Hydrogen Leak Detector

The industrial hydrogen leak detector from Archigas is engineered as an inline measurement component for continuous integrity monitoring of hydrogen systems, including hazardous and explosive atmospheres.

The detector is designed for direct OEM integration into process circuits that require fast, reliable H₂ concentration control. It operates at pressures up to 200 barg and requires no sample conditioning.

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Certifications & Standards

Archigas products confirm their reliability, quality, and safety with valid certificates.

ATEX Zone 1 (II 2 G Ex db IIC T4/T3 Gb, -40°C to +90°C/+125°C)

Certification for use in potentially explosive atmospheres

IECEx

International conformity certificate for explosive atmospheres

UL HazLoc

Certification for USA (hazardous locations)

Compliance with European Union requirements

ISO 9001:2015

Certified quality management system

Hydrogen Leak Detector TCD3000: Design & Operating Principle

Hydrogen leak detectors TCD3000 Si and Sia are housed in an ultra-compact monobloc enclosure, enabling integration even in space-constrained installations. Sensors do not require gas extraction from the system to detect leaks, are resistant to high pressure and moisture, and maintain a stable zero point.

TCD3000 SiA

TCD3000 Si

How It Works

The operating principle is based on the direct measurement of gas thermal conductivity – an approach that allows hydrogen to be monitored directly within the system, without external bypass lines or bulky sample-conditioning equipment.

H₂ concentration data is transmitted via onboard interfaces directly to the control system, making the sensor straightforward to integrate in OEM applications and industrial automation environments.

How It Works

TCD3000 Product Variants

Archigas offers two versions of its industrial hydrogen gas leak detector. Both are built on the same TCD measurement principle and serve a single purpose — continuous hydrogen leak monitoring within a process or laboratory workflow.

The difference lies in the area classification requirements:

TCD3000 SiA — designed for use in explosive atmospheres; ATEX Zone 1 certified (Ex db IIC T4/T3 Gb).
TCD3000 Si — for use in standard industrial environments.

Specifications by Model →

Parameter	TCD3000 SiA	TCD3000 Si
Hazardous area certification	ATEX Zone 1 (II 2 G Ex db IIC T4/T3 Gb), IECEx	-
Ambient temperature range	-40 to +90 °C / +120 °C	-40 to +80 °C
Dimensions (with connectors)	H: 96 mm; Ø: 45 mm	H: 91 mm; Ø: 45 mm
Weight	740 g	440 g

Factory Calibration

Key Specifications

Parameter	Value
Reaction time	30 ms
Warm-up time	< 1 min
Measurement range	ppm-level → 100 vol.% H₂
Process gas pressure	0.9…200 barg (abs.)
Process gas temperature	up to +125 °C
Process gas flow	0…10 m/s
Moisture resistance	Condensate and liquid contact does not damage the sensor
Analog output	4–20 mA, RL ≤750 Ω
Power supply	24±25% VDC, <5 W
Interface	RS485 (38400 baud)
Service life	Up to 10 years

View full product specs

Why You Can Trust Archigas Detectors

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25+

customer countries reached

125+

B2B and industrial companies served

400+

customer projects supplied

Key Benefits of the Hydrogen Leak Detector by Archigas

The features that set the TCD3000 SiA and TCD3000 Si apart from standard hydrogen gas leak detectors:

30 ms response

Critical in emergency scenarios – the sensor registers changes in hydrogen concentration in real time.

Catalytic and electrochemical sensors respond in seconds, not milliseconds.

No poisoning

TCD does not rely on a catalytic reaction and is unaffected by sulfides, silicones, and hydrocarbons that can render catalytic sensors inoperative within weeks of operation.

No drift

Reading drift is <100 ppm/week. In electrochemical sensors, drift accumulates as the electrolyte degrades, requiring more frequent recalibration.

Survives wet and high-pressure conditions

The TCD3000 SiA and TCD3000 Si operate at process pressures from 0.9 to 200 bar without loss of accuracy and remain functional on contact with moisture. Standard sensors in high-pressure and humid environments require external sample conditioning.

ATEX Zone 1 / IECEx

The TCD3000 SiA can be installed directly in a hazardous area without purge enclosures or complex isolation, simplifying system design compared to solutions that require a remotely mounted sensor.

