Searchline Excel Cross-Duct Infrared Gas Detector Technical

72
Searchline Excel Cross-Duct Infrared Gas Detector Technical Handbook

Transcript of Searchline Excel Cross-Duct Infrared Gas Detector Technical

Searchline Excel Cross-DuctInfrared Gas Detector

Technical Handbook

2

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Ensure that you read and understand these instructions BEFORE operating the equipment.

Please pay particular attention to the Safety Warnings.

WARNINGS1. TheSearchlineExcelgasdetectoriscertifiedforandintendedforuseinpotentiallyhazardousareas.

Install and use the Searchline Excel gas detector in accordance with the latest regulations.

2. For installations in Europe, the Code of Practice SELECTION, INSTALLATION AND MAINTENANCE OF ELECTRICAL APPARATUS FOR USE IN POTENTIALLY EXPLOSIVE ATMOSPHERES should be strictly observed. General recommendations are given in EN 60079-14:2008 & IEC 60079-14:2007. Refer to EN 60079-29-2:2007 & IEC 60079-29-2:2007 in Europe or the appropriate local or national regulations.

3. For installations in North America, the national Electrical Code (NFPA 70 - 1990) or later issues should be strictly observed.

4. Elsewhere, the appropriate local or national regulations should be used.

5. The Searchline Excel gas detector must be properly earthed to protect against electrical shock and minimise electrical interference. For electrical installation design considerations refer to Section 3.

6. Operators must be fully aware of the action to be taken if the gas concentration exceeds an alarm level.

7. Dismantling or repair of equipment should be carried out in the safe area only.

8. Test gases may be toxic and/or combustible. Refer to Material Safety Sheets for appropriate warnings.

9. Do not drill holes in any housing as this will invalidate the explosion protection.

10. In order to maintain electrical safety, the unit must not be operated in atmospheres with more than 21% oxygen.

11. Ensurethattheboltswhichsecureflameproofenclosuresarefullytightened.Thesecuringboltsusedaremadefromaspecialcertifiedgradeofsteel.OnlyboltssuppliedbyHoneywellAnalyticsshouldbefittedforthispurpose.

12. Do not open the enclosure in the presence of an explosive atmosphere.

13. The transmitter unit contains high voltages when operational. These are discharged when the unit is removed from its enclosure.

14. TheconduitandcableglandsfittedtoSearchlineExcelshouldnotbemodified.If,however,itbecomesnecessarytomakemodificationstheymustcomplywiththerelevantnationalCodesof Practice.

15. The optical energy emitted by the Searchline Excel is less than 20mW/mm2.

16. Searchline Excel Cross-Duct should only be used to detect gas mixtures where methane is the main constituent (>70%) and the balance is C2 - C6 hydrocarbons.

Safety

3

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Cautions1. Use only approved parts and accessories with the Searchline Excel gas detector.

2. To maintain safety standards, commissioning and regular maintenance of the Searchline Excel gas detector shouldonlybeperformedbyqualifiedpersonnel.

Important Notices1. HoneywellAnalyticscantakenoresponsibilityforinstallationand/oruseofitsequipmentifthisisnotdonein

accordance with the appropriate issue and/or amendment of the manual.

2. The user of this manual should ensure that it is appropriate in all details to the exact equipment to be installed and/oroperated.Ifindoubt,theusershouldcontactHoneywellAnalyticsforadvice.

3. Effect of explosive atmosphere on materials.

Searchline Excel is made from materials which exhibit good resistance to corrosive and solvative substances. The Exd enclosures are made from 316 stainless steel and the explosion protected windows are made from toughenedsodalimeglass.HoneywellAnalyticsarenotawareofanysignificanteffectsofexplosiveatmospheresuponthesematerials.ContactHoneywellAnalyticsoroneoftheiragentsforspecificqueries.

Special Conditions of UseInordertocomplywiththeATEX/IECExCertification,thefollowingspecialconditionsofusemustbeadheredto:-

1. The integral supply cables must be mechanically protected and terminated in a suitable terminal or junction facility.

2. Thecoverfixingscrewsshallbestainlesssteelgrade12.9minimum,gradeA2-80orgradeA4-80(onlyuseHoneywellsuppliedscrews)

Everyefforthasbeenmadetoensuretheaccuracyofthisdocument,however,HoneywellAnalyticscanassumeno responsibility for any errors or omissions in this document or their consequences.

HoneywellAnalyticswouldgreatlyappreciatebeinginformedofanyerrorsoromissionsthatmaybefoundinthe content of this document.

For information not covered in this document, or if there is a requirement to send comments/corrections about thisdocument,pleasecontactHoneywellAnalyticsusingthecontactdetailsgivenonthebackpage.

HoneywellAnalyticsreservetherighttochangeorrevisetheinformationsuppliedinthisdocumentwithoutnotice and without obligation to notify any person or organisation of such revision or change. If information isrequiredthatdoesnotappearinthisdocument,contactthelocaldistributor/agentorHoneywellAnalytics.

Safety

4

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Section Page

1. Introduction 7

2. Overview 9

2.2 Transmitter and Receiver Unit 10

2.2.1 Transmitter 10

2.2.2 Receiver 10

2.2.3 Mounting Block 11

2.3 HeatedReflectorPanel 11

3. Installation and Operation 12

3.1 Introduction 12

3.2 Siting and Mounting 12

3.2.1 General 12

3.2.2 Location for Best Coverage 12

3.2.3 Location to Maximise Reliability and Availability 12

3.2.4 Beam Path 13

3.2.5 Orientation 13

3.2.6 Access for Cleaning 14

3.3 Electrical Connections 14

3.3.1 General 14

3.3.2 Transmitter and Receiver Connections via DVC100 (M) MK2 15

3.3.3 Transmitter and Receiver Connections via DX100 (M) 15

3.3.4 Transmitter and Receiver Connections 16

3.3.5 Remote Installations 17

3.4 Power Supply 17

3.4.1 General 17

3.4.1.1 Transmitter and Receiver Unit 17

3.4.1.2HeatedReflectorPanel 17

3.4.2 Power Supply Connections - Turbo heating Disabled 19

3.5 Installation Procedure 20

3.5.1 General 20

3.5.2 Mechanical Installation 20

3.5.2.1 Transmitter and Receiver Unit 20

3.5.2.2HeatedReflectorPanel 21

Contents

5

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Section Page

3.5.3 Electrical Installation 22

3.6 Commissioning 22

3.6.1 General 22

3.6.2 Connecting the Interrogator 22

3.6.3 Power Up 24

3.6.4 Setting the Real-Time Clock 25

3.6.5 Initialising the Searchline Excel Cross-Duct Gas Detector 26

3.6.6 Functional check 28

3.6.7 Finish 28

3.7 System Controller Calibration 29

3.8 Installation Checks/ Tests 30

4. Maintenance 35

4.1 Inspection and Cleaning 35

4.2 Re-zero 36

4.3 Functional Checking 36

4.3.1 Functional Checking with Gassing Cell (Short Range versions only) 36

4.3.2 Functional Checking with Test Filters 37

5. Problem Solving 38

6. Specifications 42

6.1 System 42

7. Certification 43

7.1 General 43

7.2 Conduit Technical Characteristics (ATEX, IECEx version) 44

7.3 CertificationLabelsATEX,IECEx 44

7.3.1 Transmitter 44

7.3.2 Receiver 45

7.3.3HeatedReflectorPanel 46

7.3.4 System Diagram 47

7.4CertificationlabelsUL 48

7.4.1 Transmitter 48

Contents

6

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Section Page

7.4.2 Receiver 49

7.4.3HeatedReflectorPanel 50

7.4.4 System Diagram With DX100M Termination Unit 51

8. Warranty Summary 52

AppendixA-HandheldInterrogator 53

A.1 Introduction 53

A.2 Overview 53

A.3 Connection to System 54

A.4 Basic User Tasks 55

A.5 Menus 56

A.5.1 Main Menu 57

A.5.2 Display Menu 57

A.5.3 Calibrate Menu 58

A.5.4 Diagnose Menu 63

A.5.5ConfigMenu 65

A.5.6 Chg Mode 67

A.5.7 Power Off 67

A.6 PROBLEM SOLVING 67

Appendix B - Glossary 68

B.1 Terminology 68

B.2 Open Path Detector Measurement Units 69

B.3 Abbreviations 69

Appendix C - Accessories & Spare Parts 70

C.1 System Units 70

C.2 General 70

Contents

7

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

The Searchline Excel Cross-Duct Gas Detector is an open path infrared gas detector for methane.

It will detect hydrocarbon gas mixtures where methane is the main constituent (>70% of the composition with the balance being C2 - C6hydrocarbons).ForothergasmixturespleasecontactHoneywellAnalyticsforadvice.

SearchlineExcelCross-Duct isspecificallydesigned forusewhere thepath length isbetween0.5and5metres for applications such as air intake ducts. It consists of a Transmitter and Receiver unit, and a separate HeatedReflectorPanel.

The detector operates on the principle of infrared (IR) absorption. If a cloud of methane gas is present, part of the infrared light is absorbed by the gas, causing a reduction in the signal received that is proportional to the amount of gas in the beam.

The detector output signal is proportional to 0-100%LEL (Lower Explosive Limit) of gas.

Searchline Excel Cross-Duct is suitable for use in Zone 1 or 2 hazardous areas (International) and for Class 1 Division 1 or 2 area applications (North America).

Note: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.

Thishandbookconsistsofthefollowingparts:

• Chapter 1 Introduction

• Chapter 2 Overview

A brief description of the system components

• Chapter 3 Installation and Operation Important information regarding detector positioning, electrical connections, power supply requirements, mechanical installation and commissioning, including an installation check list

• Chapter 4 Maintenance Regular maintenance requirements and instructions for functional checks

• Chapter 5 Problem Solving

• Chapter6 Specifications

• Chapter7 Certification

• Appendix A Handheld Interrogator

• Appendix B Glossary

• Appendix C Accessories & Spare Parts

1. Introduction

8

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Information noticesThetypesofinformationnoticesusedthroughoutthishandbookareasfollows:

Caution: Indicates hazardous or unsafe practice which could result in minor injury to personnel, or product or property damage.

Note: Provides useful/helpful/additional information.

If more information beyond the scope of this technical handbook is required please contact HoneywellAnalytics.

Associated DocumentsDX100SeriesTerminationUnitsTechnicalHandbook PartNo:2104M0701

DVC100(M)MK2TerminationUnitQuickStartGuide PartNo:2104M0409

WARNING

Indicates hazardous or unsafe practice that could result in severe injury or death to personnel.

1. Introduction

9

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

2.1 IntroductionSearchlineExcelCross-DuctgasdetectorconsistsofaTransmitterandReceiverunit,andaHeatedReflectorPanel.TheTransmitterandReceiverunitgeneratesanddetectstheinfraredbeam.TheHeatedReflectorPanelismountedattheoppositesideoftheducttoreflectthebeamfromtheTransmitterbacktotheReceiver.

Note: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.

TherearetworangesofSearchlineExcelCross-Ductgasdetector.Theseare:

Version Path Length (m) Path Length (ft) Certification

Short Range: 0.5 — 2.5m (20in — 8ft) ATEX, IECEx, UL

Long Range: 2.5 — 5m (8ft — 15ft) ATEX, IECEx

ThelongrangegasdetectorusesalargerReflectorPanelthantheshortrangeversion.

2. Overview

Heated Reflector Panel

Mounting Plate

Mounting Block

Transmitter

Conduit

ReceiverJunction Box (type DVC100 (M) MK2)

10

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

2.2 Transmitter and Receiver Unit

2.2.1 TransmitterTheTransmitterproducesanintense,collimatedinfraredbeamfromaXenonarcflashlamp.TheTransmitterwindow is heated to minimise condensation and frosting. During particularly cold operating conditions, the heating of the Transmitter window is increased to turbo levels. The turbo mode can be disabled if not required.

ElectricalconnectionstotheTransmitteraremadeviawireswhichrunthroughtheprotective,flexibleconduit.There are three Transmitter wires, red (+24V), black (0V) and green/yellow (GND).

Note: The infrared beam is invisible and eye safe.

2.2.2 ReceiverThe Receiver collects infrared radiation from the Transmitter and performs measurements to enable methane gas in the beam path to be detected.

The Receiver output signal is 4 - 20mA available as a source or sink option. The output is calibrated for a range of 0 to 100% LEL methane.

Note: The detector uses the duct width in the calculation of gas reading – it is essential that this is specified correctly during installation (See Appendix B.2 for the explanation of how open path gas detectors measure gas concentration)

Output signal levels below 4mA are used to indicate Fault (0mA), Inhibit (2mA), Beam Blocked (2.5mA) and Low Signal (3mA).

TheReceivercommunicateswiththeSHC1HandheldInterrogatorusinganRS485output.TheSHC1isusedto perform commissioning, functional testing and diagnostic procedures.

The Receiver window is heated to minimise condensation and frosting.

ElectricalconnectionstotheReceiveraremadeviawireswhichrunthroughtheprotectiveflexibleconduit.There are six Receiver wires, red (+24V), black (0V), white (4 - 20mA), orange (RS485 A), blue (RS485 B) and green/yellow (GND).

2. Overview

Air Shield

Slot for test filter

Gas In/Out

Gassing Cell

Transmitter

Mounting Block

Beamsplitter

Receiver

11

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

2.2.3 Mounting BlockThe Transmitter andReceiver are factory aligned and fixed to amounting block. They should not bedisassembled. The mounting block has a top cover which can be removed to clean the Transmitter and Receiverwindows.Insidethemountingblockthereisanangledwindow(thebeamsplitter)whichreflectsthebeam into the Receiver.

