Provided: D2/D3: Parallel Combination, Connected Such That Single Open Circuit Fault Simultaneously Disconnects Voltage Source

PASS

8.6.2 Safety shunts No Transients – Battery Powered N / A

8.6.3 Shunt voltage limiters No Transients – Battery Powered N / A

8.7 Wiring, printed circuit board tracks, and connections

No Infallible Connectors Provided: None Required

N / A

8.8 Galvanically separating components

8.8.1 General No Isolators N / A

8.8.2 Isolating components between intrinsically safe and non-intrinsically safe circuits

No Isolators N / A

8.8.3 Isolating components between separate intrinsically safe circuits

No Isolators N / A

9 DIODE SAFETY BARRIERS

9.1 General No Barriers N / A

9.2 Construction No Barriers N / A

9.2.1 Mounting No Barriers N / A

9.2.2 Facilities for connection to earth No Barriers N / A

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IEC 60079-11


9.2.3 Protection of components No Barriers N / A

10 TYPE VERIFICATIONS AND TYPE TESTS

10.1 Spark ignition test

10.1.1 General Passed spark ignition testing required for some circuits [Refer to Appendix B.2 Below]

PASS

10.1.2 Spark test apparatus Passed spark ignition testing required for some circuits [Refer to Appendix B.2 Below]

PASS

10.1.3, 10.1.3.1, 10.1.3.2

Test gas mixtures and spark test apparatus calibration current

Passed spark ignition testing required for some circuits [Refer to Appendix B.2 Below]

PASS

10.1.4, 10.1.4.1, 10.1.4.2

Tests with the spark test apparatus – circuit test, safety factors

Passed spark ignition testing required for some circuits [Refer to Appendix B.2 Below]

PASS

10.1.5 Testing considerations

10.1.5.1 General

10.1.5.2 Circuits with both inductance and capacitance

None N / A

10.1.5.3 Circuits using shunt short-circuit (crowbar) protection

None N / A

10.1.5.4 Results of spark test Passed spark ignition testing required for some circuits [Refer to Appendix B.2 Below]

PASS

10.2 Temperature tests Passed Temperature Assessments (See Appendix VII Below)

PASS

Passed PCB track temp test [Refer to Appendix B.3 Below]

TEST

10.3 Dielectric strength tests Not Required/Applicable N / A

10.4 Determination of parameters of loosely specified components

Loosely Specified Component Testing:Motor measured max inductance = 120.4µH

< 108µH+20% (used for spark ignition analysis/testing)

Filters measured max inductance = 1.4µH < 1.53µH + 20% (used for spark ignition analysis/testing)

Filters measured max capacitance = 111pF < 100pF + 20% (used for spark ignition analysis/testing) [Refer to Appendix B.4 Below]

PASS

10.5 Tests for cells and batteries

10.5.1 General Batteries Passed Testing (See Test Data) PASS

10.5.2 Electrolyte leakage test for cells and batteries

Batteries Passed Testing [Refer to Appendix B.6 Below]

PASS

10.5.3 Spark ignition and surface temperature of cells and batteries

Batteries Passed Testing [Refer to Appendix B.6 Below]

PASS

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IEC 60079-11


10.5.4 Battery container pressure tests No sealed Battery Compartments N / A

10.6 Mechanical tests

10.6.1 Casting compound No Casting Compound N / A

10.6.2 Sealing of components before encapsulation

No Sealed Components N / A

10.6.3 Partitions No Partitions N / A

10.7 Tests for apparatus containing piezoelectric devices

Passed piezo testing [Refer to Appendix B.5 Below]