Inline monitoring, zero gas loss

The sensor mounts directly in the pipeline. Unlike sniffer and MS approaches, no gas is sampled or vented; measurements occur inside the closed system. This matters wherever hydrogen is recovered or losses are unacceptable.

10-year service life and recalibration every 6 months

The TCD sensor design is simpler, with no consumable components, giving a service life 3–5× longer than that of a typical electrochemical sensor and correspondingly lower operating costs and maintenance burden.

Archigas hydrogen sensors are specified when the requirement is not simply detection, but precise H₂ measurement under conditions where catalytic and electrochemical sensors rapidly lose performance. For OEM and skid integration, this translates into more predictable sensor behavior in real process conditions.

In an industrial system, this offers three practical advantages: compact integration, high-pressure operation, and fast signal formation. For the design engineer, it means sensor behavior that holds up in the field – not just in the lab. The hydrogen gas leak detector by Archigas is also resistant to moisture and condensate, maintaining accuracy where standard sensors quickly lose their factory calibration.

Get a Quote for Your Configuration

Pricing depends on the model variant, measurement range, and integration requirements. Provide your process parameters, and we will prepare a tailored proposal within one business day.

Hydrogen Leak Detection: TCD vs. Other Methods

Electrochemical and catalytic sensors depend on gas diffusion to the sensing element, which introduces a response delay of 5 to 60 seconds. Infrared analyzers are physically unable to measure H₂ directly due to the absence of IR activity in the hydrogen molecule. The TCD principle is based on the difference in thermal conductivity between gases: hydrogen has approximately 7× the thermal conductivity of air or nitrogen.

Parameter	TCD (Archigas)	Electrochemical	Catalytic	IR analyzer
T90 response time	< 1 s	10…60 s	5…30 s	2…10 s
Operating pressure	Up to 200 barg	Typically atmospheric	Typically atmospheric	Typically atmospheric
Humidity influence	Low	Drift, poisoning	Drift	Condensate on optics
Mixture-specific calibration	Yes (factory)	Limited	Limited	Limited
ATEX Zone 1 certification	Yes (TCD3000 SiA)	Rarely	Rarely	Rarely
Best for	Inline, continuous H₂ leak & concentration monitoring; LEL/UEL alarm; works under pressure & humidity	Portable/personal H₂ detectors at low ppm	Area monitoring at low cost	Open-path or trace-level H₂ in some R&D contexts
Limitations for H₂	Requires a binary or quasi-binary mixture for absolute accuracy	Short lifetime (1–2 years); slow response; affected by temperature & humidity	Sensor poisoning (silicones, sulfur); needs O₂; drift; not suitable inline	Not suitable for direct H₂ measurement (H₂ molecule has virtually no IR activity); high cost; limited installation base for H₂

Among the methods reviewed, TCD is the only approach that combines all the characteristics required for demanding industrial environments where inline measurement, operation under pressure, and the absence of a sample extraction system are non-negotiable. This is why Archigas chose TCD technology as the foundation for both the TCD3000 SiA and TCD3000 Si.

Prof. Dr. rer. Nat. habil. Friedemann Völklein

RheinMain University of Applied Sciences
Chief Scientific Advisor and Design Development

"In projects with high pressure and variable humidity, we found that standard hydrogen sensors require frequent recalibration. Archigas TCD analyzers delivered a stable signal even when mounted directly in a high-pressure line, with no bypass. This allowed us to reduce the response time of our hydrogen leak detection system from several seconds to the sub-second range."

Industrial Applications of the Hydrogen Leak Detector TCD3000 SiA and TCD3000 Si

Hydrogen gas leak detectors from Archigas are deployed in process and laboratory environments requiring continuous hydrogen leak monitoring in the working medium. Each application scenario involves building a hydrogen gas leak detection system directly into the process circuit without gas extraction or additional sample conditioning.

Electrolyzer hazardous-area monitoring

Monitoring H₂ crossover on the oxygen side of the membrane and atmospheric leaks inside the electrolyzer enclosure at working pressures up to 200 bar. The zone is classified as explosive and requires ATEX Zone 1 certification.