Themountingblockhastwofeaturesforfunctionalchecking-agascellandaslotforplastictestfilters.

2.3HeatedReflectorPanelTheHeatedReflectorPanelconsistsofaretro-reflectorsealedinadouble-glazedunit,withanintegralheaterto minimise condensation and frosting.

TheReflectorPanelshouldbemountedoppositetheTransmitterandReceiverunit,andperpendiculartothebeam.

TheReflectorrequiresanominal24Vpowersupply.

2. Overview

12

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.1 Introduction

Before designing or specifying an installation for Searchline Excel Cross-Duct, it is strongly recommended that the installation design authority reads all of this chapter and considers how the information and recommendations provided can be applied to their installation(s).

Ifyouhaveanyqueriesconcerningyourinstallationdesign,contactHoneywellAnalyticsoryourlocalagents.

HoneywellAnalyticsiscommittedtoensuringthatcustomersachievereliableoperationoftheirSearchlineExcel Cross-Duct Gas Detectors. For this reason, Searchline Excel Cross-Duct should only be installed by fully trainedpersonnel(trainedbyHoneywellAnalyticsoraHoneywellAnalyticsauthorisedtrainer).

This training will provide the installer with a clear understanding of the Searchline Excel Cross-Duct product and the associated accessories and tools. It will also provide familiarity with the installation, alignment and commissioning procedures, plus installation assessment skills to identify potential problem areas.

Foreachinstallation,aninstallationchecksheetshouldbecompletedandreturnedtoHoneywellAnalyticsortheir agents. Details of this check sheet are given at the end of this chapter.

Note: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.

3.2 Siting and Mounting

3.2.1 GeneralWhen designing an installation for a Searchline Excel Cross-Duct gas detector it is important to give consideration to where it is to be located, what potential sources of problems may be encountered in this location and how the unit is to be mounted and supported.

Caution: TheTransmitter,ReceiverandReflectorPanelunitshaveheatedwindowstominimisecondensationandfrosting.However,partialobscurationoftheReflectorandinparticularliquidwatercondensationontheReflectorcancausenegativedrift,whichhastheeffect of raising the alarm threshold. Wherever possible protect the Searchline Excel Cross-Duct from dirt and condensation by mounting well inside the duct and ideally downstreamoffilters/dampers.

3.2.2 Location for Best CoverageThe placement of gas detectors should be determined following the advice of experts having specialist knowledge of gas dispersion, experts having knowledge of the process plant system and equipment involved, safety and engineering personnel. The agreement reached on the location of detectors should be recorded.

3. Installation and Operation

WARNING

The national Code of Practice regaurding selection, installation and maintenance of electrical apparatus for use in potentially explosive

atmospheres must be complied with at all times.

13

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.2.3 Location to Maximise Reliability and AvailabilityForoptimumperformance,takecaretoavoidareaswheretheunitsmaybeadverselyaffectedbythefollowing:

Vibration - Angular vibration of the structure to which Excel units are attached should be kept to less than ±0.5°. Where possible, avoid locations where high levels of vibration will be directly induced into the mounting structure.Ifcloseproximitytosignificantsourcesofvibrationisunavoidable,takestepstoreducecouplingof this vibration and maximise the rigidity of the mounting structure.

Mounting Rigidity – The duct wall thickness should be suitable to maintain rigidity of the Searchline Excel Cross-Duct mounting to within ±0.5°.

Intense Heat-Exceliscertifiedandspecifiedforoperationinenvironmentsupto+65°C.Ifsourcesofintenseheat(flarestacks,intensesunlight,etc.)arepresent,asunshade(PartNo:2104B2323)orsimilarshieldshouldbefittedtotheunittoprotectitfromexcessiveheating.

Sources of Heavy Contamination - Avoid locations where high levels of contaminants will persistently be blown onto the unit windows. Potential sources of heavy contamination include generator/turbine exhausts, flarestacks,drillingequipment,processvents/chimneysetc. If sourcesofheavycontaminationcannotbeavoided,considerfittingextrashieldingand/orprovidinggoodaccessformoreroutinecleaning.

Snow and Ice in Ambients Below -20°C - The heated optics on Excel units will melt snow or ice on the windows in ambient temperatures down to approximately -20°C. Below this temperature, snow or ice blown onto the window will not be melted until the ambient temperature rises. If long-term, outdoor operation in very cold climates is intended, it is recommended that extra shielding/covers are employed to prevent snow/ice from being blown onto the windows and building up.

Accidental Impact-Locationswherethereisasignificantlikelihoodofequipment,personnelormovingobjectsaccidentally knocking Excel units out of alignment should where possible be avoided. If such locations cannot be avoided, measures including improved mechanical protection and warning notices should be considered. Since the Transmitter and Receiver protrude from the duct wall, adequate precautions should be taken to protect personnel.

Intense Electromagnetic Fields - Searchline Excel Cross-Duct complies with EN50270 and as such is well protectedfrominterferencebyelectromagneticfields.However, locationsincloseproximitytoradio/radartransmitters,heavyelectricalplantandhighvoltagepowercablesmayexperiencefieldstrengthsinexcessofthosespecifiedinthestandard.Wherepossible,suchlocationsshouldbeavoidedorunitsshouldbeinstalledasfaraspossiblefromthesourceoftheelectromagneticfield.Measuresincludingadditionalscreening,filteringandtransientsuppressionmayalsobeofbenefitinsuchlocations.

To ensure optimum performance, do not cover the Excel with insulation, and allow free air movement around the unit.

3.2.4 Beam PathThe path of the infrared beam inside the duct is unlikely to be affected by obstructions, however, consideration shouldbegiventoavoid:

• Steam vents

• Splash and spray

3. Installation and Operation

14

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.2.5 OrientationTheSearchlineExcelCross-Ductunitsshouldbemountedonvertical,flatsurfacessuchthattheopticalaxisishorizontal.Ensurethesurfaceisrigidandstable.Fitadditionalsupportspriortoinstallationifnecessary(see note on Vibration, above).

TheHeatedReflectorPanelshouldbemounteddirectlyopposite,andperpendiculartotheopticalaxisoftheTransmitter and Receiver unit. If the duct walls are not exactly vertical or parallel, the position of the cut out for the retro panel must be adjusted to compensate.

It is not advisable to install the Cross-Duct Excel on the top or bottom of the duct. In this orientation the ReflectorPanelortheTransmitterandReceiverunitwillbevulnerabletothebuildupofcontamination.

3.2.6 Access for CleaningSearchlineExcelCross-DuctTransmitterandReceiverunitandHeatedReflectorPanelwillneedtobecleanedregularly.InthecaseoftheReflectorPanelitmayneedtoberemovedfromtheducttocleanthewindow.Itisadvisabletoprovideanaccesspointintheduct,adjacenttothereflectorpanel,toallowittobecleaned.

3.3 Electrical Connections

3.3.1 GeneralSearchline Excel Cross-Duct complies with the EN50270. In order to maintain compliance with these standards it is essential that the electrical installation of Excel is engineered correctly.

Electrical installation standards vary for different countries, companies and applications and it is the responsibility of the installation design authority to determine the applicable standards and ensure compliance with them. WhendesigningelectricalinstallationsforExcel,HoneywellAnalyticsrecommendthattheinstallationdesignauthorityconsidersthefollowing:

a. The unit cases should not, if possible, be connected to electrically noisy (dirty) metalwork or conductors. Preferably, the case (internally connected to the green/yellow GND wire) should be connected to a low noise instrument (clean) earth. See also para e. below. In order to facilitate electrical isolation of the SearchlineExcelfromanoisyearthanisolationkitissupplied.Thiskitshouldbefittedasstandardunlesslocal regulations forbid this.

b. Theentirelengthofthefieldcablingconnectedtoeachunitshouldbefullyshielded.Thisshouldbeconnectedto a low noise (clean) earth.

c. The low noise instrument (clean) earth system should only be connected to safety earth (usually dirty) at a single point on the entire site/installation. This connection should be made in such a manner that it does not introduce noise onto the low noise instrument earth. Star earthing arrangements minimise earth current crosstalk.

d. Theshieldsofthefieldcablingshouldnotbeconnectedsuchthatearthloopsareproduced,orinamannerthat will result in the shields carrying large currents from heavy plant or equipment.

e. Ideally,thefieldcableshieldshouldbeconnectedtotheunitsgreen/yellowGNDwire,providingasingle,continuous earth shield. This connection must not be allowed to complete an earth loop.

f. The earth bonding arrangement must ensure that the maximum peak voltage between the unit case earth andanyfieldcableconductorislessthan350V.VoltagesinexcessofthiscancausepermanentdamagetotheunitsRFIprotectionfilters.

g. The use of a single, screened cable for each gas detector ensures maximum screening and minimum crosstalk.Cabling arrangementswhich use a single cable for connecting a number of fielddevicescompromise screening, increase the potential for crosstalk and prevent implementation of true star earthing.

3. Installation and Operation

15

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

h. Any electrical interference induced onto the 4 - 20mA loop conductors by the installation must be kept below the levels necessary to comply with the general requirements of EN 60079-29-2 and IEC 60079-29-2. In practice, this means that peak noise currents induced on the current loop should be no greater than ± 0.25mA

j. The 0V rail of the control card/control system is directly connected to one side of the 4 - 20mA current sensing resistor. Electrical noise on this rail is therefore directly connected to the 4 - 20mA input. In order to avoid additional noise being induced on the 0V rail, it should not be commoned with the safety earth/ground, which frequently carries a high level of electrical noise.

k. All electrical equipment connected to the gas detector should comply with EN50270.

l. The24Vsupplyshouldbefreefromlargetransientsandfluctuations.

m. Thefieldcablingconductorsshouldhavesufficientcrosssectionalareatoensurethattheminimumsupplyvoltage applied to the gas detector is 18V.

n. Searchline Excel Cross-Duct Receivers should not be installed in close proximity to the antennae of high powered radio, radar and satellite communication equipment.

3.3.2 Transmitter and Receiver Connections via DVC100 (M) MK2

3.3.3 Transmitter and Receiver Connections via DX100 (M)

3. Installation and Operation

Field Wiring

+24VDC IN (Terminal 1)0V (Terminal 3)

4-20mA (Terminal 5)Earth Terminal

MOD BUS DRAIN (Terminal 9)MOD BUS A (Terminal 10)MOD BUS B (Terminal 11)

Earth Terminal+24V (Terminal 2)

0V (Terminal 4)

Cross-DuctTransmitter Wiring

Cross-DuctReceiver Wiring

R5485 (B) (Blue) (Terminal 8)R5485 (A) (Orange) (Terminal 7)4-20mA (White) (Terminal 6)Earth (Green / Yellow) (Earth Terminal)+ 24VDC (Red) (Terminal 2)0V (Black) (Terminal 4)

16

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.3.4 Transmitter and Receiver Connections

3. Installation and Operation

1 6

1

6

Cross-Duct Reciever Connections

Control Cabinet Connections

Cross-Duct Transmitter Connections

Modbus A

Blue (B)

Orange (A)

Red (+24VDC)

White (4-20mA)

Black (0V)

Green/Yellow (Earth)

Modbus B

+24VDC - in4-20mA - out

0VDC - in

Red (+24VDC) Black (0V)

Green/Yellow (Earth)

Safety/ protec-tive ground

Screen Modbus Drain

DX100 (M) Junction BoxCable Shield

Instrument (clean) Earth

The earth bonding arrangement mustensure that the maximum peak voltagebetween the unit case earth and any field cable conductor is less than 350V.Voltages in excess of this can causepermanent damage to the unit’s RFIprotection filters.

AB

Ex d or Ex e Junction BoxSHC Protection Device

Flying Lead

(Tempo-rary Con-nection)

SHC1

Transmitter Connections

Controller Connections

Receiver Connections

Black 0V4-20mAGND0V+24V

BRN4-20mA

BLU

Red +24VGreen/ GND

2-wire crimp ferrules

Earth Terminal

GRN/YEL GNDWHITE 4-20mAORANGE ABLUE BRED +24VBLACK 0V

Earth

Cable Shield

17

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.3.5 Remote Installations Forremoteordifficult-to-accessinstallations,theDVC100(M)/DX100(M)canbepositionedinaconvenientlocation by using an intervening junction box (e.g. PL6I2/AKRON/Killark) attached to the Transmitter and Receiver unit’s mounting plate.

A maximum cable length of 1km between the unit and the DVC100 (M)/ DX100 (M) is permissible (RS485 compliant).

3.4 Power Supply

3.4.1 GeneralThe Searchline Excel Cross-Duct gas detector is designed to be operated from a nominal 24V DC supply. The supply voltage at the terminals must be within the range 18 to 32V for the Transmitter and Receiver unit, and withintherange18to28VfortheHeatedReflectorPanel.

3.4.1.1 Transmitter and Receiver Unit

TheTransmitterandReceiverunitmaximumpowerconsumptionandcablelengthsareasfollows:

Unit TypeMaximum PowerConsumption (W)

Maximum Cable Length(m) with 1.5mm2

Conductors (12 ohms/km)

Maximum Cable Length(m) with 2.5mm2

Conductors (7.6 ohms/km)

Transmitter and Receiver 13 340 540

Notes:

1. Control room supply voltage assumed to be +24V.

2. Standard configuration of the Transmitter is with turbo heating enabled.

Terminal sizes: DVC 100 (M) 0.5mm2 - 4mm2 (20AWG - 12AWG) DX100 (M) 0.5mm2 - 4mm2 (20AWG - 12AWG) HA Junction Box 00780-A-0100 0.5mm2 - 6mm2 (20AWG - 10AWG)

3.4.1.2HeatedReflectorPanel

TheHeatedReflectorPanel requires18-28Vdcsupplyvoltage.Because it isa resistiveheater, thepowerconsumptiondependsonthesupplyvoltage.Powerconsumptioncanbecalculatedasfollows:-

Power = V2 where V is the supply voltage and R is the resistance of the heater

Toensuresufficientheatingoverawiderangeofsupplyvoltage,twoconnectionoptionsareavailable,whichuse different heater resistances depending on the supply voltage available (>20V or 18-20V).