PASS

10.8 Type tests for diode safety barriers and safety shunts

No Transients – Battery Powered N / A

10.9 Cable pull test No cables N / A

10.10 Transformer tests No Transformers N / A

11 ROUTINE VERIFICATIONS AND TESTS

11.1 Routine tests for diode safety barriers

No Barriers N / A

11.1.1 Completed barriers No Barriers N / A

11.1.2 Diodes for 2-diode “ia” barriers No Barriers N / A

11.2 Routine tests for infallible transformers


12 MARKING

12.1 General None of the specific markings applicable N / A

12.2 Marking of connection facilities No connection facilities N / A

12.3 Warning markings No required warnings N / A

12.4 Examples of marking

13 DOCUMENTATION Adequate instructions provided PASS

ANNEX A

ASSESSMENT OF INTRINSICALLY SAFE CIRCUITS (NORMATIVE)

Passed Spark Ignition and Temperature Assessments (See Appendices VI & VII Below)

PASS

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IEC 60079-11


ANNEX B

SPARK TEST APPARATUS FOR INTRINSICALLY SAFE CIRCUITS (NORMATIVE)

ANNEX C MEASUREMENT OF CREEPAGE DISTANCE, CLEARANCES AND SEPARATION DISTANCES THROUGH CASTING COMPOUND AND THROUGH SOLID INSULATION (INFORMATIVE)

ANNEX D ENCAPSULATION (INFORMATIVE)

ANNEX E ENCAPSULATION (INFORMATIVE)

ANNEX F ALTERNATIVE SEPARATION DISTANCES FOR ASSEMBLED PRINTED CIRCUIT BOARDS AND SEPARATION OF COMPONENTS (NORMATIVE)

F.1 General Annex F Not Used N / A

F.2 Control of pollution access Annex F Not Used N / A

F.3 Distances for printed circuit boards and separation of components

Annex F Not Used N / A

F.3.1 Level of protection “ia” and “ib” Annex F Not Used N / A

F.3.2 Level of protection “ic” Annex F Not Used N / A

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Measurement Section, including Additional Narrative Remarks

APPENDIX A: Description of product

A.1 General overviewA.1.1 CIRCUIT DESCRIPTION (ST-Ex-H-C-001, Rev. 1.1 and/or Rev. 1.0):The product is battery powered (single ½ AA Size Lithium/Thionyl Chloride Cell). The battery includes solder tabs for both polarities. The solder tabs directly connect to the bottom of the PCB Assembly. There is only one PCB Assembly. The positive (+) battery has three separate branches through three current-limiting resistors (22Ω, ±5%, 1W, 2512): R37 makes supply “VD” (Only on Rev 1.1, Rev 1.0 makes “VM” directly from “VD”; All Analysis/Tests Based on Rev 1.1 which is Most Severe), R42 makes the “High Voltage Area” supply (Piezo Buzzer Circuit), and R44 makes supply “VM”. The “High Voltage Area” (Piezo Buzzer Circuit) includes a switched capacitor DC-DC Converter (U3) that drives the Piezo. The CPU14 connection of the “High Voltage Area” includes voltage clamping to prevent excessive voltages from becoming present on any other circuits. The maximum voltage inside the “High Voltage Area is limited only by the function of the switched capacitor DC-DC supply. Other than isolation/separations, there are no other protective features.

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A.1.2 VOLTAGES:1. Single Lithium Thionyl Cell Supply:Per Table 10 (IEC 60079-0:2009):

VBatt = 3.9Vp|3.6Vnom2. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) T1 OUT:±13.2V (Per Absolute Maximum Ratings)

VT1-OUT = ±13.2V3. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) T2 OUT:±13.2V (Per Absolute Maximum Ratings)

VT2-OUT = ±13.2V4. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) R1 OUT:±13.2V (Per Absolute Maximum Ratings)

VR1-OUT = ±13.2V5. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) R2 OUT:±13.2V (Per Absolute Maximum Ratings)

VR2-OUT = ±13.2V6. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) V+:7V (Per Absolute Maximum Ratings)

V+ = 7V7. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) V-:-7V (Per Absolute Maximum Ratings)

V- = -7V8. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) [V+] + [V-]:13V (Per Absolute Maximum Ratings)

[V+] + [V-] = 13V9. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) CPU14 Connection:Clamped by D2/D3: KEC Semiconductor, KDZ5.6EV, 6.0Vmax, 150mW @ Ta = 25°C.

