Measurement Section, Including Additional Narrative Remarks

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

IECEx TEST REPORT IEC 60079-11 Explosive atmospheres – Part 11: Equipment protection by intrinsic safety "i"

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 Page 1 of 29 ExTR Reference No. US/ETL/ExTR12.0007/00 (100677772CRT-001b)

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, Level of protection Refer to Appendix A.1 for details. PASS 5.4

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 Meets T4 (See Appendix A.3 Below) PASS components 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 PASS Possible Power Dissipation In Any Component Or PCB Track = 0.62W < 1.25W (T4 @ +50°C) [Refer to Appendix A.3 Below] Passed temp test on PCB track across battery: PASS 57.5°C MAX MEASURED [Refer to Appendix B.3 Below]

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 PASS Appendix B.1 Below] 6.1.2 Apparatus complying with Annex F Annex F Not Used N / A

6.2 Facilities for connection of external No External Connections N / A circuits 6.2.1 Terminals No External Connections N / A

IEC 60079-11 Clause Requirement – Test Result – Remark Verdict 6.2.2 Plugs and sockets No External Connections N / A 6.2.3 Determination of maximum Not a Power Source N / A external inductance to resistance ratio (Lo/Ro) for resistance limited power source 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 PASS Appendix B.1 Below] 6.3.1.1 Distances according to Table 5 Adequate Separations Provided [Refer to PASS Appendix B.1 Below] 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 PASS Appendix B.1 Below] 6.3.3 Clearance Adequate Separations Provided [Refer to PASS Appendix B.1 Below] 6.3.4 Separation distances through No Casting Compound N / A casting compound 6.3.5 Separation distances through solid Adequate Separations Provided [Refer to PASS insulation Appendix B.1 Below] 6.3.6 Composite separations No Composite Separations N / A 6.3.7 Creepage distance Adequate Separations Provided [Refer to PASS Appendix B.1 Below] 6.3.8 Distance under coating No PCB Coating N / A 6.3.9 Requirements for assembled No PCB Coating N / A printed circuit boards 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 Non-Replaceable Battery Cell PASS Reversal

6.5 Earth conductors, connections and Portable Battery Powered N / A terminals

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 N / A components assumed to be no-count-fallible

IEC 60079-11 Clause Requirement – Test Result – Remark Verdict 7.2 Connectors for internal No Plug-Ins N / A connections, plug-in cards and components

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 PASS During/Following Short Circuit Test [Refer to Appendix B.6 Below] 7.4.3 Cell voltages Values Per UL 60079-0 Used: 3.9Vpeak| PASS 3.6Vnom 7.4.4 Internal resistance of cell or Cell Resistance Not Used N / A battery 7.4.5 Batteries in apparatus protected No Associated Apparatus N / A by other means of protection 7.4.6 Batteries used and replaced in No replaceable current-limiting devices N / A explosive gas atmospheres 7.4.7 Batteries used but not replaced in Non-replaceable Battery Cell N / A explosive gas atmospheres 7.4.8 External contacts for charging No charging contacts N / A batteries 7.4.9 Battery construction Battery Passed Spark Ignition And PASS Temperature Testing [Refer to Appendix B.6 Below]

7.5 Semiconductors 7.5.1 Transient effects No Transients – Battery Powered N / A 7.5.2 Shunt voltage limiters See 8.6 Below PASS 7.5.3 Series current limiters None N / A

7.6 Failure of components, All applicable faults considered/applied PASS connections and separations

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

7.8 Electrochemical cells for the Gas Detectors Considered For Spark Ignition PASS detection of gases Contribution Based on Most Severe Parameters (See Appendix A Below)

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

8.1 Mains transformers No Transformers N / A

IEC 60079-11 Clause Requirement – Test Result – Remark Verdict 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 No Transformers N / A transformers 8.3 Infallible windings No Transformers N / A 8.3.1 Damping windings No Transformers N / A 8.3.2 Inductors made by insulated No Transformers N / A conductors