3. Installation and Operation

R

18

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

ShortRangeHeatedReflectorPanel(Partnumbers2104B0715,2104B0717)

Terminal Identification Wire ColourCustomer Connection

(>20V)Customer Connection

(<20V)Heater Resistance

(R)

1 White 0V 0V

2 Black or Brown >20Vdc 100Ω3 Blue 18-20Vdc 68Ω6 Green Earth Earth

LongRangeHeatedReflectorPanel(Partnumber2104B0716)

Terminal Identification Wire ColourCustomer

Connection (>20V)Customer

Connection (<20V)Heater Resistance (R)

1 White 0V 0V

2 Black or Brown >20Vdc 33Ω3 Blue 18-20Vdc 23Ω6 Green Earth Earth

Important:IftheTransmitterandReceiverunitsharesapowersupplycablewiththeHeatedReflectorPanel, a check must be made to verify that a minimum voltage of 18V is available at the TransmitterandReceiverwhentheReflectorPanelisoperating.

3. Installation and Operation

Terminal 6

Terminal 3Terminal 2Terminal 1

Conduit

External Earth (GND) Insulating Adaptor Field Wiring

Earth (GND) Terminal

19

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.4.2 Power Supply Connections - Turbo heating DisabledWhen connected as shown in section 3.3 Transmitter and Receiver Connections the Transmitter has turbo heating mode enabled.

This means that during conditions of low ambient temperature, additional heating power is applied to the unit’s window to minimise condensation, frosting and snow buildup.

If the application/installation does not require turbo heating, power consumption can be reduced by disabling this mode.

The turbo heating is disabled by reversing the power supply connections to the Transmitter as shown in the following diagram. All other connections remain the same.

Notes:

1. Only Transmitters have turbo mode heating which can be disabled. The Receiver uses proportional heating, which cannot be disabled.

2. Even with turbo mode heating disabled the Transmitter window still receives standard levels of heating.

3. Do not reverse the Receiver power supply connections. This will not damage the unit, but the unit will not work.

3. Installation and Operation

Junction BoxTransmitter Connections

Reverse these connections to disable turbo-heating Cable Shield

Control Cabinet Connections

Black 0V+24V DC Supply

Tx +24V

Tx 0V

Instrument (Clean) Earth

0V DC SupplyRed +24V

Green/ GND Yellow

20

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.5 Installation Procedure

3.5.1 GeneralInstalling the Searchline Excel Cross-Duct is done in two stages. First the duct is prepared, and the Excel componentsmechanicallyfixedinplace.Secondly,theelectricalwiringisconnected.TheTransmitterandReceiver assembly must be fully assembled and mounted to the duct structure before making the electrical connections.

3.5.2 Mechanical InstallationVerify that the equipment to be installed is correct for the type of installation required (i.e. short or long range.)

3.5.2.1 Transmitter and Receiver Unit

Identifytheholesinthemountingplateusingthefollowingdrawingandtable:

3. Installation and Operation

155m

m

100mm

Identity Quantity Size Used for

A 4 M6 tapped Mounting block mounting

B 8 6.5mmMounting plate to support

bar mounting

C 2 14mmClearance for support bar

fixing nuts

D 1 10mm Drain for mounting block

E 1 25mmCross-Duct optical measurement path

F 1 M6 tapped

DVC100 (M) junction box mounting

(used in conjunction with bottom two F1 holes)

F1 4 M6 tappedDVC100 (M) MK2 junction

box mounting

G 4 M6 tappedBARTEC junction box

mounting

H 2M10

tappedDX100 (M) junction box

mounting

NOTE: If unused, the top two F1, top two G and the F holes should be blanked off to avoid leakage from the duct. Use the 5 off M6 x 8 screws, single coil washers and plain washers supplied.

21

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3. Installation and Operation

(1) Stick the supplied self-adhesive mounting plate cut-out template onto the duct wall in the position chosen for the Transmitter and Receiver unit.

Note: The intersection of the bold lines on the template (point X) corresponds with the centre of the unit’s infrared beam.

(2) AtthisstageitisadvisabletomarkthecorrespondingpositionfortheReflectorPanelontheoppositesideoftheduct.SticktheReflectorPanelcut-outtemplatetotheoutsideoftheductwalloppositetheTransmitter and Receiver.

Ensure that point X* on the Reflector Panel template is directly opposite point X on the mounting plate template.

(3) Drill 10 mounting holes (diameter 7mm) in the positions marked G on the Transmitter and Receiver unit template.

(4) Cut a rectangular aperture in the duct wall.

Follow outline H.

(5) Check that the path from the aperture to the opposite wall of the duct is clear and unobstructed.

(6) Measure the distance (in metres) across the duct.

Record this distance as it is required later during commissioning.

(7) Insert the two mounting plate support bars through the aperture and attach them to the inside of the duct, using an M6 nut and washer screwed onto the stud in each support bar.

Check that the threaded holes in the support bars line up with the holes drilled in the duct.

(8) Attach the mounting plate, Transmitter and Receiver unit and junction box assembly.

Use M6 x 20 cap head screws and washers for the mounting plate.

(9) Run the Transmitter and Receiver conduits into the junction box cable entries. (see 3.5.3 (2)).

3.5.2.2HeatedReflectorPanel

(1) Ifnotalreadyinplace,sticktheReflectorPanelcut-outtemplatetotheoutsideoftheductwalloppositethe Transmitter and Receiver.

Ensure that point X* is directly opposite point X on the mounting plate template. This ensures that the beam from the Transmitter hits the centre of the reflector.

(2) Drill six mounting holes (7mm diameter) in the positions marked J on the template.

(3) Following outline K, cut a square aperture in the duct wall.

(4) InsertthetwoReflectorPanelsupportbarsthroughtheapertureandattachthemtotheinsideoftheduct,using an M6 nut and washer screwed onto the stud in each support bar.

Check that the threaded holes in the support bars line up with the holes drilled in the duct.

(5) Fit four M6 x 20 cap head screws into the holes in the support strips leaving approximately 5mm of thread exposed on the outside of the duct.

(6) Slottheretro-reflectorassemblyovertheheadsofthescrewsandallowitsweighttobesupportedonthe exposed sections of thread.

(7) Tightenthefourscrewstoclamptheretro-reflectorassemblyinposition.

22

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.5.3 Electrical Installation(1) Isolate all associated power supplies and ensure that they remain OFF until the instruction in the

commissioning procedure to apply power.

See section 3.6 Commissioning. If the units are to be installed with junction boxes other than DVC100(M)/DX100 (M) types, ensure that the boxes have:

a. M20 cable gland entries for BASEEFA units, or 3/4 NPT for UL

b. terminals for five wires and an earth.

(2) RemovetheM20blankingplugs(iffitted)andattachtheSearchlineExcelCross-DuctTransmitterandReceiver cables to their junction box.

Fit the locking rings (if supplied) before terminating the cables in the junction box.

(3) Fit approved cable glands to the junction box cable entries.

Use sealing washers where necessary to maintain the ingress protection rating.

(4) Fit approved blanking plugs to all unused cable entries.

(5) Make electrical connections. See section 3.3.

3.6 Commissioning

3.6.1 GeneralDuringcommissioningtheSHC1HandheldInterrogatorisusedtocommunicatewiththeSearchlineExcelCross-Duct.FulldetailsoftheSHC1HandheldInterrogatorcanbefoundinAppendix A.

Thecommissioningprocessconsistsofthefollowingsteps:

• Connect the Handheld Interrogator to the gas detector

• Power up the gas detector and set the interrogator for operation with Excel

• Set the Excel real time clock

• Initialise the Excel gas detector

• Functionalcheckwithtestfilters

• Finish

3.6.2 Connecting the InterrogatorConnecttheSHC1HandheldInterrogatortothegasdetectorinoneofthefollowingways:

• viaaHoneywellAnalyticsDVC100(M)/DX100(M)JunctionBox-connecttheInterrogator directly to the junction box via the IS socket, e.g.

3. Installation and Operation

ESC

CalibratorType SHC1

23

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

• viaanothertypeofjunctionbox,e.g.HawkePL612-usingtheSHCProtectionDevice.

See the following diagram and description and Appendix C - Spare Parts

Notes:

1. The protection device must always be used for this type of connection.

2. A hot work permit may be required for this procedure.

Carryoutthefollowingproceduretoconnectusingtheprotectiondevice.:

(1) Isolate all power supplies.

(2) Remove the cover of the junction box.

(3) HardwiretheflyingleadoftheSHCProtectionDevicetothecommunicationslinkterminalsintheboxasshown:

(4) ConnecttheInterrogatortotheISconnectorontheendoftheSHCProtectionDevice.

3. Installation and Operation

Flying LeadIS Connector

Junction Box

To Receiver SHC Protection Device Flying Lead

Blue B

Orange A

Black 0V

White 4-20mA

Red +24V

Green/Yellow GND

24

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3. Installation and Operation

ESC

Z - SHC1 EXCELInterrogator

CalibratorType SHC1

3.6.3 Power Up(1) ApplypowertotheSearchlineExcelCross-DuctTransmitterandReceiverandHeatedReflectorPanel

units.

(2) Press and hold the (Enter) key on the Interrogator keypad for at least two seconds. This switches on the unit.

Note: Full details of the SHC1 Handheld Interrogator can be found in Appendix A.

TheInterrogatordisplaysthefollowingstart-upmessageforapproximatelythreeseconds:

Z - SCH1 Excel Interrogator 4V0

(3) Quickly check the type of connected detector shown on the top line of the message.

The display shows Excel or Optima+ or Optima.

(4) If the unit displays Optima+ or Optima immediately press the ESC key on the keypad.

The ESC key must be pressed within 3 seconds to have any effect. Also see Appendix A, section 5.6.

This toggles the Interrogator mode between Excel, Optima Plus and Optima.

The start-up message is updated and displayed again for 3 seconds then the unit displays the Main menu, which is the top level of its Interrogator’s menu style interface, as follows:

Main Display v

The first line of the display shows the current level in the menu tree and the second line displays a sub-menu title, action or data.

v

25

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.6.4 Setting the Real-Time ClockThe gas detector clock needs to be initially set so that faults, events, etc., can be accurately recorded and tracked for diagnostic purposes.

(1) Select Calibrate from the Main menu by pressing the (up) and (down) keys on the keypad to navigate through the menu options.

(2) Press (Enter) on the Interrogator keypad to display the Calibrate menu.

(3) Select SetTime/Date from the Calibrate menu.

(4) Press Enteronthekeypadandaninitialsettimedisplaysimilartothefollowingappears:

Time 09:26 09

The top line shows the current time and the second line shows the new hours setting.

(5) Set the hour using the up and down keys on the keypad.

(6) Press Enter on the keypad and the new minutes setting is now displayed on the second line.

Time 09:26 09:26

(7) Set the minutes using the up and down keys on the keypad.

(8) Press Enteronthekeypadandthedisplayforsettingthedatenowappearsasfollows:

Date 20APR03 20

The second line shows the new day setting.

(9) Set the day using the up and down keys on the keypad.

(10) Press Enter on the keypad and the new month setting is then displayed.

(11) Repeat the procedure to set the month and year.

(12) When complete press Enter on the keypad to return to the Calibrate menu.

Notes:

1. The time and date will not be updated unless both are entered and accepted without error.

2. Pressing ESC on the keypad at any time, aborts the current setting immediately and returns to the previous setting or menu option.

3. Installation and Operation

vv

vv

vv

26

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.6.5 Initialising the Searchline Excel Cross-Duct Gas DetectorIn this part of the procedure details about the gas detector must be entered so that the Interrogator can then complete the commissioning of the gas detector using the correct data.

(1) Select CALIBRATE from the Main menu.

Press the and keys on the keypad to navigate through the menu options..

(2) Press on the interrogator keypad to display the calibrate menu

(3) Select INSTALL from the calibrate menu.

(4) Press ontheinterrogatorkeypadandthefollowingisdisplayed:

System Type Duct Mount

The gas detector type cannot be changed.

(7) Press on the keypad and the current path length setting in metres is displayed, e.g.

Path Length 2.5

(8) Set the path distance (in metres, to the nearest 0.1metre) between the transmitter and receiver unit and thereflectorpanel.

Use the and keys on the keypad.

Note: Do not double the distance, enter only the duct width.

IMPORTANT – THE PATH LENGTH IS USED TO CALCULATE THE GAS READING. ENSURE THAT IT IS ENTERED CORRECTLY

(9) Press onthekeypadandthefollowingmessageisdisplayed:

When finished the interrogator displays the following message for at least three seconds:

The following message is now displayed:

No alignment adjustments are provided. If the mechanical installation is satisfactory Searchline Excel Cross-Duct can now be initialised.

3. Installation and Operation

vv

vv

Self Test Please Wait

Checks Passed

SIG: TGT:

27

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

(10) Press onthekeypadandthedisplayshows:

(11) Press andthedisplaywillshowthefollowingmessagewhilsttheunitisinitialising:

When the gas detector has completed initialisation, the following message is displayed for three seconds:

The display changes to show:

(12) Press on the keypad. The installation is now complete.