VCPU14 = 6.0V10. “Gas Sensor” Worst CaseVOC MAX = -1.34V (Per Data Sheets/Application Documents)

VGAS-SENSOR = -1.34V

NO OTHER VOLTAGE SOURCES OR LIMITERS

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A.1.3 CURRENTS:1. “VD” Resistor Limited (R37 = 22Ω, ±5%)IVD = VBatt/R37Min = 3.9Vpeak|3.6Vnominal/(22Ω)(0.95)

IVD = 0.187Apeak|0.173Anominal2. “VM” Same As 1 Above

IVM = 0.187Apeak|0.173Anominal3. “R42” Same As 1 Above

IR42 = 0.187Apeak|0.173Anominal4. “Common/Battery Return/0V” (Three Equal Branches)ICOMMOM = 3 x IVD

ICOMMON = 0.561Apeak|0.519Anominal5. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) Output V+, V-, TOUT, ROUT:±0.1A (Per Absolute Maximum Ratings)

IV+ = 0.1AIV- = 0.1AITOUT = 0.1AIROUT = 0.1A

6. “Gas Sensor” Worst CaseISC MAX = 1A (Per Data Sheets/Application Documents)

IGAS-SENSOR = 1A

NO OTHER CURRENT SOURCES OR LIMITERS

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A.1.4 POWERS:1. R37/R44/R42 (22Ω, ±5%)PR37/R44/R42 = V2/RMIN = (3.6V)2/(22Ω)(0.95)

PR37/R44/R42 = 0.62W (W1)2. “VD” Resistor Limited (R37 = 22Ω, ±5%)PVD = (VBatt)2/4 x R37Min = (3.6Vnominal)2/(4)(22Ω)(0.95)

PVD = 0.156W2. “VM” Same As 1 Above

PVM = 0.156W3. “R42” Same As 1 Above

PR42 = 0.156W4. “R45” (4.7kΩ, ±5%)PR45 = (VD2)2/R45Min = (6V)2/(4.7kΩ)(0.95)

PR45 = 0.008W (W1)5. “R41” (1.2kΩ, ±5%)PR41 = (VD2)2/R45Min = (6V)2/(1.2kΩ)(0.95)

PR41 = 0.032W (W1)6. D2/D3PD2/D3 = (PR45 + PR41)/4

PD2/D3 = 0.010W (W1)

NO OTHER POWER SOURCES OR LIMITERS

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A.2 Spark ignition consideration (IIC, ia)A.2.1 Resistive spark ignition1. Battery Cell

Passed Spark Test [See B6.2 Below] (PASS)2. Outside “High Voltage Area”VOC-MAX = 7.34V (High Voltage Out + Gas Sensor Out = 6V + 1.34V)ISC-MAX = 1.561A (Common Return + Gas Sensor Out = 0.561A + 1A)From Table A.1 (IEC 60079-11:2006): At I = 1.63A, V = 13.4V (IIC, x 1.5)

7.34V < 13.4V, 1.561A < 1.63A (PASS)3. Inside “High Voltage Area”VOC-MAX = 26.4VISC-MAX = 0.1AFrom Table A.1 (IEC 60079-11:2006): At I = 0.101A, V = 30V (IIC, x 1.5)

26.4V < 30V, 0.1A < 0.101A (PASS)

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A.2.2 Inductive spark ignition1. Motor (MT1):MT1 = 108µH (No Tolerance = 20%)V-MAX = 7.34VL-MAX = (108µH + (3) x (1.53µH)) x 1.2 = 130µHI-MAX = 0.187AFrom Figure A.6 (IEC 60079-11:2006): At L = 150µH, I = 0.7A (8V)

