Honeywell Searchline Excel Cross-Duct Technical Handbook Download Page 5

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MAN0530 Issue 09 October 03

Searchline Excel

2104M0506

CONTENTS

SAFETY

HELP US TO HELP YOU

1. INTRODUCTION

2. OVERVIEW

2.1

Introduction

2.2

Transmitter

2.3

Receiver

2.4

Adjustable Mountings

3. INSTALLATION AND OPERATION

3.1

Introduction

3.2

Siting and Mounting

3.3

Electrical connections

3.4

Power supply

3.5

Unpacking

3.6

Installation procedure

3.7

Alignment and commissioning

3.8

System Controller calibration

3.9

Installation Checks/Tests

4. CROSS-DUCT EXCEL

4.1

Introduction

4.2

Gas Detector Description

4.3

Installation and Operation

4.4

Installation Procedure

4.5

Electrical Installation

4.6

Initialising the Excel Gas Detector

4.7

Maintenance

4.8

Problem Solving

5. MAINTENANCE

5.1

Inspection and Cleaning

5.2

Functional Checking

5.3

Calibration Check using the Gassing Cell

5.4

Display Gas Reading

5.5

Alignment Telescope

5.6

Operational Maintenance (FM)

Summary of Contents for Searchline Excel Cross-Duct

Page 1: ...Searchline Excel Infrared Gas Detectors Open Path and Cross duct Technical Handbook ...

Page 2: ... 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 Operatorsmustbefullyawareoftheactiontobetakenifthegasconcentrationexceedsanalarm level 7 Dismantling or repair of equipment should be carried out in the safe area only...

Page 3: ...d If in doubt the user should contact ZellwegerAnalytics Limited for advice 3 Effect of explosive atmosphere on materials SearchlineExcelismadefrommaterialswhichexhibitgoodresistancetocorrosiveandsolvative substances TheExdenclosuresaremadefrom316stainlesssteelandtheexplosionprotected windows are made from toughened soda lime glass Zellweger Analytics are not aware of any significant effects of ex...

Page 4: ...de the following form for you to photocopy complete and return to us so that we may take the appropriate action HELPUSTOHELPYOU Marked up copies attached as appropriate Yes No Please inform me of the outcome of this change Yes No For Marketing Communications ZellwegerAnalytics Limited Actioned By Date Response Date To Marketing Communications ZellwegerAnalytics Limited Hatch Pond House 4 Stinsford...

Page 5: ...edure 28 3 7 Alignment and commissioning 34 3 8 System Controller calibration 49 3 9 Installation Checks Tests 50 4 CROSS DUCT EXCEL 57 4 1 Introduction 57 4 2 Gas Detector Description 57 4 3 Installation and Operation 58 4 4 Installation Procedure 61 4 5 Electrical Installation 65 4 6 Initialising the Excel Gas Detector 68 4 7 Maintenance 70 4 8 Problem Solving 72 5 MAINTENANCE 73 5 1 Inspection ...

Page 6: ... 84 8 2 CENELEC 85 8 3 UL 91 8 4 CSA FM 96 APPENDIX A HANDHELD INTERROGATOR 100 A 1 Introduction 100 A 2 Overview 100 A 3 Connection to System 101 A 4 Basic User Tasks 102 A 5 Menus 103 A 6 Problem Solving 116 APPENDIX B GLOSSARY 117 B 1 Terminology 117 B 2 Measurement Units 117 B 3 Abbreviations 118 APPENDIX C ACCESSORIES SPARE PARTS 120 C 1 System Units 120 C 2 General 120 ...

Page 7: ... 4 20mA analogue output equivalent to 0 5 LEL m Lower Explosive Limit metres of gas NOTE THE INFRARED BEAM IS INVISIBLE AND EYE SAFE Searchline Excel is designed for use in the most demanding environments applications and provides a sensitive fast and reliable response The sophisticated open path technology provides immunity to sunlight and minimises the effects of environmental factors such as ra...

Page 8: ... as follows WARNING Indicates hazardous or unsafe practice that could result in severe injury or death to personnel 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 Zellweger Analyt...