If Excel does not initialise, check that:

• the actual duct width agrees with the value entered in step 8 above.

• the reflector panel is clean and fitted securely.

• the reflector panel is mounted opposite the Transmitter and Receiver unit, and perpendicular to the beam

For further help see Chapter 5, Problem Solving.

3. Installation and Operation

Signals OK

Ensure Zero gas then press Enter

Zero Cal OK

Installation complete

Press Enter to release 4-20mA

28

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.6.6 Functional checkCarryoutafunctionalcheckusingplastictestfilters(partnumber2104N3000).Plastictestfiltersinsertedinthe measuring path produce infrared absorption which approximates that of methane gas.

ThefunctionaltestfilterssuppliedfortestingSearchlineExcelCross-Ductdonothaveaspecifiedgasreadingrange.Instead,theyaremarkedwithlettersBtoH,withthereadingproducedbyeachfilterincreasingfromfilterBtofilterH.

TheprocedurefortestingaSearchlineExcelCross-Ductusingthefunctionaltestfiltersisasfollows:-

(1) Select DISPLAY from the Calibrate menu. (This inhibits the Searchline Excel Cross-Duct output).

(2) Remove the top cover from the mounting block.

The cover is retained by 3 x M4 captive bolts, and a chain attaches the lid to the mounting block when opened. There are no electrical hazards inside the mounting block and a hot work permit is NOT required.

(3) Insertasuitablefunctionaltestfilter(seetablebelow)intotheslotinthemountingblockinfrontofthereceiver.

Duct Width Minimum Test Filter Recommended Test Filter

0.5 - 0.75m B B

0.75 - 1.0m B C

1.0 - 1.5m C D

1.5 - 2.0m D E

2 - 3m E F

3 - 4m F G

4 - 5m F H

(4) Record the gas reading that is produced. This reading should be treated as correct and should be used to verify correct operation in the future.

(5) Removethetestfilterandreplacethetopcoverofthemountingcell.

(6) UsingtheSHC1HandheldInterrogatorreleasetheSearchlineExcelsignaloutput.

The output can be released by pressing ESC followed by on the keyboard

3.6.7 FinishTofinishthecommissioningprocess:

(1) Select the Power Off option from the interrogator Main menu

(2) Press on the keypad

Alternatively, press the and ESC keys simultaneously for a fast power off.

Notes:

1. The SHC1 Handheld Interrogator powers down automatically after five minutes of inactivity in order to preserve battery life.

2. The fast power off facility and auto power off are disabled when a menu option is selected that modifies the unit’s configuration.

(3) Disconnect the interrogator from the Excel gas detector, reversing the steps described in section 3.6.2.

3. Installation and Operation

29

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3.7 System Controller CalibrationThis procedure is used to set up the system controller using the Searchline Excel Cross-Duct gas detector. Achosenfixedoutputsignal issentfromthegasdetectortothesystemcontrollerallowingcalibrationofthe 0 - 100% scale of the controller without having to use gas. The steps use procedures described in the previous section.

Tocalibratethecontrollercarryoutthefollowingprocedure:

(1) Connect the Interrogator to the gas detector.

See Connecting the Interrogator to Searchline Excel Cross-Duct Gas Detector.

(2) Turn on the Interrogator.

See Powering Up.

(3) Select Calibrate from the main menu.

Press the up and down keys on the keypad to navigate through the menu options.

(4) Press Enter on the Interrogator keypad and the Calibrate menu is displayed.

(5) Select Force 4-20 from the Calibrate menu.

(6) Press Enteronthekeypadandadisplaysimilartothefollowingappears:

(7) Use the up and down keys on the keypad to set the displayed output current to the desired value.

The values can be changed in steps of 0.1mA in the range 1mA to 21mA.

(8) Press Enter on the keypad.

This selects the currently displayed value and forces the gas detector to output that current. Once complete adisplaysimilartothefollowingappears:

(9) Carry out checks on the controller by following the instructions in the controller documentation.

(10) When checks are complete press ontheInterrogatorkeypadandthefollowingdisplayappears:

(11) Press Enter on the keypad.

The following message is displayed:

The fixed output is released and the gas detector returns to normal operation.

3. Installation and Operation

4-20 current 4.5 mA vv

Fixed 4-20 mA Press Enter vv

Press Enter to Release 4-20 vv

4-20 Released

30

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

(12) Turn off the Interrogator and disconnect it from the gas detector.

Note: The recommended alarm level settings for Searchline Excel Cross-Duct are as follows:-

Operating range Minimum low alarm Maximum high alarm

0.5m - 2.0m 20%LEL 40%LEL

2.0m – 5.0m 10%LEL 30%LEL

3.8 InstallationChecks/TestsThe following information is for the guidance of personnel carrying out installation checks/tests on Searchline ExcelCross-Duct.Ingeneralitshouldbenotedthat:

• SearchlineExcelCross-Ductshouldonlybeinstalledbyfullytrainedpersonnel,trainedbyHoneywellAnalyticsoranauthorisedHoneywellAnalyticstrainer.

• Detailed information concerning installation, alignment and commissioning is provided in this Technical Handbook.

• SearchlineExcelCross-Ductisexplosionprotectedbyacertified,flameproofenclosure.

• Carefullyreadthesafetywarnings,cautionsandcertificationdetailsinthishandbook.

• Ensure that they have been complied with, before and during the installation.

• A copy of the subsequent Installation Check Sheet should be completed for each Searchline Excel Cross-Ductgasdetectorinstalled.InordertohelpHoneywellAnalyticstoprovideefficientassistance/serviceintheeventofproblems,thesheetshouldbereturnedtoHoneywellAnalyticsortooneoftheir agents.

3. Installation and Operation

31

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Searchline Excel Cross-Duct: Installation Check SheetCUSTOMER/OPERATOR

SITE / FACILITY

SYSTEMTYPE: Short Range Long Range OPERATING RANGE

GASTABLE: METHANE

DETECTORLOCATION:

TAGNO.(TX/RX): TAGNO.(Reflector):

SERNO.(TX/RX): SERNO.(Reflector):

MODSTATE(TX/RX):MOD STATE (Reflector)

CERTIFICATION:

CHECK/TEST TRANSMITTER/RECEIVER CHECK/TEST REFLECTOR

Mount Rigidity Mount Rigidity

Vibration: Vibration:

Excessheat: ExcessHeat:

SupplyVoltage: Supply Voltage

Earthing: Earthing:

RFI/EMC RFI/EMC

Contaminants: Contaminants:

BEAMOBSTRUCTIONS/BLOCKS:

(cont.)

TESTFILTER: (B–H) Response: %LEL Pass: Fail:

4-20 mA LOOP INTEGRITY Pass: Fail: Untested:

FAULT/WARNINGLOG: Clear: Faults/Warnings:

(cont.)

INSTALLATIONSATISFACTORY: Yes: No: SIGNED:

INSTALLED BY (PRINT) DATE:

IF INSTALLATION UNSATISFACTORY, REASONS

RECOMMENDATIONS

CUSTOMERNOTIFIED:

SYSTEMSTATUS: Operational: Nonoperational:

3. Installation and Operation

32

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

3. Installation and Operation

The following notes are to help the installer enter the correct information onto the check sheet.

Site/Facility

Enter the name and geographical location of the site/facility.

Operating Range

Enterthedistance(preferablyinmetres),betweentheTransmitterandReceiverunitandtheHeatedReflectorPanel.

Detector Location

Enter the location/position of the detector

Tag No

Enter the Tag No,orequivalent,thathasbeenallocatedtotheTransmitterandReceiverunitandtheReflectorPanel.

Mod State

Enter the Mod Stateoftheunitsasindicatedontheircertification/productlabels.

Certification

Enterthecertificationoftheunits,e.g.

ATEX, IECEx, UL

Mount Rigidity

When pushed hard and released, the mount/supporting structure should return quickly to its original position andshouldnotwobbleorsway.Ifthemount/supportisunacceptable,brieflydescribetheproblem,e.g.

Mount wobbles unacceptably

Vibration

Check the installation and its close surrounds for potential or existing sources of excessive vibration. Such sources could include heavy plant/machinery, turbines, generators etc.

Excess Heat

Checktheinstallationanditssurroundsforpotentialsourcesofexcessiveheat.Theunitisspecifiedupto+65ºC.Potentialsourcesofexcessiveheat includedirectsunlight inhotclimates,flare-stacks,generator/turbine exhausts and steam vents.

Enter a brief description, e.g.

Flare-stack 2 metres away

33

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Supply Voltage

Checkthatthesupplyvoltageappliedtotheunitiswithinthespecified18Vto32Vrange(TransmitterandReceiver)or18to28Vrange(HeatedReflectorPanel)andisstable.Enterthesupplyvoltageandstability,e.g.

22.5V, stable, 19V,+2Vfluctuation

Earthing

Inspect the earth connections to the units. If the unit is connected to local metalwork or the safety/general use earth, enter ‘Local Safety. If the unit has been isolated from local metalwork/ earths and is connected to a clean, instrument earth, enter Instrument earth. (See section 3.3, Electrical Connections).

RFI/EMC

Assess the installation, cabling and its close surrounds for known/potential sources of excessive RF/Electromagnetic Interference. Such sources could include radio/radar transmission antennae, high voltage switch-gear, large electrical generators/motors etc.

SearchlineExcelCross-DuctcomplieswiththemoststringentrequirementsspecifiedinEN50270.Itisthereforemorelikelythatthefieldcablingwillpickupinterferencedirectlyonthe4-20mAand0Vconnectionsandthatthis will affect the reading received at the control room.

Enterbriefdetailsofknown/potentialEMIsourcesthatarewithinfivemetresofthegasdetectorand/oritscabling. If cable is unscreened or inadequately protected, note concerns.

Examplesofthesortofinformationtoenterare:

10m cable, unscreened, Radar, 2m from Receiver, Cable routed over 400kW generator

(See section 3.3 Electrical Connections).

Contaminants

Assess the installation and its surrounds for sources of contaminants that could build up on the unit’s windows. Such contaminants could include oil mist, heavy sea spray, drilling mud, dirty exhaust fumes, wave splash etc.

If there is a realistic possibility that such contaminants could cause a significant problem, enter a briefdescription, e.g.

Drilling mud spray, Diesel generator exhaust

Test Filter

After completing the installation procedure, enter the DISPLAY mode and test the gas detector response with aplastictestfilter.Enterthenominalvalueofthetestfilter,andtheunit’sdisplayedresponse.Whentestinginfuture,usethesametestfilterandcomparetheresponsetothevalueobtainedatinstallation.SeeChapter4, Maintenance.

4 - 20mA Loop Integrity

Test the 4 - 20mA loop integrity by forcing the unit to output a known current and monitoring this at the control room or with a multimeter inserted into the loop. Mark the appropriate box.

3. Installation and Operation

34

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Fault/WarningLog

Check the fault/warning log. In order for the unit to complete installation satisfactorily, the ACTIVE FAULTS log must be CLEAR.UsetheHandheldInterrogatortodiagnoseandremedyallACTIVE FAULT.

Wherever possible, it is recommended to CLEAR any ACTIVE WARNINGS, since these may lead to faults in the future.

Faults/Warning

Enter any ACTIVE FAULTS or ACTIVE WARNINGS that could not be cleared from the log, e.g.

BEAM BLOCK, E_ZERO_NOT_CALIBRATED

Installation Satisfactory

OnlyfullytrainedpersonneltrainedbyHoneywellAnalyticsorHoneywellAnalyticsauthorisedtrainerscandeclare an installation satisfactory. Mark the YESboxandsigntheformif:

a. having completed the installation and testing, the unit is operating correctly, and

b. in the trained installer’s opinion, the unit should continue to operate reliably in this installation/ operating environmentprovidingthatnothingsignificantabouttheinstallation/environmentischanged.

If the unit is not operating correctly or there are aspects of the installation/ operating environment which in the trained installer’s opinion could or will result in unreliable operation, mark the NO box.

Reasonsfordeclaringaninstallationunsatisfactorycouldinclude:

excessivemovement/vibrationofunit’smounting, received signal levels too low,

supply voltage too low, 4 - 20mA loop integrity faults,

unclearable active faults, any prevailing or probable condition which is known to unacceptably reduce reliability or availability

If Installation is Unsatisfactory, Reasons

Brieflystatetheprincipalreasonswhytheinstallationisunsatisfactory,e.g.

Excessivemovement,insufficientreceivedsignallevels,Unitoverheatedbyintensesunlight

Recommendations

Brieflydescribe the recommendedactionswhichneed tobeperformed inorder tomake the installationsatisfactory, e.g.

Mountingrequiresbracing/stiffening, Provide correct supply voltage

CustomerNotified

Makesurethattherelevantcustomer/operatorisnotifiedoftheinstallationproblem(s).Markboxaccordingly.

System Status

Upon leaving, note the gas detectors status, i.e. operational or nonoperational.

3. Installation and Operation

35

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

4. Maintenance

The Searchline Excel Cross-Duct maintenance should include regular cleaning of the Transmitter and Receiver unitwindowsandtheHeatedReflectorPanel,re-zerooftheCross-DuctunitandfunctionaltestusingTestFilters (2104N3000).

Note: The objective is to keep the windows clean. The rate of build up of contamination depends on local site conditions. It is recommended that the installation is closely monitored during the first few weeks of operation to establish how frequently cleaning will be required.

Depending on the local regulations and site conditions, cleaning and functional testing of the gas detector can be carried as described in the following sub-sections. The gas detector should remain powered during these procedures.

Caution: Searchline Excel Cross-Duct does not contain any user serviceable parts. Do not open or disassemble the Transmitter and Receiver unit (other than as instructed), or the Heated ReflectorPanel.Thewarrantyofunitswhichhavebeenopenedisinvalidated.