7.34V < 8V; 130µH < 150µH; 0.187A/0.7A = 0.267 = 3.74FOS > 1.5 (PASS)2. Filters (F1/F2/F3):F1/F2/F3 = 1.53µH (No Tolerance = 20%)V-MAX = 7.34VL-MAX = 1.53µH x 1.2 = 1.84µHI-MAX = 1A (From Gas Sensor, Worst Case)From Figure A.6 (IEC 60079-11:2006): At L = 10µH, I = 2A (8V)

7.34V < 8V; 1.84µH < 10µH; 1A/2A = 0.5 = 2FOS > 1.5 (PASS)

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A.2.3 Capacitive spark ignition

1. Capacitors at 3.9V (All Capacitors Shorted Between VD and Common)V-MAX = 3.9VI-MAX = 0.187AC-MAX = 31µFFrom Table A.1 (IEC 60079-11:2006): At V = 12.1V, I = 5A0.187A/5A = 0.0374From Table A.2 (IEC 60079-11:2006): At C = 32µF, V = 9.4V3.9V/9.4V = 0.415

0.0374 + 0.415 = 0.4524 = 2.2FOS > 1.5 (PASS)2. Capacitors at 6V (All Capacitors Shorted Between High Voltage Output and Common)V-MAX = 6VI-MAX = 0.0053AC-MAX = 30.5µFFrom Table A.1 (IEC 60079-11:2006): At V = 12.1V, I = 5A0.0053A/5A = 0.0011From Table A.2 (IEC 60079-11:2006): At C = 32µF, V = 9.4V6V/9.4V = 0.781

0.0011 + 0.781 = 0.7821 = 1.27FOS < 1.5: Passed Spark Test [See B2.1 Below] (PASS)

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3. Capacitors at 7.34V (All Floating Caps Shorted Between High Voltage Output and Gas Sensor Output)V-MAX = 7.34VI-MAX = 1AC-MAX = 0.44µFFrom Table A.1 (IEC 60079-11:2006): At V = 12.1V, I = 5A0.0053A/5A = 0.0011From Table A.2 (IEC 60079-11:2006): At C = 32µF, V = 9.4V6V/9.4V = 0.781

0.0011 + 0.781 = 0.7821 = 1.27FOS < 1.5 Passed Spark Test [See B2.2 Below] (PASS)4. Capacitors at 13V (Capacitors Shorted Inside High Voltage Area)V-MAX = 13VI-MAX = 0.1AC-MAX = 0.44µFFrom Table A.1 (IEC 60079-11:2006): At V = 13V, I = 3.02A0.1A/3.02A = 0.0034From Table A.2 (IEC 60079-11:2006): At C = 0.442µF, V = 24.3V13V/24.3V = 0.54

0.0034 + 0.54 = 0.5434 = 1.84FOS > 1.5 (PASS)5. Capacitors at 26.4V (Piezo)V-MAX = 26.4VI-MAX = 0.1AC-MAX = 19.5nFFrom Table A.1 (IEC 60079-11:2006): At V = 26.4V, I = 0.207A0.1A/0.207A = 0.483From Table A.2 (IEC 60079-11:2006): At C = 40nF, V = 55V26.4V/55V = 0.48

0.483 + 0.48 = 0.963 = 1.034FOS < 1.5 Passed Spark Test [See B2.3 Below] (PASS)A.2.4 Combination of inductive and capacitive spark ignitionNAA.2.5 Shunt short-circuit (crowbar) spark ignitionNoneA.2.6 Other spark ignition considerationsNone

NO OTHER CIRCUITS REQUIRING SPARK IGNITION ASSESSMENT

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A.3 Thermal ignition considerationA.3.1 Temperature for small componentsA.3.1.1 Components > 20SQ-MM: can be awarded T4 as the maximum dissipated power < 1.25W:

A.3.1.2 Components < 20SQ-MM: can be awarded T4 as the calculated temperature < 275°C:

A.3.2 Wiring within apparatusNoneA.3.3 Tracks on printed circuit boardsPCB can be awarded T4 as the maximum dissipated power < 1.25WPassed Temperature Test [See B3 Below] (PASS)A.3.4 Battery Cell:Passed Temperature Test [See B6.1 Below] (PASS)