Page 9: ...basis for open path gas detection There are no transceiver units or retro panels available for the Searchline Excel except for the Cross Duct version which is only for use between 0 5 and 5 metres path length For a description of Cross Duct Excel see Chapter 4 PL612 or other junction box Flexible conduit DVC100 DX100 DX100 M or other junction box Mounting bracket Pivot block Monitored path 5 200m ...

Page 10: ...d flexibility of Searchline Excel and its mounting arrangements are intended to make correct installation design as simple as possible Installation details are given in Chapter 3 2 2 TRANSMITTER The Searchline ExcelTransmitter produces an intense collimated infrared beam which is produced by a Xenon arc flashlamp The flashlamp s infrared output is collimated using mirrors which enables a more unif...

Page 11: ...l Receiver collects infrared radiation from the Transmitter and performs measurements to enable hydrocarbon gases in the beam path to be detected Infrared radiation is collected by a single silicon lens which is common to both the sample and reference measurement channels This radiation is divided by a beamsplitter and fed to two filtered detectors sample and reference The sample detector input is...

Page 12: ...ulations to determine the correct gas reading and output state The primary output of the Receiver is a signal in the range 4 20mA and is available as either source or sink options For most applications the output is calibrated for a range of 0 to 5 LEL m See Appendix B for the explanation of LEL m and other terms The Receiver also features an RS485 output which is used to communicate with the asso...

Page 13: ... Made from stainless steel Fully adjustable for alignment Coarse and fine settings in both horizontal and vertical planes Adjustment range Vertical 45o Horizontal 90o Alignment details are given in Chapter 3 Clamp nut Mounting bracket adjusting screw 2 off Adjustment clamp lock screw 2 off Clamp nut Pivot block adjusting screw 2 off Adjustment clamp lock screw 2 off 2 OVERVIEW ...

Page 14: ...nded 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 If you have any queries concerning your installation design contact Zellweger Analytics or your local agents Zellweger Analytics is committed to ensuring that customers achieve reliable operation of their Searchline Excel Gas De...

Page 15: ...ignificantly to the overall reliability and availability When locating units attempt to avoid areas where they may be adversely affected by the following 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 If close proximity t...

Page 16: ...arthquake the units of an Excel gas detector will become misaligned with respect to each other Provided that the Excel units do not suffer from direct mechanical impact damage during an earthquake they should remain undamaged by such events Anti vibration mounts are unlikely to be of any benefit and are not recommended After an earthquake it is recommended that Excel gas detectors are visited and ...

Page 17: ...s etc e Parking loading cranes vehicle temporary stops e g bus stops road junctions etc f Vegetation e g shrubs bushes branches etc if currently clear movement due to weather and future growth or planting must be considered Note Where c and d cannot be avoided consider indicating the beam by marking the walkway or road with paint Unit cowl Telescope clearance arc radius more than 30cm Beam clearan...

Page 18: ...e supporting structure shown is recommended 5 5 3 15 4 5 75 5 500mm minimum 500mm minimum Concrete foundation 500mm minimum Up to 3m 150mm dia steel pipe nominal 6mm wall thickness Excel mounting plate U bolts 8mm dia 166mm centres Note The pipe can be filled with concrete to provide extra robustness if necessary 3 2 5 Orientation Searchline Excel is solar immune and therefore there is no need to ...

Page 19: ...e instrument earth Star earthing arrangements minimise earth current crosstalk d The shields of the field cabling should not be connected such that earth loops are produced or in a manner that will result in the shields carrying large currents from heavy plant or equipment e Ideally the field cable shield should be connected to the units green yellow GND wire providing a single continuous earth sh...

Page 20: ...ae of high powered radio radar and satellite communication equipment 3 3 2 Receiver Connections via DVC100 3 3 3 Receiver Connections via DX100 24V DC supply 4 20mA output 0V DC supply Rx 0V Rx SIG Rx 24V 8 Instrument clean earth Cable shield Blue B Orange A TB1 TB2 Green GND Yellow Red 24V White 4 20 Black 0V DX100 Junction Box Receiver connections Control cabinet connections Safety protective gr...