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

8.5 Blocking capacitors No Blocking Capacitors N / A

8.6 Shunt safety assemblies 8.6.1 General Adequately Rated Zener Diode Shunt Assembly PASS Provided: D2/D3: Parallel Combination, Connected Such That Single Open Circuit Fault Simultaneously Disconnects Voltage Source 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, No Infallible Connectors Provided: None N / A and connections Required

8.8 Galvanically separating components 8.8.1 General No Isolators N / A 8.8.2 Isolating components between No Isolators N / A intrinsically safe and non- intrinsically safe circuits 8.8.3 Isolating components between No Isolators N / A separate intrinsically safe circuits

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

IEC 60079-11 Clause Requirement – Test Result – Remark Verdict 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 PASS circuits [Refer to Appendix B.2 Below] 10.1.2 Spark test apparatus Passed spark ignition testing required for some PASS circuits [Refer to Appendix B.2 Below] 10.1.3, Test gas mixtures and spark test Passed spark ignition testing required for some PASS 10.1.3.1, apparatus calibration current circuits [Refer to Appendix B.2 Below] 10.1.3.2 10.1.4, Tests with the spark test Passed spark ignition testing required for some PASS 10.1.4.1, apparatus – circuit test, safety circuits [Refer to Appendix B.2 Below] 10.1.4.2 factors 10.1.5 Testing considerations 10.1.5.1 General 10.1.5.2 Circuits with both inductance and None N / A capacitance 10.1.5.3 Circuits using shunt short-circuit None N / A (crowbar) protection 10.1.5.4 Results of spark test Passed spark ignition testing required for some PASS circuits [Refer to Appendix B.2 Below]

10.2 Temperature tests Passed Temperature Assessments (See PASS Appendix VII Below) Passed PCB track temp test [Refer to Appendix TEST B.3 Below]

10.3 Dielectric strength tests Not Required/Applicable N / A

10.4 Determination of parameters of Loosely Specified Component Testing: PASS loosely specified components 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]

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 Batteries Passed Testing [Refer to Appendix PASS and batteries B.6 Below] 10.5.3 Spark ignition and surface Batteries Passed Testing [Refer to Appendix PASS temperature of cells and batteries B.6 Below]

IEC 60079-11 Clause Requirement – Test Result – Remark Verdict 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 No Sealed Components N / A encapsulation 10.6.3 Partitions No Partitions N / A

10.7 Tests for apparatus containing Passed piezo testing [Refer to Appendix B.5 PASS piezoelectric devices Below]

10.8 Type tests for diode safety barriers No Transients – Battery Powered N / A and safety shunts

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 No Barriers N / A barriers 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 No Transformers N / A 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 ASSESSMENT OF Passed Spark Ignition and Temperature PASS A INTRINSICALLY SAFE CIRCUITS Assessments (See Appendices VI & VII Below) (NORMATIVE)

ANNEX SPARK TEST APPARATUS FOR INTRINSICALLY SAFE CIRCUITS (NORMATIVE) B

IEC 60079-11 Clause Requirement – Test Result – Remark Verdict

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

ANNEX ENCAPSULATION (INFORMATIVE) D

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 Annex F Not Used N / A and separation of components 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

Measurement Section, including Additional Narrative Remarks

APPENDIX A: Description of product

A.1 General overview A.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.