NO OTHER CIRCUITS REQUIRING TEMPERATURE ASSESSMENT

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A.4 Rating of components

A.4.1 Resistors1. R37/R44/R42 (22Ω, ±5%, 1W, 2512)PR = 1W (W2)PR37/R44/R42 = 0.62W (W1)W1/W2 = 0.62W/1W = 0.62 < 0.667 (PASS)2. R45 (4.7kΩ, ±5%, 1/4W, 1206)PR = 0.25W (W2)PR45 = 0.008W (W1)W1/W2 = 0.008W/0.25W = 0.032 < 0.667 (PASS)3. R41 (1.2kΩ, ±5%, 1/4W, 1206)PR = 0.25W (W2)PR41 = 0.032W (W1)W1/W2 = 0.032W/0.25W = 0.128 < 0.667 (PASS)A.4.2 Shunt voltage limiters1. D2/D3 (KDZ5.6EV; 150mW @ 25°C)PR > 100mW (W2) @ 50°C (From KEC Data Sheet, Conservative Accounting For Precision Of Plot)PD2/D3 = 0.01W (W1)W1/W2 = 0.01W/100mW = 0.10 < 0.667 (PASS)A.4.3 Series current limiterNoneA.4.4 OtherNone

NO OTHER PROTECTIVE COMPONENTS

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APPENDIX B: Tests

Option 1: If tests records are provided as an attachment, please complete the following table:

Document number Number of Pages Name of TestsNA NA NA

Option 2: If tests records are not provided as an attachment, please complete the following table:

IEC 60079-0


B1 Measurements of Separation DistancesEquipment Tested: Gas Detector; PCB Assembly

Date of Test (yyyy/mm/dd): 2011/March/29

Clause and Standards: 6.3 Separation distances; IEC 60079-11:2006

6.3 Test Procedure The separation distances in question were measured using various measurement means and tools including Documentation and Data, Calibrated Vernier Calipers, Rulers, Optical Loupe, and Gerber File Viewer Software. All measuring means and tools were verified by use of a calibrated Vernier Calipers and provided samples.

Test Equipment Calipers: N813S; Cal Due: 3/31/2011

Test Conditions NA

Acceptance criteria

6.3.1.1 Distances according to Table 5

For Circuits Up To 30V:

Per Table 5 (IEC 60079-11:2006):

Required Clearance: 2.0mm;

Required Creepage Distance: 2.0mm;

Required Distance Through Solid Insulation: 0.5mm

Test Results

6.3.2 Voltage between conductive parts

The maximum possible potential difference in the product is 26.4V < 30V

PASS

6.3.3 Clearance Minimum Measured Clearances Across Current Limiting Resistors:

R42 = > 2.5mm

R37 = > 2.5mm

R44 = > 2.5mm

PASS

6.3.5 Separation distances through solid insulation

Minimum Measured Separation Distances Through Solid Insulation Across Current Limiting Resistors:

R42 = > 0.5mm

R37 = > 0.5mm

R44 = > 0.5mm

PASS

6.3.7 Creepage distance Minimum Measured Creepage Distances Across Current Limiting Resistors:

R42 = > 2.5mm

R37 = > 2.5mm

R44 = > 2.5mm

PASS

TRF No. ExTR60079-11_5B-1 of 29


APPENDIX B: Tests

IEC 60079-0


B2 Spark Ignition TestingB2.1 Capacitors at 6V

Equipment Tested: Gas Detector, Simulated Circuits

Date of Test (yyyy/mm/dd): 2011/May/5Clause and Standards: 10.1 Spark ignition test; IEC 60079-11:2006

10.1 Test Procedure The necessary circuit was simulated using DC Power Supply, Capacitance Substitution Box, and Non-Inductive Resistors. The simulated circuit was spark tested, accordingly. The spark test gas was 21±2% Hydrogen in Air. The spark ignition test sequence was comprised of the following (Cal circuit consisted of 24VDC Supply and 95mH Inductor):

1. Calibration/Verification Of Test Gas Mixture;2. Spark Ignition Test (Positive Polarity);3. Spark Ignition Test (Negative Polarity);4. Calibration/Verification Of Test Gas Mixture.