Note: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.

4.1 Inspection and CleaningCaution: Do not use solvents or abrasives on the Searchline Excel Cross-Duct units.

(1) Inspect the Searchline Excel Cross-Duct units, junction boxes and cabling for signs of physical damage.

(2) UsingtheSHC1HandheldInterrogatorinhibittheSearchlineExcelCross-Ductsignaloutput.

Since the signal output may vary during cleaning, due to the optical path being disturbed, it is important to inhibit the analogue output. The quickest way to inhibit the Excel output is to select DISPLAY from the Calibrate menu.

(3) To access the Transmitter and Receiver windows, and the beamsplitter, remove the top cover from the mounting block.

The cover is retained by 3 x M4 captive bolts, and a chain attaches the lid to the mounting block when opened. There are no electrical hazards inside the mounting block and a hot work permit is NOT required.

(4) Clean any dust or dirt from the Transmitter and Receiver windows and the beamsplitter using soapy water or window cleaner and a soft cloth.

(5) Replace the top cover of the mounting block.

(6) LoosenthefixingswhichsecuretheHeatedReflectorPanelandremoveitfromtheductwall.

(7) CleananydustordirtfromtheHeatedReflectorPanelusingsoapywaterorwindowcleanerandasoftcloth.

(8) ReplacetheReflectorPanelontheductwallandtightenfixings.

(9) UsingtheSHC1HandheldInterrogatorreleasetheSearchlineExcelsignaloutput.

The output can be released by pressing ESC followed by on the keyboard.

(10)Re-zerothesystem(seesection4.2).

To reduce the need for cleaning, it is possible to connect a supply of compressed air to the Air Shield port on themountingblock(seediagraminsection4.3).Theairshieldportistheoneclosesttotheduct.Byflowingclean air into the mounting block (which then moves out into the duct), the build up of contamination inside the mounting block will be reduced. It is essential that this air supply is oil and dirt free. Precautions such as afilterandaliquidtrapshouldbeinstalledintheair-line.

36

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

4.2 Re-zero(1) UsingtheSHC1HandheldInterrogator,selectCalSensor from the Calibrate menu. The analogue output

will be inhibited. (See Appendix A for details about how to use the Interrogator).

Note There must be no gas in the system beam path whilst this procedure is carried out.

(2) Thefollowingmessageisdisplayed:

(3) PressEnter.Thefollowingmessageisdisplayedwhilethecalibrationoperationisbeingperformed:

(4) Ifthecalibrationissuccessful,thefollowingmessageisdisplayedforaperiodofthreeseconds:

(5) UsingtheSHC1HandheldInterrogatorreleasetheSearchlineExcelsignaloutput.

The output can be released by pressing ESC followed by on the keyboard.

4.3 Functional Checking

4.3.1 Functional Checking with Gassing Cell (Short Range versions only)Searchline Excel Cross-Duct incorporates a built in gassing cell for functional test purposes. In order to use the gassing cell, the mounting block lid must be in place, to maintain a gas tight seal.

Beforeusingthegassingcellforthefirsttime,removetheendsoftheplasticnozzles(withaknifeorwirecutters). Rubber end caps are used to seal the tubes afterwards.

4. Maintenance

Ensure Zero Gas Press Enter

Processing Data Please Wait...

Zero Calibrated

Air Shield

Slot for test filter

Gas In/Out

Gassing Cell

Transmitter

Mounting Block

Receiver

37

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Togetthebestaccuracywhenusingthegassingcell:

(1) Ensurethatthegassingcellcontainsfreshair,andperformazerocalibrationontheExcel

(2) ApplythetestgasandallowsufficienttimetofullyfillthegassingcellandcheckthattheSearchlineExcelCross-Duct output stabilises.

A flow rate of less than 0.5 litres per minute is advisable, to avoid pressurising the gassing cell.

(3) For a methane calibrated unit tested with 100%v/v methane (UL version) or 88%v/v methane (ATEX, IECEx version),theexpectedreadingcanbecalculatedfrom:

Gasreading=100%LEL/(2xductwidth)

A few examples are shown in the following table, and the tolerance to be applied is ± 20% of reading or ± 10%LEL (whichever is greater). The variability in the readings is due to a number of factors such as variation in air pressure,flowrate,andtolerancesinthegascomposition.

Test GasUL version

Test GasATEX, IECEx version

Duct Width Expected Reading

100% v/v Methane 88%v/v Methane 0.5m 100%LEL ± 20%LEL100% v/v Methane 88%v/v Methane 0.8m 60%LEL ± 12%LEL100% v/v Methane 88%v/v Methane 1.0m 50%LEL ± 10%LEL100% v/v Methane 88%v/v Methane 1.5m 33%LEL ± 10%LEL100% v/v Methane 88%v/v Methane 2.0m 25%LEL ± 10%LEL100% v/v Methane 88%v/v Methane 2.5m 20% LEL ± 10%LEL

(4) Aftercheckingthereading,ensurethatthegasisflushedoutofthegassingcell,withcleanairornitrogen,untilthereadingreturnstozero.

(5) Finally replace the rubber caps over the gassing ports.

4.3.2 Functional Checking with Test FiltersFunctionalcheckingoftheSearchlineExcelCross-Ductcanalsobedoneusingplastictestfilters(partnumber2104N3000).Plastictestfiltersinsertedinthemeasuringpathproduceinfraredabsorptionwhichapproximatesthat of methane gas. For the procedure see section 3.6.6.

Comparethegasreadingtotheoriginalvaluerecordedforthisunitwhentestedwiththisfilter.Providedthatthe reading is within ±15% LEL of the original value, the unit is working correctly.

Ifthegasreadingisnotwithintheexpectedrangeitispossiblethattheunitneedscleaningorre-zeroing.See section 4.1.

4. Maintenance

WARNING:

Testsgasesmaybeflammableand/ortoxic.Takeappropriateprecautionswhen handling

WARNING:

Take the necessary precautions to ensure safety when dealing with high concentration gases

38

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

5. Problem Solving

The majority of gas detector problems/faults can be diagnosed and corrected using the installation kit.

Theinstallationkitincludes:

• SHC1 Handheld Interrogator

• setoffunctionaltestfilters

An electrical multimeter is also useful when diagnosing electrical/wiring problems.

Refer to the troubleshooting tables in this chapter for a list of problems, possible causes and actions.

Caution: Searchline Excel Cross-Duct does not contain any user serviceable parts. Do not open or disassembletheTransmitterandReceiverunit,ortheHeatedReflectorPanel.Thewarrantyof units which have been opened is invalidated.

Note: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.

RS485 Modbus signal errors may occur when Excel is connected via a DXI00 (M) Termination Unit and is interrogated/commanded from a network control centre. For troubleshooting these issues refer to the DX100 Series Termination Units Technical Handbook.

If, after following the recommendations in this section, the problem persists, please make available the following informationbeforecontactingHoneywellAnalytics:

• Installation Check Sheet See Chapter 3.

• Any error message DisplayedontheHandheldInterrogatorscreen.

• Any error code DisplayedontheHandheldInterrogatorscreen.

Fault/Problem Causes Remedies

No mA output Electrical installation problem

1) Check that the +24V supply is reaching the unit. Voltage at the unit should be between +18V and +32V.

2) Check cables and connections to the unit, especially the 4-20mA loop connections.

3) Check that the unit has the correct type of 4-20mA output sink/source for use with the controller that it is connected to.

Output is 0mA (nominal)

Unit is in FAULT conditionConnect the SHC1 Interrogator to the unit and use its DIAGNOSTIC menu options to ascertain the reason for the FAULT report.

Beam block Check that beam path is clear from the Transmitter and Receiver to the Reflector. Remove any obstruction if present.

Heavy contamination of opticsCheck the Transmitter and Receiver windows and the Heated Reflector Panel for build up of contamination. Clean the windows if required. Re-zero unit.

Output is 2.5mA. (BEAM BLOCK)

Beam path is blocked Check that beam path is clear from the Transmitter and Receiver to the Reflector. Remove any obstruction if present.

Output is 3mA(LOW SIGNAL)

Heavy contamination of opticsCheck the Transmitter and Receiver windows and the Heated Reflector Panel for build up of contamination. Clean the windows if required. Re-zero unit.

39

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Output is 2mA(INHIBIT)

Unit has been inhibited by the Interrogator

Release output from INHIBIT state using SHC1 Interrogator.

Unit executing power-up routine

1) Wait for 1 minute. When power-up routine is completed satisfactorily the unit’s output should exit the INHIBIT state.

2) If unit remains in INHIBIT, check the +24V supply is reaching the unit. If the voltage is below +18V or is fluctuating above and below +18V, the unit may be being prevented from completing power-up. (This is an electrical installation problem.)

Comms Error 99 reported by Interrogator software

Wrong communication mode selected on the Interrogator

1) Select Change Mode option on the Interrogator.

2) Change the communication mode to Excel

Interrogator software version is incompatible with Excel software version

Version 1V0 Interrogator software to be used with Excels running 1V0 software.

Version 2V0 Interrogator software can be used with Excels running 2V0 software or higher.

Version 3V0 and 3V1 Interrogator software can be used with Excels running 3V0 software or higher.

The latest version of Interrogator software is 4V0. This version works with 3V0 and higher Excels, Optima and Optima Plus.

Comms Error 100 reported by Interrogator software

Incorrect communication connection

1) Check that Interrogator is correctly plugged into the IS socket on the DVC100(M)/DX100(M) junction box.

2) Check that the RS485 A and B wires from the Excel unit have been connected to the correct terminals inside the DVC100(M)/DX100(M) junction box

Excel unit is not powered up Check that the +24V supply is reaching Excel unit correctly. The Supply voltage at unit should be between +18V and +32V.

Interrogator battery lowCheck the Interrogator battery and replace if low. See Appendix A. Section A.4

Interrogator Installation Failed message when attempting initialisation

The installation has failed to meet the acceptable criteria for signal levels

1) Check that the signal levels reaching the Receiver are greater than 0.7 and less than 1.5. If not, check that the Reflector Panel is mounted opposite the Transmitter and Receiver unit and perpendicular to the beam.

2) Check that the correct range has been entered for the installed path length.

3) Check that there are no objects obscuring part or all of the beam path.

4) Check that the windows of the Receiver and Transmitter and the Heated Reflector Panel are clean.

5) Check that the structures that the Transmitter and Receiver are mounted on are stable and free from significant angular movement/vibration.

6) Check that there is no gas in the beam - which prevents successful zeroing.

5. Problem Solving

40

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

No signal or very low signal at Receiver

The beam path has become obscured

Check that the beam path is clear from Transmitter and Receiver to the Reflector Panel. Remove any obstruction if present.

No output from Transmitter

1) Check that the Transmitter is flashing. When viewed on the axis, an orange flash can be seen coming from the Transmitter.Alternatively, listen for a distinct ticking sound when the lamp flashes.

Note: The infrared beam is invisible and eye safe.

2) If the Transmitter is not flashing, check that the +24V supply is reaching the Transmitter correctly.

Unit does not respond exactly as expected to test filters

Plastic test filters are only an approximate simulation of gas

Searchline Excel units are calibrated on real gas. This results in a variation of the response of different Excel units to plastic test filters. See section 3.6.6

1) Check that the response to the test filters is within the limits stated in this handbook compared to the response obtained at initial installation. See section 4.3.2

2) Check that the correct test filter is being used.

Contamination of windows

1) Check the Transmitter and Receiver and Heated Reflector Panel windows for build up of contamination. Clean windows if required. See Chapter 4.

2) Re-zero unit.

Drift of unit’s zero position1) Verify that there is no gas in the beam path.

2) Re-zero the unit

Unit appears to be reporting a negative gas reading on the 4-20mA

Misinterpretation of INHIBIT, BEAM-BLOCK or LOW SIGNAL currents that are output on the 4-20mA

Searchline Excel does not report negative gas readings on the 4-20mA.

1) Configure controller/PLC to interpret and present currents below 4mA correctly, or

2) Familiarise operators with the interpretation of sub 4mA output currents from Excel as follows:

FAULT 0mA INHIBIT 2mA BEAM-BLOCK 2.5mA LOW SIGNAL 3mA, or3) Reconfigure the INHIBIT, BEAM-BLOCK and LOW SIGNAL

currents output by the Excel unit.

Diagnostics report Neg Gas Reading

Contamination of windows

1) Check the Transmitter and Receiver and Heated Reflector Panel windows for build up of contamination. Clean windows if required. See Chapter 4.

2) Re-zero the unit.

Negative drift of unit’s zero position

Re-zero the unit

Diagnostics report Baseline Drift

Contamination of windows

1) Check the Transmitter and Receiver and Heated Reflector Panel windows for build up of contamination. Clean windows if required. See Chapter 4.

2) Re-zero the unit.Drift of unit’s baseline Re-zero the unit

5. Problem Solving

41

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Diagnostics reportBad Temperature

Unit has been operated at a temperature outside its specified and certified range

1) When Ex certified equipment is operated outside its certified range, its type approval certification is invalidated along with its warranty. Such equipment should be removed from service in potentially explosive atmospheres.

2) Investigate the cause of the excessive temperature excursion and take steps to prevent recurrence. (e.g. fit sunshade or heat-shield, or relocate detector, etc.)

Diagnostics report Supply Fault

Incorrect supply voltage reaching unit

1) Check that the +24V supply voltage reaching the unit (it should be between +18V and +32V).

2) Identify the cause of incorrect supply voltage reaching the unit and rectify.