R37 GAS SENSOR VD VBatt

REMAINING CIRCUITRY CPU14

R44 VM

R42 HIGH VOLTAGE AREA

R45 R41 U3

A.1.2 VOLTAGES: 1. Single Lithium Thionyl Cell Supply: Per Table 10 (IEC 60079-0:2009): VBatt = 3.9Vp|3.6Vnom 2. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) T1 OUT: ±13.2V (Per Absolute Maximum Ratings) VT1-OUT = ±13.2V 3. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) T2 OUT: ±13.2V (Per Absolute Maximum Ratings) VT2-OUT = ±13.2V 4. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) R1 OUT: ±13.2V (Per Absolute Maximum Ratings) VR1-OUT = ±13.2V 5. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) R2 OUT: ±13.2V (Per Absolute Maximum Ratings) VR2-OUT = ±13.2V 6. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) V+: 7V (Per Absolute Maximum Ratings) V+ = 7V 7. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) V-: -7V (Per Absolute Maximum Ratings) V- = -7V 8. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) [V+] + [V-]: 13V (Per Absolute Maximum Ratings) [V+] + [V-] = 13V 9. “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 = 6.0V 10. “Gas Sensor” Worst Case VOC MAX = -1.34V (Per Data Sheets/Application Documents) VGAS-SENSOR = -1.34V

REMAINING CIRCUITRY R37 GAS SENSOR -1.34V VD = 3.9Vpeak|3.6Vnominal Vbatt = 3.9Vpeak|3.6Vnominal

VCPU14 = 6V

R44 VM = 3.9Vpeak|3.6Vnominal

R42 HIGH VOLTAGE AREA

VR42 = 3.9Vpeak|3.6Vnominal R45 R41 U3 TOUT/ROUT +7V/-7V/13V 6V

+13.2V/-13.2V

NO OTHER VOLTAGE SOURCES OR LIMITERS

A.1.3 CURRENTS: 1. “VD” Resistor Limited (R37 = 22Ω, ±5%) IVD = VBatt/R37Min = 3.9Vpeak|3.6Vnominal/(22Ω)(0.95) IVD = 0.187Apeak|0.173Anominal 2. “VM” Same As 1 Above IVM = 0.187Apeak|0.173Anominal 3. “R42” Same As 1 Above IR42 = 0.187Apeak|0.173Anominal 4. “Common/Battery Return/0V” (Three Equal Branches) ICOMMOM = 3 x IVD ICOMMON = 0.561Apeak|0.519Anominal 5. “High Voltage Area” Switched Capacitor DC-DC Converter (U3) Output V+, V-, TOUT, ROUT: ±0.1A (Per Absolute Maximum Ratings) IV+ = 0.1A IV- = 0.1A ITOUT = 0.1A IROUT = 0.1A 6. “Gas Sensor” Worst Case ISC MAX = 1A (Per Data Sheets/Application Documents) IGAS-SENSOR = 1A

REMAINING CIRCUITRY GAS SENSOR R37 = 22, 5% 1A VD = 3.9Vpeak|3.6Vnominal Vbatt = 3.9Vpeak|3.6Vnominal IVD = 0.187Apeak|0.173Anominal

VCPU14 = 6V IVCPU14 = 5.3mA

R44 = 22, 5% VM = 3.9Vpeak|3.6Vnominal IVM = 0.187Apeak|0.173Anominal

R42 = 22, 5% HIGH VOLTAGE AREA

VR42 = 3.9Vpeak|3.6Vnominal R45 = 4.7K, 5% R41 = 1.2K, 5% IR42 = 0.187Apeak|0.173Anominal U3 TOUT/ROUT +7V/-7V/13V 0.1A 6V

+13.2V/-13.2V 0.1A

NO OTHER CURRENT SOURCES OR LIMITERS

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 = 0.156W 2. “VM” Same As 1 Above PVM = 0.156W 3. “R42” Same As 1 Above PR42 = 0.156W 4. “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/D3 PD2/D3 = (PR45 + PR41)/4 PD2/D3 = 0.010W (W1)

REMAINING CIRCUITRY R37 = 22, 5% VD = 3.9Vpeak|3.6Vnominal PR37 = 0.62W IVD = 0.187Apeak|0.173Anominal 3.9Vpeak|3.6Vnominal PVD = 0.156W

VCPU14 = 6V IVCPU14 = 5.3mA R44 = 22, 5% VM = 3.9Vpeak|3.6Vnominal PR44 = 0.62W IVM = 0.187Apeak|0.173Anominal PVM = 0.156W