Test Equipment RCL Meter: R162; Cal Due: 6/18/2011

Environmental Monitor: T1256; Cal Due: 10/12/2011

Timer: Q107; Cal Due: 1/10/2012

Rev Counter: Q108; Cal Due: 1/10/2012

Flow Meter: F263; Cal Due: 8/24/2011

Multimeter: M075S; Cal Due: 1/13/2012



Oxygen Analyzer: O193; Maintenance: 2/12/2011

Test Conditions Temperature: 24.5°CHumidity: 28%Pressure: 947hPa

Acceptance criteria

10.1 Spark ignition test No ignition of test gas

10.1 Test Results Test Voltage: 9V(= 1.5 x 6V);Test Current: 5.3mA;Test Capacitance: 30.5µF;1. Calibrate Before Test (30-31mA):

Ignition At: 1 Second;2. Positive Polarity:

No Ignition At 204 Revs;3. Negative Polarity:

No Ignition At 205 Revs;4. Calibrate After Test (30-31mA):

Ignition At: 19 Seconds .

PASS

TRF No. ExTR60079-11_5B-1 of 29


IEC 60079-0


B2 Spark Ignition TestingB2.2 Capacitors at 7.34V







Timer: Q107; Cal Due: 1/10/2012








Acceptance criteria


10.1 Test Results Test Voltage: 11.01V(= 1.5 x 7.34V);Test Current: 1A;Test Capacitance: 0.44µF;1. Calibrate Before Test (30-31mA):

Ignition At: 13 Seconds;2. Positive Polarity:



Ignition At: 2 Seconds.

PASS

TRF No. ExTR60079-11_5B-1 of 29


IEC 60079-0


B2 Spark Ignition TestingB2.3 Capacitors at 26.4V







Timer: Q107; Cal Due: 1/10/2012








Acceptance criteria


10.1 Test Results Test Voltage: 39.6V(= 1.5 x 26.4V);Test Current: 0.1A;Test Capacitance: 19.5nF;1. Calibrate Before Test (30-31mA):

Ignition At: 2 Seconds;2. Positive Polarity:



Ignition At: 3 Seconds.

PASS

TRF No. ExTR60079-11_5B-1 of 29


APPENDIX B: Tests

IEC 60079-0


B3 Temperature TestingEquipment Tested: Gas Detector, PCB Assembly

Date of Test (yyyy/mm/dd): 2011/May/5Clause and Standards: 10.2 Temperature tests; IEC 60079-11:2006

10.2 Test Procedure As a result of inadequate spacing between R44 and Common (Rev 1.1), a short circuit between + Battery and –Battery can be imposed. This results in a PCB Track being subjected to unlimited battery short circuit current. A fully populated PCB Assembly (Battery Powered) was subjected to a direct short circuit across the +Battery and –Battery at the point discussed above. During the application of the short circuit, the temperatures of the PCB track in question were measured and recorded.

Test Equipment Data Logger: T1159; Cal Due: 3/16/2012



10.2 Acceptance criteria Maximum allowed temperature (for T4/135°C) = 125°C (Accounts for required 5K safety margin for type testing and 5K for measurement uncertainty).

10.2 Test Results PCB Track Measured Maximum Temperature, Adjusted for +50°C Ambient = + 57.5 ° C .

PASS

TRF No. ExTR60079-11_5B-1 of 29

As a result of a short here.

Test of this track shorted across battery.