Diagnostics reportDSP Fault

Fault on the unit’s digitalPCB

If this fault is displayed when the unit is interrogated, it cannot be remedied in the field.

Diagnostics report NV-RAM Fault

A fault has been detected in the NV-RAM

If this fault is displayed when the unit is interrogated, it cannot be remedied in the field.

DiagnosticsreportRTC Fault

The time and date recordbeing stored by the RealTime Clock (RTC) has been lost

1) Re-enter the time and date using the Interrogator.

2) Cycle the power applied to the unit.

3) Verify that the time and date record was maintained after cycling the power.

DiagnosticsReport Volt Ref Fault

Voltage reference faultdetected

If this fault is displayed when the unit is interrogated, it cannot be remedied in the field.

5. Problem Solving

42

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

6.Specifications

6.1 System

Available Gases Methane

Range0 - 100%LEL

UL version - LEL level 5%v/v

ATEX, IECEx version – LEL level 4.4%v/v

Minimum Low Alarm Setting

20%LEL (0.5 – 2.0m) 10%LEL (2.0 - 5.0m)

Maximum High Alarm Setting

40%LEL (0.5 – 2.0m) 30%LEL (2.0 – 5.0m)

Path LengthShort Range 0.5 - 2.5mLong Range 2.5 - 5.0m

Speed of Response T90 less than 1 second

Output signal4 — 20mANormal operation(0 —100%LEL)

0mAFault

2mAInhibit

2.5mABeam blockConfigurable

3mALow signalConfigurable

Operating Temp.The Searchline Excel Cross-Duct operating temperature range is -40 °C to 50 °C (-40 °F to 122 °F).An internal duct temperature of up to 60 °C (140 °F) is acceptable, provided the ambient temperature outside the duct at the Transmitter and Receiver unit is within the operating range.

Humidity 0 — 99%RH Non-condensing

Pressure 91.5kPa — 105.5kPa (915 — 1055mBar, non-compensated)

Repeatability±10%LEL (<1metre duct width)

±2.5%LEL (1 - 5metre duct width)

TemperatureDrift (-40°C to+65°C)

±10%LEL @ zero±15%LEL @60%LEL

Warm-up Time Less than 5 minutes (operational), Less than 1 hour (fully stabilised)

Power Supply Receiver and Transmitter: 18 to 32V, Heated Reflector Panel: 18 to 28V

Power Consumption Tx/Rx total: 13W maximum Reflector: supply voltage dependent

Enclosure Material 316 Stainless Steel

Weight

Tx/Rx including mounting plate 13kg

Reflector panel

5kg (short range)

10kg (long range)

Vibration 2 — 60Hz, maximum peak to peak amplitude 1mm.

Divergence/ Misalignment Tolerance

Tx/Rx ±1.5° Reflector Panel ±5° (at 5m)

IP rating IP66 and 67

6.2 Response to other gasesSearchline Excel Cross-Duct is a methane gas detector. It should only be used to detect gas mixtures where methane is the main constituent (>70%) and the balance is C2 - C6 hydrocarbons.

43

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

7.Certification

7.1 GeneralTheSearchlineExcelCross-DuctTransmitterandReceiverunitiscertifiedtoExdandhasthefollowingATEX,IECExandULapprovalsforworldwideacceptance:

ATEX, IECEx

II 2 G Ex d IIC T5 (Tamb -40 to +65°C) Gb

Ex d IIC T6 (Tamb -40 to +40°C)

Certificatenumbers:

BAS98ATEX2165X

IECEx BAS 09.0100X

UL

Class 1 Groups B, C, D

Class1Zone1AExdIIB+Hydrogen(Amb-40°Cto+65°C)

File No. E91044

TheSearchlineExcelCross-DuctHeatedReflectorPaneliscertifiedtoExdandhasthefollowingATEXandULapprovalsforworldwideacceptance:

ATEX

II 2 G Ex d IIC Gb T3 (Tamb -40 to +60°C)

Certificatenumber:

Baseefa06ATEX0226X

UL

Class 1, DIV 1, Groups B, C, D

Tamb -40 to +60°C

File No. E91044

The Searchline Excel system has been designed, built and tested to meet the latest European standards for Radio Frequency Immunity (RFI). It has been tested and approved to BS EN 50270.

44

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

7.Certification

7.2 Conduit Technical Characteristics (ATEX, IECEx version)

Ingress Protection IP66 and 67.

Temperature Rating -40 to +105ºC.

ConstructionA helically wound galvanised steel core with cotton packing and enhanced oil resistant PVC covering. Covering material displays good resistance to dilute acids, alkalis and hydrocarbon products.

Colour Grey

Electrical Flash Voltage More than 24kV.

Insulation Resistance More than 100M ohms.

Connector Pull off Classifica-tion

FRG04: Heavy.

Conductor Crush Classification FRG04: Heavy.

Flame Propagation Flame dies in less than 30 seconds after ignition source is removed.

Approvals Bureau Veritas.

45

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

7.3CertificationLabelsATEX,IECEx

7.3.1 Transmitter

7.3.2 Receiver

7.Certification

46

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

7.3.3HeatedReflectorPanel

7.Certification

47

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

7.3.4 System Diagram

7.Certification

H

AZA

RD

OU

S A

REA

TRA

NSM

ITTE

R/S

ENSO

R E

NTR

Y

SUPP

LY E

NTR

YSA

FE A

REA

OPT

ION

AL

CO

NTR

OL

EQU

IPM

ENT

NO

TE 1

OPT

ION

AL

TRA

NSM

ITTE

R/

SEN

SOR

TER

MIN

ATIO

N U

NIT

DVC

100

(M) M

K2

Bas

eefa

03A

TEX0

261

IEC

Ex B

AS

09.0

125

AN

Y SU

ITA

BLE

ATE

X/IE

CEx

A

PPR

OVE

D S

ENSO

R/D

ETEC

TOR

SEN

SOR

EN

TRY

SEN

SOR

/D

ETEC

TOR

AN

Y SU

ITA

BLE

ATE

X/IE

CEx

A

PPR

OVE

D S

ENSO

R/D

ETEC

TOR

CO

MM

UN

ICAT

ION

SFI

XED

SO

CK

ET I.

S.O

UTP

UT

TO C

ALI

BR

ATO

R(F

AC

TORY

FIT

TED

)

HA

ND

HEL

DC

ALI

BR

ATO

RTY

PE S

CH

1B

asee

fa03

ATEX

0073

IEC

Ex B

AS

09.0

120

NO

TES

:1.

A

PPA

RAT

US

WH

ICH

IS U

NS

PE

CIF

IED

EX

CE

PT

TH

AT IT

MU

ST

NO

T B

E S

UP

PLI

ED

FR

OM

, NO

R

C

ON

TAIN

IN N

OR

MA

L O

R A

BN

OR

MA

L

CO

ND

ITIO

NS

, A S

OU

RC

E O

F P

OTE

NTI

AL

WIT

H

R

ES

PE

CT

TO E

AR

TH IN

EX

CE

SS

OF

250V

rms

O

R 2

50V

d.c

.2.

IN

STA

LL IN

CO

MP

LIA

NC

E W

ITH

IEC

600

79-1

43.

E

NTR

IES

: AN

Y S

UIT

AB

LY A

PP

RO

VE

D E

x e,

Ex

d, IE

CE

x e

& IE

CE

x d

CA

BLE

GLA

ND

/CA

BLE

.4.

E

NTR

IES

MU

ST

BE

SE

ALE

D T

O P

RO

VID

E A

DE

GR

EE

OF

PR

OTE

CTI

ON

OF

AT L

EA

ST

IP54

.5.

S

EN

SO

R E

NTR

Y: E

ITH

ER

DIR

EC

TLY

C

ON

NE

CTE

D O

R V

IA S

UIT

AB

LE G

LAN

D

- S

EE

NO

TE 3

.

48

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

7.Certification

7.3.5 ATEX Special Conditions of Safe Use

7.3.5.1 Transmitter and Receiver The integral supply cables must be mechanically protected and terminated in a suitable terminal or junction facility.

Thecoverfixingscrewsshallbegrade12.9minimum.

7.3.5.2HeatedReflectorPanelThe integral supply cables must be mechanically protected and terminated in a suitable terminal or junction facility.

In addition to the integral earth conductor, external equipotential bonding may be maintained via the rear mounting thread.

49

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

7.4CertificationlabelsUL

7.4.1 Transmitter

7.4.2 Receiver

7.Certification

50

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

7.4.3HeatedReflectorPanel

7.Certification

51

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

7.4.4 System Diagram With DX100(M) Termination Unit

7.Certification

TER

MIN

ATIO

NU

NIT

DX

100

(M)

UL

FILE

E13

6193

CO

MM

UN

ICAT

ION

SFI

XE

DS

OC

KE

TI.S

.O

UTP

UT

TOC

ALI

BR

ATO

R.

(FA

CTO

RY

FITT

ED

)

NO

TE2

CO

NTR

OL

EQ

UIP

ME

NT

NO

TE1

SE

NS

OR

AN

YS

UIT

AB

LEU

LLI

STE

DO

RC

LAS

SIF

IED

EX

PLO

SIO

NP

RO

OF

AP

PAR

ATU

S.

HA

ND

HE

LDC

ALI

BR

ATO

RTY

PE

SH

C1

UL

FILE

E13

6193

NO

TES

:

1.A

PPA

RAT

US

WH

ICH

ISU

NS

PE

CIF

IED

EX

CE

PT

THAT

ITM

US

TN

OT

BE

SU

PP

LIE

DFR

OM

,NO

RC

ON

TAIN

INN

OR

MA

LO

RA

BN

OR

MA

LC

ON

DIT

ION

SA

SO

UR

CE

OF

PO

TEN

TIA

LW

ITH

RE

SP

EC

TTO

EA

RTH

INE

XC

ES

SO

F25

0Vrm

sO

R25

0Vd.

c.

2.W

IRIN

GFR

OM

THE

HA

ND

HE

LDC

ALI

BR

ATO

R(S

HC

1)TO

THE

TER

MIN

ATIO

NU

NIT

(DX

100)

ISN

OT

TOE

XC

EE

D15

ME

TRE

SM

AX

.

3.IN

STA

LLE

QU

IPM

EN

TIN

CLU

DIN

GFI

ELD

WIR

ING

INA

CC

OR

DA

NC

EW

ITH

AR

TIC

LES

OF

THE

NAT

ION

AL

ELE

CTR

ICA

LC

OD

EFO

RD

IVIS

ION

1HA

ZAR

DO

US

LOC

ATIO

NS

.

SE

NS

OR

EN

TRY

(CO

ND

UIT

CO

NN

EC

TIO

NR

EQ

UIR

ED

WIT

HS

EA

L)

NO

NH

AZA

RD

OU

SA

RE

AS

UP

PLY

EN

TRY

(CO

ND

UIT

CO

NN

EC

TIO

NR

EQ

UIR

ED

WIT

HS

EA

L)

OP

TIO

NA

LTR

AN

SM

ITTE

RS

EA

RC

HLI

NE

EX

CE

LFI

LEN

o.E

9104

4

TRA

NS

MIT

TER

EN

TRY

P(C

ON

DU

ITC

ON

NE

CTI

ON

PR

EQ

UIR

ED

WIT

HS

EA

L)

HA

ZAR

DO

US

(CLA

SS

IFIE

D)L

OC

ATIO

NC

LAS

S1

DIV

.1G

RO

UP

SB

,C,D

.

52

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

HoneywellAnalyticswarrantstheSearchlineExcelCross-Ductagainstdefectivepartsandworkmanshipandwill repair or (at its option) replace any instruments which are or may become defective under proper use within 36monthsfromdateofshipmentfromHoneywellAnalytics.

This warranty does not cover consumable items, normal wear and tear or damage caused by accident, abuse, improper installation, poisons, contaminants or abnormal operating conditions. Under no circumstances shall HoneywellAnalyticsliabilityexceedtheoriginalpurchasepricepaidbythebuyerfortheproduct.

AnyclaimundertheHoneywellAnalyticsProductWarrantymustbemadewithinthewarrantyperiodandassoon as reasonably possible after a defect is discovered. In the event of a warranty claim please contact your localHoneywellAnalyticsServicerepresentative.

Thisisasummary,forfullwarrantytermspleaserefertotheHoneywellAnalytics“GeneralStatementofLimitedProduct Warranty” available upon request.

8. Warranty Summary

53

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

A.1 IntroductionThisappendixprovidesreferenceinformationabouttheSHC1HandheldInterrogator.

The interrogator provides the user end of a two-way communication link between the Excel system and the operator.

Itfeaturesfacilitieswhichlettheoperatorconfigure,align,functionallytestanddiagnosefaultsinthesystem.

Theappendixgives:

• an overview of the interrogator features

• information about how to connect the interrogator to the Excel systems

• basic user tasks, including switching on/off and changing the battery

• a detailed description of the menus which the interrogator provides

• problem solving information if trouble occurs when using the interrogator

Details of how to use the interrogator for different tasks with the system are given in Chapter 3 and Chapter 4 of this handbook.

A.2 OverviewThe interrogator consists of an LCD screen and four keypad buttons. It links to the Excel Receiver unit via an ISconnectorontheendofaflexiblecableconnectedtotheassociatedjunctionbox.

SHC1 Handheld Interrogator Main Features

Appendix A - Handheld Interrogator

ESC

Z - SHC1 EXCELInterrogator

CalibratorType SHC1

LCD screen

Up key

Enter key

Down key

Escape key

54

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

The interrogator is powered by a standard 9V battery and has a management system which reduces power consumption by placing the unit in an idle mode when it is waiting for user input or for a communication operation to complete.