R42 = 22, 5% PR42 = 0.62W HIGH VOLTAGE AREA

VR42 = 3.9Vpeak|3.6Vnominal R45 = 4.7K, 5% R41 = 1.2K, 5% IR42 = 0.187Apeak|0.173Anominal PR45 = 0.008W PR41 = 0.032W PR42 = 0.156W U3

+7V/-7V/13V 0.1A VD2/D3 = 6V PD2/D3 = 0.01W +13.2V/-13.2V 0.1A

NO OTHER POWER SOURCES OR LIMITERS

A.2 Spark ignition consideration (IIC, ia) A.2.1 Resistive spark ignition 1. 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 = 26.4V ISC-MAX = 0.1A From 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)

REMAINING CIRCUITRY GAS SENSOR R37 = 22, 5% -1.34V VD = 3.9Vpeak|3.6Vnominal 1A 3.9Vpeak|3.6Vnominal IVD = 0.187Apeak|0.173Anominal

VCPU14 = 6V IVCPU14 = 5.3mA

R44 = 22, 5% VM = 3.9Vpeak|3.6Vnominal IVM = 0.187Apeak|0.173Anominal

R42 = 22, 5% HIGH VOLTAGE AREA

VR42 = 3.9Vpeak|3.6Vnominal R45 = 4.7K, 5% R41 = 1.2K, 5% IR42 = 0.187Apeak|0.173Anominal U3

+7V/-7V/13V 0.1A 6V

+13.2V/-13.2V 0.1A

A.2.2 Inductive spark ignition 1. Motor (MT1): MT1 = 108µH (No Tolerance = 20%) V-MAX = 7.34V L-MAX = (108µH + (3) x (1.53µH)) x 1.2 = 130µH I-MAX = 0.187A From 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 = 7.34V L-MAX = 1.53µH x 1.2 = 1.84µH I-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)

A.2.3 Capacitive spark ignition

1. Capacitors at 3.9V (All Capacitors Shorted Between VD and Common) V-MAX = 3.9V I-MAX = 0.187A C-MAX = 31µF From Table A.1 (IEC 60079-11:2006): At V = 12.1V, I = 5A 0.187A/5A = 0.0374 From Table A.2 (IEC 60079-11:2006): At C = 32µF, V = 9.4V 3.9V/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 = 6V I-MAX = 0.0053A C-MAX = 30.5µF From Table A.1 (IEC 60079-11:2006): At V = 12.1V, I = 5A 0.0053A/5A = 0.0011 From Table A.2 (IEC 60079-11:2006): At C = 32µF, V = 9.4V 6V/9.4V = 0.781 0.0011 + 0.781 = 0.7821 = 1.27FOS < 1.5: Passed Spark Test [See B2.1 Below] (PASS)

3. Capacitors at 7.34V (All Floating Caps Shorted Between High Voltage Output and Gas Sensor Output) V-MAX = 7.34V I-MAX = 1A C-MAX = 0.44µF From Table A.1 (IEC 60079-11:2006): At V = 12.1V, I = 5A 0.0053A/5A = 0.0011 From Table A.2 (IEC 60079-11:2006): At C = 32µF, V = 9.4V 6V/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 = 13V I-MAX = 0.1A C-MAX = 0.44µF From Table A.1 (IEC 60079-11:2006): At V = 13V, I = 3.02A 0.1A/3.02A = 0.0034 From Table A.2 (IEC 60079-11:2006): At C = 0.442µF, V = 24.3V 13V/24.3V = 0.54 0.0034 + 0.54 = 0.5434 = 1.84FOS > 1.5 (PASS) 5. Capacitors at 26.4V (Piezo) V-MAX = 26.4V I-MAX = 0.1A C-MAX = 19.5nF From Table A.1 (IEC 60079-11:2006): At V = 26.4V, I = 0.207A 0.1A/0.207A = 0.483 From Table A.2 (IEC 60079-11:2006): At C = 40nF, V = 55V 26.4V/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 ignition NA A.2.5 Shunt short-circuit (crowbar) spark ignition None A.2.6 Other spark ignition considerations None NO OTHER CIRCUITS REQUIRING SPARK IGNITION ASSESSMENT