APPENDIX B: Tests

IEC 60079-0


B4 Measurements of Loosely Specified ComponentsB4.1 Motor Inductance Measurement

Equipment Tested: Vibrator Motor (T1); VibratorMotor.com, Z6SC0B0060081

Date of Test (yyyy/mm/dd): 2011/May/9Clause and Standards: 10.4 Determination of parameters of loosely specified

components; IEC 60079-11:2006

10.4 Test Procedure Ten (10) samples of the vibrator motor were measured for winding inductance.

Test Equipment RCL Meter: M208; Cal Due: 10/1/2011





Test Conditions Temperature: 25°CHumidity: 29%Pressure: 947hPa

10.4 Acceptance criteria The maximum allowed inductance = 129.6µH (108µH + 20%)

10.4 Test Results Sample Inductance PASS1 120.4µH

2 107.0µH

3 110.4µH

4 112.2µH

5 114.9µH

6 119.4µHµ

7 111.1µH

8 111.7µH

9 108.5µH

10 117.9µH

TRF No. ExTR60079-11_5B-1 of 29


IEC 60079-0


B4 Measurements of Loosely Specified ComponentsB4.2 Filter Inductance Measurement

Equipment Tested: Filter; TDK, MEM2012P10R0T



10.4 Test Procedure Ten (10) samples of the filter were measured for inductance.







10.4 Acceptance criteria The maximum allowed inductance = 1.83µH (1.53µH + 20%)

10.4 Test Results Sample Inductance PASS1 1.0µH

2 1.0µH

3 1.0µH

4 1.1µH

5 1.0µH

6 1.0µH

7 1.0µH

8 0.9µH

9 1.2µH

10 1.4µH

TRF No. ExTR60079-11_5B-1 of 29


IEC 60079-0


B4 Measurements of Loosely Specified ComponentsB4.3 Filter Capacitance Measurement

Equipment Tested: Filter; TDK, MEM2012P10R0T



10.4 Test Procedure Ten (10) samples of the filter were measured for capacitance.







10.4 Acceptance criteria The maximum allowed capacitance = 120µf (100µF + 20%)

10.4 Test Results Sample Capacitance(Pin 1 – 2)

Capacitance (Pin 3 – 4)

PASS

1 101pF 101pF

2 105pF 105pF

3 105pF 104pF

4 109pF 109pF

5 106pF 106pF

6 103pF 103pF

7 111pF 111pF

8 106pF 106pF

9 102pF 102pF

10 99pF 99pF

TRF No. ExTR60079-11_5B-1 of 29


APPENDIX B: Tests

IEC 60079-0


B5 Piezo Electric Device TestingEquipment Tested: Piezo buzzer; Keum Kang, CAP-1440

Date of Test (yyyy/mm/dd): 2011/MAY/9Clause and Standards: 10.7 Tests for apparatus containing piezoelectric devices;

IEC 60079-11:2006

10.7 Test Procedure Two samples of the product (Gas Detector) were prepared with wires connected directly across the piezo in question. The capacitance value of the piezos were measured. Then the product samples were impacted tested at 0.7J in accordance with the “high” column of Table 8 (IEC 60079-0). The voltages across the piezos were measured during the impact test.



Tape Measure: U058C; Cal Due: 4/19/2012

Oscilloscope: E055S; Cal Due: 4/20/2011

Scale: S222S: Cal Due: 4/25/2012


10.7 Acceptance criteria The maximum stored energy of the piezo, calculated using the following equation, E = 1/2CV2, shall not exceed 50µJ.

10.7 Test Results Impact Capacitance Voltage Energy PASSFront 13.56uF 25.83V 4.52µJ

Front 13.56uF 18.75V 2.4µJ

TRF No. ExTR60079-11_5B-1 of 29


APPENDIX B: Tests

IEC 60079-0Clause Requirement – Test Result – Remark VerdictB6 Cell Testing

B6.1 Electrolyte Leakage and TemperatureEquipment Tested: Cell; Vitzrocell, SB-AA02


Clause and Standards: 10.5.2 Electrolyte leakage test for cells and batteries,10.5.3 (b) …Surface temperature of cells and batteries,10.2 Temperature tests;IEC 60079-11:2006

Test Procedure


Ten (10) samples of the cell in question had all outer insulators removed. Each cell was placed on white paper and then short circuited using a shunt having a resistance less than 3mΩ. The short circuit remained applied until the cell was discharged. The cells remained on the blotting paper for at least 12 hours following completion of the short circuit. During the short circuit application, the cell temperatures (Per 10.2) and short circuit current were recorded.