The interrogator also features a 2k byte non-volatile RAM (NV-RAM) split into two sections. These sections are used to store the current operating mode and a backup copy.

Liquid Crystal Display ScreenThis screen consists of a two-line, 16-character dot-matrix liquid crystal display (LCD). The screen displays messages which communicate information from/to the user.

It displays a menu system that enables the user to select the command mode for the system, and can also displayinformationaboutthesystemconfigurationanditssettings,plusanyerrormessages.

Keypad ButtonsThe four keypad buttons are used to provide operator input in response to messages shown on the display.

Thisincludesmenuoptionselectionsandchangingparametervalues.Thefourbuttonsare:

UpMove to the previous menu option, list item, or increase a displayed data value. Move to the next menu option, list item, or decrease a displayed data value.

Down

ESC Escape Quit the current menu level or operation and return to the previous menu, e.g. stop displaying a list, abort a command. No change if already at the top level.

Enter Select, i.e. Invoke/accept, the currently displayed menu option, list item, data value, or configuration change.

Note: If the and keys are used to advance beyond the end of a list a wrap around to the other end of the list occurs.

A.3 Connection to SystemDetails of how to connect the interrogator to the Searchline Excel Cross-Duct are given in Chapter 3. The diagram shows a typical example.

Note: If connecting via a non-HA junction box then the SHC Protection Device needs to be used.

Appendix A - Handheld Interrogator

ESC

CalibratorType SHC1

55

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

A.4 Basic User TasksSwitching On

(1) Press for two seconds.

The unit recalls its previously set operating mode, i.e. EXCEL, OPTIMA or OPTIMA PLUS, and displays the following message for approximately three seconds:

The unit then displays the top level of the menu style interface in the following way:

During use the first line of the display shows the current level in the menu tree.

The second line displays the sub menu title, action to be invoked, or data value to be checked/changed.

Note: To change the operating mode at switch-on, e.g. from OPTIMA to EXCEL, press the ESC key whilst the initial message is displayed. This changes the mode and re-displays the message.

Switching Off(1) Select the Power Off option from the Main Menu,

Alternatively press the and ESC buttons simultaneously for a fast power off.

Notes:

1. The unit powers down automatically after five minutes of non-use.

2. The fast power off facility and auto power off are disabled when a menu option is selected that modifies the interrogator’s configuration.

Changing the BatteryTofit/replacethebatteryproceedasfollows:

(1) Loosen the four rear cover screws. Use a 2.5mm Allen hexagon key.

(2) Carefully lift the front half of the interrogator away from the rear cover. Ensure that the flexible connector between the keypad and the electronics module is not damaged.

(3) Unclip and remove the battery.

(4) Fit the new battery, reuse the protective sleeve.

(5) Carefullyrefitthefronthalfoftheinterrogatortotherearcover. Ensure that the flexible connector lies flat.

(6) Tighten the four rear cover screws.

Appendix A - Handheld Interrogator

Z - SHC1 Excel Interrogator 4V0

Main Displayvv

56

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Appendix A - Handheld Interrogator

A.5 MenusThe interrogator top level menu structure and menu choices are as follows.

All menu options are implemented by pressing the keypad key. The menu options and types are shown in the diagram:

where:

D a single set of data is displayed.

DL a list of data is displayed - use the and keys to navigate the entries in the list.

Sub another menu of options is displayed when this choice is selected - use the and keys to navigate the sub menu choices.

Sw the displayed option is immediately activated.

Tog the displayed option is toggled between three choices using the and keys.

Chapter 3 and Chapter 4 of this handbook describe how the Interrogator and menus are used when the system is being installed/in use.

Main Menu: Display

Main Menu: Calibrate

Main Menu: Diagnose

Main Menu: Config

Main Menu: Chg Mode

Main Menu: Power Off

Display: Gas Reading

Display: Signal

Magnitude

Display: Dynamic Reserve

Display: S/W Version

Calibrate: Display

Calibrate: Install

Calibrate: Set Time

Calibrate: Cal Sensor

Calibrate: Force mA

Calibrate: Normal mA

Calibrate: Show Status

Sub Sub Sub

DL

DL

Sub

D

DL

Sub

D

D

DD

Tog

DL

Sw

Sub

Sw

DL

Sw

Sub Sw D

57

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

A.5.1 Main MenuThismenuconsistsofthefollowingsubmenuoptions:

Display Display gas and other unit readings.

Calibrate Installandcalibratethesystem,forcetheanalogueoutput,showthecalibrationcoefficientsor show the instrument status.

Diagnose Inspect the fault and warning logs, perform a self-test or perform a soft reset.

Config Readtheconfigurationparametersoftheunit,updatetheuserconfigurationparameters.

Chg Mode Toggle the operating mode of the interrogator.

Power Off Switch the interrogator off.

A.5.2 Display MenuThissubmenudisplaysgasandotherunitreadings.Ithasthefollowingoptions:

Gas Reading Display the gas type and system status.

Signal magnitude Show the level of the sample and reference signals.

Dynamic Reserve Shows the acceptable drop in signal level before beam block occurs as a percentage of the current signal level.

S/WVersion Displays the system software version and the current time and date.

Gas ReadingDisplaythegastypeandsystemstatus.Thedisplayisinthefollowingformat:

where: gggggggg Gas name. For a special gas table this shows <Gnnn> where nnn is the identifier.

rrrrrr Gas reading.

uuuu Measurement units.

/ Thisisastatuscharacterwhichindicatesoneofthefollowing:

/ - A spinning line shows the system is operating normally i.e. in a fully active state.

| - A stationery line shows the system is in an inactive state.

W - Active Warning.

F - Active Fault.

B - Beam Block.

A - Alarm

Appendix A - Handheld Interrogator

Excel gggggggg rrrrrr uuuu /

58

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Signal MagnitudeShowthelevelofthesampleandreferencesignals.Thedisplayisinthefollowingformat:

where: aaaaaaa Signal magnitude for the sample channel.

bbbbbbb Signal magnitude for the reference channel.

Dynamic ReserveShows the acceptable drop in signal level before beam block occurs as a percentage of the current signal level.Thedisplayisinthefollowingformat:

where: xxx.xx The acceptable drop in signal level before beam block measured as a percentage of the current signal level.

S/WVersionDisplaysthesystemsoftwareversionandthecurrenttimeanddate.Thedisplayisinthefollowingformat:

where: vvVvv Version number of the Excel system software.

hh.mm System time as hours and minutes.

dd/mm/yy System date as day of the month, month number and the last two digits of the year.

A.5.3 Calibrate MenuThissubmenuisusedwheninstallingandcalibratingthesystem.Ithasthefollowingoptions:

Display Display system readings.*

Install Direct the alignment and initialisation of the system.*

Set Time Set the system real time clock time and date.

Cal Sensor Calibratethesystemzero.*

Force mA Fix the 4-20mA analogue output at a selected level.

Normal mA Restore the analogue output to its normal output state.

Show Status Showthecalibrationandconfigurationstatusofthesystem.

The options marked with an asterisk, (*), require the system’s analogue 4-20 output to be inhibited during their operation. Where this occurs then the following sequence is automatically added to the affected operation.

Appendix A - Handheld Interrogator

Sample: aaaaaaa Ref: bbbbbbb

Dynamic Reserve: xxx.xx %

Excel S/W vvVvv hh:mm dd/mm/yy

59

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Before the selected sub menu operation is started the following message is displayed for at least three seconds:

The analogue output is inhibited and the chosen sub menu operation proceeds. After the sub menu operation is completed, or aborted by pressing the ESCkey,thefollowingmessageisdisplayed:

Press toreleasethe4-20receiveroutputandthefollowingmessagewillbedisplayedforthreeseconds:

DisplayDisplay system readings. This choice is the same as the GAS READING DISPLAY option on the DISPLAY MENU.

Notes:

1. The 4-20 output is inhibited during the display. See the earlier description.

2. No spinning line is displayed as the receiver is not in a fully activated state.

InstallThis choice is used to complete the alignment and commissioning operations after the system is mechanically andelectricallyinstalled.Itprovidesasequentialsetofoperationsto:

• view the system type

• set the system path length

• perform a system self test

• check system alignment

• initialise the system and make it live

Note: The 4-20 output is inhibited during this procedure. See the earlier description.

System Type

TheinitialdisplayafterInstallischosenisinthefollowingformat:

Appendix A - Handheld Interrogator

Inhibiting 4-20 Please Wait

Press Enter To Release 4-20

4-20 Released

System Type tttttttt

60

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

where: tttttttt Systemtype.Thesystemtypedisplayedisoneofthefollowing:

Display Text System Type

Duct Mount 0.5 - 5m range system

Note: It is not possible to change the system type. This is set during calibration and configuration of the unit at the factory.

Path Length

Thefollowingmessageisdisplayed:

where: nnnn The path length in metres.

Thefollowingrangesofpathlengthcanbeentered:

System Type Minimum Range (m) Maximum Range (m) Step Size (m)

Duct Mount 0.5 5 0.1

Self Test

Thisstartsthesystemselftestprocess.Thefollowingmessageisdisplayed:

Whenfinishedtheinterrogatordisplaysthefollowingmessageforatleastthreeseconds:

Thefollowingmessageisnowdisplayed:

Alignment

No alignment adjustments are provided for the Searchline Excel Cross-Duct. If the mechanical installation is satisfactory Searchline Excel Cross-Duct can now be initialised.

Press Enter onthekeypadandthedisplayshows:

Appendix A - Handheld Interrogator

Path Length nnnn vv

Self Test

Please Wait

Checks Passed

Signals OK

SIG: TGT:

61

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Press Enterandthedisplaywillshowthefollowingmessage:

This message is displayed for three seconds at the end of a successful initialisation process.

Note: The Searchline Excel system is live after a successful initialisation.

Set TimeThis option lets you set the system’s time and date.

The initial display after SET Time is chosen is in the following format:

where: hh Hours.

mm Minutes.

Whenfirstdisplayedonlythecurrenthourisshown.

All settings are adjusted by means of the and keys on the keypad. After setting the hour the minutes are displayed.

After the time has been entered then the same process is used to set the date which is displayed in the followingformat:

Appendix A - Handheld Interrogator

Ensure Zero Gas then press Enter

Zero Cal OK

Installation complete

Time HH:MM hh:mm vv

Date DD/MM/YY dd/mm/yy vv

62

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

where: dd Day.

mm Month.

yy Last two digits of the year.

Note: The time and date will not be updated unless both are entered and accepted without error.

Cal SensorThismenuoptionzerosthesystem.

Notes:

1. The 4-20 output is inhibited during this procedure. See the earlier description.

2. There must be no gas in the system beam path whilst this procedure is carried out. The following message is displayed:

Thefollowingmessageisdisplayedwhilethecalibrationoperationisbeingperformed:

Ifthecalibrationissuccessful,thefollowingmessageisdisplayedforaperiodofthreeseconds:

Force mAThisoptionallowsthesystemsanalogueoutputsignaltobeadjustedtoafixedlevel,e.g.whensettingupasystemcontroller.Thefollowingmessageisdisplayed:

where: mmmmm Current to output.

This is adjusted using the and keys over the range 1mA to 21mA in steps of 0.1mA. After adjustment the outputisforcedtothesetlevelandthefollowingmessageisdisplayed:

where: mmmmm Analogue output current previously set.

Appendix A - Handheld Interrogator

Ensure Zero Gas Press Enter

Processing Data Please Wait...

Zero Calibrated

Fixed: mmmmmm mA Press Enter

O/P current mA mmmmmm vv

63

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Normal mAThis menu option returns the system to its normal analogue output state, irrespective of its previous state. If successful,thefollowingmessageisdisplayedforthreeseconds:

Show StatusThismenuoptiondisplaysthecalibrationandconfigurationstatusofthesystem.Thestatusinformationisdisplayedinthefollowingformat:

where: cccccccc... Titleofthecalibrationstatusfield.

sssssssss Current state of calibration.

The different settings from the list are selected using the and keys on the keypad.

Thecalibrationstatusfieldsandvaluesaregivenbelow:

Calibration Status Fields Display Text False State True State

Temperature Cal. Temp Sensor Uncalibrated Calibrated

Zero Calibration Zero Ratio Uncalibrated Calibrated

Span Calibration Span Sensitivity Uncalibrated Calibrated

4-20mA Calibration Analogue Output Uncalibrated Calibrated

Det. Temp. Comp. T Compensation Uncalibrated Calibrated

Det. Sens. Comp. Det Sensitivity Uncalibrated Calibrated

Installation Installation Required Complete

Valid Date Time Date and Time Estimated Set

Loop Test Analogue Check Failed Passed

A.5.4 Diagnose Menu

Thissubmenuhasthefollowingoptions:

Active Faults Display the active faults in the system.

Active Warns Display the active warnings in the system.

Self Test Perform a diagnostic system self test.

Soft Reset Reset the system.

Active FaultsThis menu option displays operational faults when the system is in service.

Appendix A - Handheld Interrogator

4-20mA Released

ccccccccccccccc

64

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

If there are one or more faults present, then the faults are displayed one at a time.

Use the and keys to navigate the list.

Ifnoactivefaultsarepresentthedisplayshowsthefollowingforthreeseconds:

The Diagnose sub menu is then displayed.

Ifthereareoneormorefaultspresent,thedisplayshows:

where: F Indicates that the message displayed is a fault.

hh:mm Time the fault occurred.

DD/MM/YY Date the fault occurred.

eeeeeee Fault description. See the following table for a list of error messages.

See also Chapter 6, Problem Solving.

Display Text Fault Description Meaning

Bad 4-20mA Loop ERR_EXCEL_LOOP_FAULT A fault has occurred in the 4-20mA signal loop.