A.3 Thermal ignition consideration A.3.1 Temperature for small components A.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 apparatus None A.3.3 Tracks on printed circuit boards PCB can be awarded T4 as the maximum dissipated power < 1.25W Passed 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

A.4 Rating of components REMAINING CIRCUITRY R37 = 22, 5% VD = 3.9Vpeak|3.6Vnominal PR37 = 0.62W IVD = 0.187Apeak|0.173Anominal 3.9Vpeak|3.6Vnominal PVD = 0.156W

VCPU14 = 6V IVCPU14 = 5.3mA R44 = 22, 5% VM = 3.9Vpeak|3.6Vnominal PR44 = 0.62W IVM = 0.187Apeak|0.173Anominal PVM = 0.156W

R42 = 22, 5% PR42 = 0.62W HIGH VOLTAGE AREA

VR42 = 3.9Vpeak|3.6Vnominal R45 = 4.7K, 5% R41 = 1.2K, 5% IR42 = 0.187Apeak|0.173Anominal PR45 = 0.008W PR41 = 0.032W PR42 = 0.156W U3

+7V/-7V/13V 0.1A VD2/D3 = 6V PD2/D3 = 0.01W +13.2V/-13.2V 0.1A

A.4.1 Resistors 1. 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 limiters 1. 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 limiter None A.4.4 Other None NO OTHER PROTECTIVE COMPONENTS

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 Tests NA NA NA

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

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B1 Measurements of Separation Distances Equipment 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 For Circuits Up To 30V: 5 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 The maximum possible potential difference in PASS parts the product is 26.4V < 30V 6.3.3 Clearance Minimum Measured Clearances Across Current PASS Limiting Resistors: R42 = > 2.5mm R37 = > 2.5mm R44 = > 2.5mm 6.3.5 Separation distances through Minimum Measured Separation Distances PASS solid insulation Through Solid Insulation Across Current Limiting Resistors: R42 = > 0.5mm R37 = > 0.5mm R44 = > 0.5mm 6.3.7 Creepage distance Minimum Measured Creepage Distances PASS Across Current Limiting Resistors: R42 = > 2.5mm R37 = > 2.5mm R44 = > 2.5mm

APPENDIX B: Tests

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B2 Spark Ignition Testing B2.1 Capacitors at 6V Equipment Tested: Gas Detector, Simulated Circuits Date of Test (yyyy/mm/dd): 2011/May/5 Clause 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 Multimeter: M065S; Cal Due: 6/9/2011 Multimeter: M135S; Cal Due: 6/18/2012 Oxygen Analyzer: O193; Maintenance: 2/12/2011 Test Conditions Temperature: 24.5°C Humidity: 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); PASS 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 .

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B2 Spark Ignition Testing B2.2 Capacitors at 7.34V Equipment Tested: Gas Detector, Simulated Circuits Date of Test (yyyy/mm/dd): 2011/May/5 Clause 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 Multimeter: M065S; Cal Due: 6/9/2011 Multimeter: M135S; Cal Due: 6/18/2012 Oxygen Analyzer: O193; Maintenance: 2/12/2011 Test Conditions Temperature: 24.5°C Humidity: 28% Pressure: 947hPa Acceptance criteria 10.1 Spark ignition test No ignition of test gas 10.1 Test Results Test Voltage: 11.01V(= 1.5 x 7.34V); PASS Test Current: 1A; Test Capacitance: 0.44µF; 1. Calibrate Before Test (30-31mA): Ignition At: 13 Seconds; 2. Positive Polarity: No Ignition At 201 Revs; 3. Negative Polarity: No Ignition At 202 Revs; 4. Calibrate After Test (30-31mA): Ignition At: 2 Seconds.