10.5.3 (b) Temperature of cells and batteries

Test Equipment Multimeter: M135S; Cal Due: 6/18/2011Environmental Monitor: T1256; Cal Due: 10/12/2011Data Logger: T1044; Cal Due: 1/11/2012Low Resistance Meter: B030S; Cal Due: 4/27/2011


Acceptance criteria


No allowed leakage

10.5.3 (b)10.2

Temperature of cells and batteries

Maximum allowed case temperature (for T4/135°C) = 125°C (Accounts for required 5K safety margin for type testing and 5K for measurement uncertainty).

Test Results


For all ten (10) cells, no venting, leakage, rupture, or electrolyte on the blotting paper observed.

PASS

10.5.3 (b) Temperature of cells and batteries

Sample ISC Max Temperature[Adjusted For +50°C Ambient]

PASS

1 741A 84.4°C

2 684A 79.8°C

3 757A 101.9°C

4 684A 101.8°C

5 741A 98.1°C

6 705A 104.2°C

7 736A 101.6°C

8 720A 100.3°C

9 720A 86.9°C

10 715A 73.6°C

TRF No. ExTR60079-11_5B-1 of 29


APPENDIX B: Tests

IEC 60079-0Clause Requirement – Test Result – Remark VerdictB6 Cell Testing

B6.2 Spark IgnitionEquipment Tested: Cell; Vitzrocell, SB-AA02


Clause and Standards: 10.5.3 (a) Spark ignition…of cells and batteries10.1 Spark ignition test;IEC 60079-11:2006

Test Procedure

10.5.3 (a) Spark ignition of cells and batteries

Samples of the cells were spark tested (Per 10.1) using the enhanced gas mixture for Group IIC (60±0.5% Hydrogen in 40±0.5% Oxygen) to provide for the necessary 1.5 factor of safety. In accordance with UL 913, Edition 5; four (4) cell spark ignition trials using new cells were performed. The spark ignition test sequence was comprised of the following (Cal circuit consisted of 24VDC Supply and 95mH Inductor):

1. Calibration/Verification Of Test Gas Mixture;2. Spark Ignition Test Of new Cell (Positive Polarity);3. Spark Ignition Test Of new Cell (Negative Polarity);4. Spark Ignition Test Of new Cell (Positive Polarity);5. Spark Ignition Test Of new Cell (Negative Polarity);6. Calibration/Verification Of Test Gas Mixture.

Test Equipment Multimeter: M065S; Cal Due: 6/9/2011Environmental Monitor: T1256; Cal Due: 10/12/2011Timer: Q107; Cal Due: 1/10/2012Rev Counter: Q108; Cal Due: 1/10/2012Flow Meter: F263; Cal Due: 8/24/2011Multimeter: M075S; Cal Due: 1/13/2012Oxygen Analyzer: O193; Maintenance: 2/12/2011


Acceptance criteria

10.5.3 (a),10.1

Spark ignition of cells and batteries

No ignition of test gas

Test Results

10.5.3 (a) Spark ignition of cells and batteries

1. Calibrate Before Test (20-21mA):Ignition At: 20 Seconds / 24 Revs;

2. Positive Polarity (1):No Ignition At 209 Revs;

3. Negative Polarity (1):No Ignition At 204 Revs;

4. Positive Polarity (2):No Ignition At 204 Revs

5. Negative Polarity (2):;No Ignition At 202 Revs;

6. Calibrate After Test (20-21mA):Ignition At: 19 Seconds / 22 Revs.

PASS

TRF No. ExTR60079-11_5B-1 of 29