DSP Fault ERR_EXCEL_DSP_FAULT Fault on the gas detector’s digital PCB.

Hardware Fault ERR_EXCEL_HW_FAULT A hardware fault has occurred.

NV-RAM Fault ERR_EXCEL_FRAM_FAULT A fault has been detected in the unit’s NV-RAM.

RTC Fault ERR_EXCEL_RTC_FAULTThe time and date record stored by the RealTime Clock (RTC) has been lost.

Software Fault ERR_EXCEL_SW_FAULT An gas detector software error has occurred.

Supply Fault ERR_EXCEL_SUPPLY_FAULT Incorrect supply voltage reaching the gas detector. Active WarnsThis menu option displays the active warnings in the system. They are displayed in the same way as described for Active Faults except that a W is displayed instead of Fonthefirstlineofthedisplay.

Display Text Fault Description Meaning

Alarm ERR_EXCEL_LOG_ALARM The Excel log has become damaged.

Bad Temperature ERR_EXCEL_TEMPERATURE_LIMITUnit has been operated at a temperature outside its specified and certified range.

Baseline Drift ERR EXCEL_DRIFT_LIMIT Drift of unit’s baseline.

Beam Blocked ERR_EXCEL_BEAM_BLOCKEDThe infrared beam between the Transmitterand Receiver has become blocked.

Neg Gas Reading ERR_EXCEL_NEGATIVE_DRIFT Negative drift of gas detector’s zero position.

Not Installation ERR_EXCEL_BAD_INSTALLATION Incorrect gas detector installation has occurred.

None Present

F-hh:mm DD/MM/YY eeeeeeeeeeeeeeee

Appendix A - Handheld Interrogator

65

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Overrange ERR_EXCEL_OVERRANGE An overrange signal has occurred.

Power Failed ERR EXCEL_LOG_POWER_FAIL The gas detector has suffered an internal power failure.

Reset Occurred ERR_EXCEL_RESET A gas detector reset has occurred.

Time Adjusted ERR_EXCEL_LOG_TIME_ADJUST The Excel log time has been changed.

Uncalibrated ERR_EXCEL_UNCALIBRATED The gas detector requires calibration.

Volt Ref Fault ERR_EXCEL_VOLTAGE_REF_FAIL Voltage reference fault detected.

Self TestThis option lets you start a system diagnostic self test.

Thefollowingmessageisdisplayedduringtheselftestprocess:

The following message is displayed for three seconds at the end of a successful self test process.

Soft ResetThis option lets you reset the system.

Thismessageisdisplayedduringtheresetprocess:

Thefollowingmessageisdisplayedforthreesecondswhentheprocessiscompleted:

A.5.5ConfigMenuThissubmenu letsyouchecktheconfigurationparametersof theunitandupdatetheuserconfigurationparameters.Ithasthefollowingoptions:

Show Gas Showthegasrelatedconfigurationparameters.

ShowConfig Showtheuserrelatedconfigurationparameters.

Show Install Showtheinstallationrelatedconfigurationparameters.

Show GasThisoptiondisplaystheusefulgastableconfigurationparametersinthefollowingway:

Appendix A - Handheld Interrogator

Processing Data Please Wait

Processing Data Please Wait

Unit Reset

cccccccccccccccc vvvvvvvvv

Checks Passed

66

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

where: ccccccc... Titleoftheconfigurationsetting.

vvvvvvvv Setting value.

Note: The settings are not field configurable:

Gas Configuration Parameters

Display Text Min Value Max Value Step Size

Gas ID Gas Ident

01 = Methaneall other IDs shown as G<nnn>

255 1

Gas Units Gas Units %LEL (Cross-Duct only)

Effective Full Scale Gas Full Scale 0.1 100000 0.05

ShowConfigThisoptiondisplaystheconfigurationparameterstheusercansetinthesamewayasfortheShowGasoption.Theconfigurablesettingsandvaluesareshowninthefollowingtable:

Configuration Parameters Display Text Min Value Max Value Step Size Default Values

Protocol Address Digital Address 0 255 1 0

Time to Block Block Warn Time 5s 600s 5s 30

Time to Fault Block Fault Time 0s 600s 5s 120

Max Response Maximum T90 1s 60s 1s 60

Analogue Style Analogue Mode Alarm or Continuous C

Inhibit Current Inhibit mA 0mA 3mA 0.05mA 2.0

Block Current Blocked mA 0mA 4mA 0.05mA 2.5

Low Signal Current Low Signal mA 0mA 4mA 0.05mA 3.0

Low Signal Level Low Signal % 0% 90% 1% 33%

Alarm Threshold Alarm Threshold 10% 100% 1% 20%

Report fault due to blockage

RPRT Blocked Fault Enable or Disable E

Show InstallThisoptiondisplaystheinstallationconfigurationparametersinthesamewayasfortheShowGasoption.Theconfigurablesettingsandvaluesareshownbelow:

Installation Configuration Parameters

Display Text Description

Path Length Path Length 0.5m min 5m max 0.1m steps

Appendix A - Handheld Interrogator

67

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

A.5.6 Chg ModeThis menu option toggles the operating mode of the interrogator between Excel, Optima and Optima Plus to matchthegasdetectoritisattachedto.Wheninvokedthemodeisdisplayedintheidentificationbanner(thesameastheonedisplayedwhentheunitisswitchedon)forthreesecondsasfollows:

where: aaaaaa The type of gas detector that the interrogator is currently set to, i.e. Excel, OPTIMA or OPTIMA PLUS.

A.5.7 Power OffThis menu option switches the interrogator off.

Alternatively press the and ESC buttons simultaneously for a fast power off.

Notes:

1. The unit powers down automatically after five minutes of non-use.

2. The fast power off facility and auto power off are disabled when a menu option is selected that modifies the unit’s configuration.

A.6 PROBLEM SOLVINGInterrogator problems that occur during communication with the system or as a result of a command failure willbedisplayedinthefollowingformat:

where: eee Error code.

ssssssss... Textual description of the error.

If an error message of this kind is displayed note down the error code and text description and contact HoneywellAnalytics.

Appendix A - Handheld Interrogator

Z - SHC1 aaaaaa Interrogator 4V0

Error: eee ssssssssssssssss

68

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

B.1 Terminology

Ex d

FlameprooforexplosionproofwithintheconfinesoftheEuropeanseriesofstandardsEN60079.Anenclosurethat can withstand the pressure developed during the internal explosion of an explosive mixture and that prevents transmission of the explosion to the explosive atmosphere surrounding the enclosure.

Ex e

IncreasedsafetywithintheconfinesoftheEuropeanseriesofstandardsEN60079appliedtoelectricalapparatusthat does not produce arcs or sparks in normal service, in which additional measures are applied so as to give increased security against the possibility of excessive temperatures.

Instrument Assisted Alignment (IAA)

AmethodofcommissioningtheExcelsystemusingtheassociatedelectronicHandheldInterrogatordevice.The process will not allow the Excel system to initialise unless the alignment of the Receiver and Transmitter is correct and the signal strength is correct.

IS

Intrinsicallysafe,apparatusinwhichthecircuitsthemselvesareincapableofcausingignitionofaflammablegas.

Lower Explosive Limit (LEL)

Thevolumeofflammablegasorvapourinairbelowwhichanexplosivegasatmospherewillnotbeformed.

RS485

An industry-wide serial communication link protocol.

Turbo heating

Increased Transmitter window heating at low operating temperatures.

Appendix B - Glossary

69

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

B.2 Open Path Detector Measurement UnitsOpenpathdetectorsmeasuretheamountofgaspresent inthebeam.However,theycannotdiscriminatebetween a low concentration gas cloud over a large area and a high concentration gas cloud in a small area. Generally, gas readings of LEL.m (Lower Explosive Limit metres) are used. LEL.m is calculated by multiplying thesizeofagascloudbyitsconcentration.

Anopenpathalarmsetat1LEL.mwouldbetriggeredbyanyofthesituationsshownbelow:

The Searchline Excel Cross-Duct operates with a very short path length, making it reasonable to assume that the gas concentration is uniform across the duct. Therefore Searchline Excel Cross-Duct uses the duct width to convert the measured gas reading from LEL.m to %LEL. It is important that the duct width is entered correctlyduringcommissioningotherwisethedetectorcouldreportasignificantunderoroverreadofgasconcentration.

B.3 AbbreviationsEMC Electro-Magnetic Compatibility

IAA Instrument Assisted Alignment

IP Ingress Protection

IR Infrared

IS Intrinsically Safe

LEL Lower Explosive Limit

NPT National Pipe Thread

RFI Radio Frequency Interference

UL Underwriters Laboratories

Appendix B - Glossary

100% LEL

1m

2m

10m

ESC

CalibratorTypeSHC1

ESC

CalibratorType SHC1

50% LEL

ESC

CalibratorTypeSHC1

ESC

CalibratorType SHC1

10% LEL

ESC

CalibratorTypeSHC1

ESC

CalibratorType SHC1

70

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

C.1 System UnitsThe following table lists the different types of system units and provides the part numbers for the various certificationoptions.

All types of Transmitters and Receivers include conduit and glands.

Short Range 0.5m – 2.5m

2104N0011Short range cross duct system 0.5m to 2.5m. ATEX approved, current source with DVC100M MK2 interface box and single tile heated reflector panel

2104N0031Short range cross duct system 0.5m to 2.5m. ATEX approved, current sink with DVC100M MK2 interface box and single tile heated reflector panel

2104N1010Short range cross duct system 0.5m To 2.5m. UL approved, current source including single tile heated reflector panel

2104N1030Short range cross duct system 0.5m To 2.5m. UL approved, current sink including single tileheatedreflectorpanel

Long Range 2.5m – 5.0m

2104N0021Long range cross duct system 2.5m to 5.0m. ATEX approved, current source with DVC100M MK2 interface box and four tile heated reflector panel

2104N0041Long range cross duct system 2.5m to 5.0m. ATEX approved, current sink with DVC100M MK2 interface box and four tile heated reflector panel

C.2 General

Accessories

Handheld Interrogator and accessories

04230-A-1001 Hand Held Interrogator ATEX Certified (4V0 software) for Optima, Optima Plus and Excel

2104B2351 Hand Held Interrogator UL Certified (4V0 software) for Optima, Optima Plus and Excel

2108B1455 Hand Held EEPROM upgrade (4V0)

04320-A-1025 SHC Protection Device Module and Lead

2104B6250 SHC Calibrator Connector System 10m

DVC/DX Interfaces

2104B6212 DVC100M MK2 Termination Unit ATEX with MODBUS capability

2104B2382 DX100M XP Termination Unit UL with MODBUS capability

Installation Accessories

2104D0295 Sun/Heat Shade (Deluge Cover)

00780-A-0100 Honeywell Analytics Junction Box

210-190-045 Killark Junction Box (excludes terminals)

2992A0071 Conduit Assembly for Excel UL certified

0230-0069 Stainless Steel enclosure NEMA 4X 3/4” NPT UL

02104-N-9880 Upgrade to Nickel Plated Glands

Appendix C - Accessories & Spare Parts

71

MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook

Gas Test Equipment

2104N3000 Searchline Excel Cross-Duct Test filters kit & Manual

2108D0271 Remote Gassing Pipe

Manuals (Hard Copy)

Note: Electronic copies of the manuals are supplied on CD with each instrument

2104M0520 Searchline Excel Cross-Duct Technical Handbook (English)

2104M0409 DVC100(M) MK2 Termination Unit Quick Start Guide Guide (English)

2104M0701 DX100 Series Termination Units Technical Handbook (English)

2104M0524 Searchline Excel Cross-Duct Test Filter Leaflet (English)

Cross-Duct

2104B0715 Heated Reflector Panel for Short Range ATEX

2104B0717 Heated Reflector Panel for Short Range UL Certified

2104B0716 Heated Reflector Panel for Long Range ATEX

2104D2537 Retro-reflector mounting plate for Long Range

2104D2536 Retro-reflector mounting plate for Short Range

2104D2505 Mounting plate, Cross-Duct, Stainless Steel

2104D2506 Support strap, Cross-Duct mounting plate

2104D2542 Support strap, Cross-Duct retro-reflector for Long Range

2104D2541 Support strap, Cross-Duct retro-reflector for Short Range

Appendix C - Accessories & Spare Parts

Issue 3 03/2013

H_MAN0889_EMEAI

2104M0520_A03993

©2013HoneywellAnalytics 1268

3

Please Note:While every effort has been made to ensure accuracy in this publication, no responsibility can be accepted for errors or omissions. Data may change, as well as legislation and you are strongly advised to obtain copies of the most recently issued regulations, standards and guidelines. This publication is not intended to form the basis of a contract.

Contact Honeywell Analytics:

Find out more

www.honeywellanalytics.com

Europe, Middle East, Africa, IndiaLife Safety Distribution AGJavastrasse 28604 HegnauSwitzerlandTel: +41 (0)44 943 4300Fax: +41 (0)44 943 4398India Tel: +91 124 [email protected]

AmericasHoneywell Analytics Inc. 405 Barclay Blvd.Lincolnshire, IL 60069USATel: +1 847 955 8200 Toll free: +1 800 538 0363 Fax: +1 847 955 [email protected]

www.honeywell.com

Technical ServicesEMEAI: [email protected]: [email protected]: [email protected]

Asia Pacific Honeywell Analytics Asia Pacific #508, Kolon Science Valley (I) 187-10 Guro-Dong, Guro-Gu Seoul, 152-050 Korea Tel: +82 (0)2 6909 0300Fax: +82 (0)2 2025 [email protected]