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B2 Spark Ignition Testing B2.3 Capacitors at 26.4V Equipment Tested: Gas Detector, Simulated Circuits Date of Test (yyyy/mm/dd): 2011/May/5 Clause 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 Multimeter: M065S; Cal Due: 6/9/2011 Multimeter: M135S; Cal Due: 6/18/2012 Oxygen Analyzer: O193; Maintenance: 2/12/2011 Test Conditions Temperature: 24.5°C Humidity: 28% Pressure: 947hPa Acceptance criteria 10.1 Spark ignition test No ignition of test gas 10.1 Test Results Test Voltage: 39.6V(= 1.5 x 26.4V); PASS Test Current: 0.1A; Test Capacitance: 19.5nF; 1. Calibrate Before Test (30-31mA): Ignition At: 2 Seconds; 2. Positive Polarity: No Ignition At 202 Revs; 3. Negative Polarity: No Ignition At 210 Revs; 4. Calibrate After Test (30-31mA): Ignition At: 3 Seconds.

APPENDIX B: Tests

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B3 Temperature Testing Equipment Tested: Gas Detector, PCB Assembly Date of Test (yyyy/mm/dd): 2011/May/5 Clause 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 of this track shorted across As a battery. result of a short here.

Test Equipment Data Logger: T1159; Cal Due: 3/16/2012 Environmental Monitor: T1256; Cal Due: 10/12/2011 Test Conditions Temperature: 24.5°C Humidity: 28% Pressure: 947hPa 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, PASS Adjusted for +50°C Ambient = + 57.5 ° C.

APPENDIX B: Tests

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B4 Measurements of Loosely Specified Components B4.1 Motor Inductance Measurement Equipment Tested: Vibrator Motor (T1); VibratorMotor.com, Z6SC0B0060081 Date of Test (yyyy/mm/dd): 2011/May/9 Clause 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 Environmental Monitor: T1256; Cal Due: 10/12/2011 Multimeter: M065S; Cal Due: 6/9/2011 Multimeter: M075S; Cal Due: 1/13/2012 Multimeter: M135S; Cal Due: 6/18/2011 Test Conditions Temperature: 25°C Humidity: 29% Pressure: 947hPa 10.4 Acceptance criteria The maximum allowed inductance = 129.6µH (108µH + 20%) 10.4 Test Results Sample Inductance PASS 1 120.4µH 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

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B4 Measurements of Loosely Specified Components B4.2 Filter Inductance Measurement Equipment Tested: Filter; TDK, MEM2012P10R0T Date of Test (yyyy/mm/dd): 2011/May/9 Clause and Standards: 10.4 Determination of parameters of loosely specified components; IEC 60079-11:2006 10.4 Test Procedure Ten (10) samples of the filter were measured for inductance. Test Equipment RCL Meter: M208; Cal Due: 10/1/2011 Environmental Monitor: T1256; Cal Due: 10/12/2011 Multimeter: M065S; Cal Due: 6/9/2011 Multimeter: M075S; Cal Due: 1/13/2012 Multimeter: M135S; Cal Due: 6/18/2011 Test Conditions Temperature: 25°C Humidity: 29% Pressure: 947hPa 10.4 Acceptance criteria The maximum allowed inductance = 1.83µH (1.53µH + 20%) 10.4 Test Results Sample Inductance PASS 1 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