Fuel cell test benches and FCEV manufacturing

Leak detection on the anode side, in the reformer, and at high-pressure connectors. In enclosed test chambers, hydrogen accumulates at the top – the sensor is mounted at ceiling level.

Hydrogen refueling stations (HRS)

Continuous leak monitoring in compressors, dispensers, and storage vessels operating at 350/700 bar. Mandatory compliance with ISO 19880-1 and ISO 19880-8.

H₂ storage and transport

Monitoring of gasholders, tube trailers, and liquid hydrogen tankers. Coverage includes perimeter areas and the interstitial space of tanks.

Hydrogen blending into natural gas networks

Detection of H₂ leaks from H₂/CH₄ blends in gas distribution networks where hydrogen is admixed with natural gas.

R&D / catalyst testing/semiconductor

Leak monitoring of forming gas (5% H₂ / 95% N₂) in reactor lines and test chambers. Used in research laboratories and semiconductor manufacturing.

Describe your process conditions – pressure, gas composition, installation zone. An Archigas engineer will prepare a configuration and commercial proposal within 2–3 business days.

Installation & Integration

Mounting Position
Hydrogen is 14.37× lighter than air and accumulates beneath the ceilings of rooms and enclosures. For ambient leak detection, the sensor must be installed in the upper part of the space. For inline monitoring in a pipeline, the mounting position is determined by the gas flow direction.

Inline vs. Ambient Monitoring
For process lines (electrolyzer, compressor, storage vessel), the sensor is threaded directly into the pipeline via G 1/2″ or NPT 1/2″ connections. For room or enclosure installations, a pickup configuration is used — gas reaches the sensor by diffusion or ventilation, with no active sampling.

Control System Integration
The digital RS485 interface (38400 baud, 8 data bits) provides connectivity to a control or safety system, transmitting measurement data and diagnostic information. A USB–RS485 converter is used for connecting to a PC.

Power Supply
24 V DC, consumption below 5 W. Recommended power supply: Phoenix Contact STEP3-PS/1AC/24DC/0.63/PT.

Calibration
Initial calibration is performed at the factory for the specific gas mixture. Field recalibration, every 6 months, is performed by the user using pure H₂ or the background gas (air or N₂). Calibration is initiated via the RS485 interface without stopping the process.

Trial Phase
Not included in the standard supply. Available on a project basis (case-by-case) and discussed individually.

Need Integration Support?

Embedding a TCD sensor in an existing line requires careful consideration of pressure, gas temperature, background mixture composition, installation zone, and other factors. Contact an Archigas engineer, and we will define the right configuration for your process diagram.

Tom Burkard

Archigas engineer

Clients and Partners

FAQ

How do I choose a hydrogen leak detector?

When selecting a hydrogen leak detector, the primary factors to consider are system pressure, required measurement range, background gas composition, and operating environment. For standard applications, the TCD3000 Si is the optimal choice. For more demanding conditions such as pressures up to 200 barg, humid environments, or high explosion risk – the TCD3000 SiA with ATEX Zone 1 certification should be considered. Archigas provides individual factory calibration for your specific binary gas mixture.

What determines the hydrogen leak detector price?

Pricing depends on the model variant, measurement range, area classification requirements, and integration parameters. Cost is calculated individually based on the project specification.

Is the module suitable for continuous leak monitoring?

Yes. The T90 response time of

Does the process need to be stopped for installation?

The module threads into a standard fitting (G 1/2" or NPT 1/2"). It is necessary to locally depressurize the installation section before mounting.

When do standard hydrogen leak detection methods fail?

When building a hydrogen gas leak detection system under high pressure, in a humid environment, or in a hazardous area, conventional approaches have inherent design limitations: catalytic sensors lose sensitivity on contact with sulfides and silicones; electrochemical sensors are not rated for above-atmospheric pressure and degrade within 1–2 years; optical sensors cannot distinguish H₂ in a methane-containing mixture. In these conditions, TCD remains the only method suitable for continuous inline monitoring without additional infrastructure.

How often is servicing required?

The recommended recalibration interval is every 6 months, performed by the user.

Get a Configuration for Your Application

Engineering consultation on model selection, calibration for your gas mixture, and system integration conditions.