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B4 Measurements of Loosely Specified Components B4.3 Filter Capacitance Measurement Equipment Tested: Filter; TDK, MEM2012P10R0T Date of Test (yyyy/mm/dd): 2011/May/9 Clause and Standards: 10.4 Determination of parameters of loosely specified components; IEC 60079-11:2006 10.4 Test Procedure Ten (10) samples of the filter were measured for capacitance. Test Equipment RCL Meter: M208; Cal Due: 10/1/2011 Environmental Monitor: T1256; Cal Due: 10/12/2011 Multimeter: M065S; Cal Due: 6/9/2011 Multimeter: M075S; Cal Due: 1/13/2012 Multimeter: M135S; Cal Due: 6/18/2011 Test Conditions Temperature: 25°C Humidity: 29% Pressure: 947hPa 10.4 Acceptance criteria The maximum allowed capacitance = 120µf (100µF + 20%) 10.4 Test Results Sample Capacitance Capacitance PASS (Pin 1 – 2) (Pin 3 – 4) 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

APPENDIX B: Tests

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B5 Piezo Electric Device Testing Equipment Tested: Piezo buzzer; Keum Kang, CAP-1440 Date of Test (yyyy/mm/dd): 2011/MAY/9 Clause 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. Test Equipment RCL Meter: M208; Cal Due: 10/1/2011 Environmental Monitor: T1256; Cal Due: 10/12/2011 Tape Measure: U058C; Cal Due: 4/19/2012 Oscilloscope: E055S; Cal Due: 4/20/2011 Scale: S222S: Cal Due: 4/25/2012 Test Conditions Temperature: 25°C Humidity: 29% Pressure: 947hPa 10.7 Acceptance criteria The maximum stored energy of the piezo, calculated using 1 2 the following equation, E = /2CV , shall not exceed 50µJ. 10.7 Test Results Impact Capacitance Voltage Energy PASS Front 13.56uF 25.83V 4.52µJ Front 13.56uF 18.75V 2.4µJ

APPENDIX B: Tests

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B6 Cell Testing B6.1 Electrolyte Leakage and Temperature Equipment Tested: Cell; Vitzrocell, SB-AA02 Date of Test (yyyy/mm/dd): 2011/March/16 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 10.5.2 Electrolyte leakage test for Ten (10) samples of the cell in question had all outer cells and batteries insulators removed. Each cell was placed on white paper and 10.5.3 (b) Temperature of cells and then short circuited using a shunt having a resistance less batteries 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. Test Equipment Multimeter: M135S; Cal Due: 6/18/2011 Environmental Monitor: T1256; Cal Due: 10/12/2011 Data Logger: T1044; Cal Due: 1/11/2012 Low Resistance Meter: B030S; Cal Due: 4/27/2011 Test Conditions Temperature: 23°C Humidity: 31% Pressure: 946hPa Acceptance criteria 10.5.2 Electrolyte leakage test for No allowed leakage cells and batteries 10.5.3 (b) Temperature of cells and Maximum allowed case temperature (for T4/135°C) = 125°C 10.2 batteries (Accounts for required 5K safety margin for type testing and 5K for measurement uncertainty). Test Results 10.5.2 Electrolyte leakage test for For all ten (10) cells, no venting, leakage, PASS cells and batteries rupture, or electrolyte on the blotting paper observed. 10.5.3 (b) Temperature of cells and Sample ISC Max Temperature PASS batteries [Adjusted For +50°C Ambient] 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

APPENDIX B: Tests

IEC 60079-0 Clause Requirement – Test Result – Remark Verdict B6 Cell Testing B6.2 Spark Ignition Equipment Tested: Cell; Vitzrocell, SB-AA02 Date of Test (yyyy/mm/dd): 2011/March/17 Clause and Standards: 10.5.3 (a) Spark ignition…of cells and batteries 10.1 Spark ignition test; IEC 60079-11:2006 Test Procedure 10.5.3 (a) Spark ignition of cells and Samples of the cells were spark tested (Per 10.1) using the batteries 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: 6/9/2011 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°C Humidity: 26% Pressure: 951hPa Acceptance criteria 10.5.3 (a), Spark ignition of cells and No ignition of test gas 10.1 batteries Test Results 10.5.3 (a) Spark ignition of cells and 1. Calibrate Before Test (20-21mA): PASS batteries 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.

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