Page 21: ...Modbus Drain 0VDC in Cable shield Instrument clean earth DX100 M Junction Box Receiver connections Control cabinet connections Safety protective ground Instrument clean earth Cable shield The earth bonding arrangement must ensure that the maximum peak voltage between the unit case earth and any field cable conductor is less than 350V Voltages in excess of this can cause permanent damage to the uni...

Page 22: ... length of 1km between the unit and the DVC100 DX100 DX100 M is permissible RS485 compliant The connections are as follows Wiring with DVC100 DX100 Blue B Orange A Black 0V White 4 20 Red 24V Green GND Yellow 8 Blue B Orange A Black 0V White 4 20 Red 24V Green GND Yellow Instrument earth 0V DC supply 4 20mA output 24V DC supply Rx 0V Rx SIG Rx 24V Cable shield Instrument clean earth Control cabine...

Page 23: ...unction box mounted on Receiver mounting plate DX100 M junction box mounted in a convenient and accessible position Modbus A Modbus B Screen Modbus Drain 24VDC in 4 20mA out 0VDC in Cable shield Instrument clean earth TB2 TB1 1 Instrument clean earth Cable shield Safety protective ground The earth bonding arrangement must ensure that the maximum peak voltage between the unit case earth and any fie...

Page 24: ...0 1 300 Turbo heating disabled 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 0 5mm2 4mm2 20AWG 12AWG DX 100 DX100 M 0 5mm2 4mm2 20AWG 12AWG PL612 0 5mm2 6mm2 20AWG 10AWG 3 4 2 Power Supply Connections Turbo heating Disabled When connected as shown in section 3 3 4 Transmitter Connections all ra...

Page 25: ...rd 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 5 UNPACKING 1 Carefully unpack the equipment observing any instructions that may be printed on or contained within the packaging 2 Check the contents for damage and against the packing note for deficiencies In the event of damage or loss in transit notify the carri...

Page 26: ...ets with grub screws 2 x Pivot Blocks 4 x Adjustment Clamps with grub screws with grub screws 4 x Nyloc Self locking Nuts 4 x Washers M12 or M20 6 x Mounting Bracket 8 x Junction box Mounting Bolts Fixing Bolts M10 or M12 2 x Isolation Kit 3 INSTALLATION AND OPERATION 3 INSTALLATION AND OPERATION ...

Page 27: ... SI ON S W idt h 5 51 in 1 40 m m He igh t 5 9 0 in 1 50 m m De pt h 5 98 in 1 52 m m He igh t wi th se ns or 1 0 63 in 2 70 m m 11 1 3in 2 82 m m wi th O se ns or fitt ed 5 51 in 1 40 m m He igh t 5 9 0 in 1 50 m m De pt h 5 98 in 1 52 m m He igh t wi th se ns or 1 0 63 in 2 70 m m 11 1 3in 2 82 m m wi th O se ns or fitt 2 2 3 1U NI T DI M EN SI ON S W idt h 5 51 in 1 40 m m He igh t 5 9 0 in 1 5...

Page 28: ...th the Receiver and the Transmitter 1 Ensure that the gas detector equipment supplied is compatible with the required application i e short medium or long range 2 Fit the mounting bracket and isolation kit to the mounting plate for the unit as shown Mounting plate Mounting bracket Isolation kit 8 3 Fit the mounting plate to the supporting structure The plate can be fitted in one of the following w...

Page 29: ... 298 312 336 340 74 84 140 143 150 181 Always mount plate this way up 6mm thick Stainless Steel Plate to BS1449 PT2 1983 316 Notes 1 Drawing is not to scale 2 Mounting plate fixing holes are clear Searchline Excel gas detector component mounting holes are tapped 3 The mounting plate fixings are not supplied Identity Quantity Size Used For A 8 7 5mm Dual 2 pipe or pole mounting flat surface mountin...

Page 30: ...unction box mounting G 4 M6 tapped Sun heat shade mounting H 3 M8 tapped Short range Transmitter and all Receiver brackets J 3 M10 tapped Medium Long range Transmitter mounting bracket The following drawings show typical mountings M8 mounting bolt 4 off not supplied using holes B Mounting Plate Fixed to Flat Surface 6in U bolt 2 off not supplied using holes B Mounting Plate Fixed to Single Pipe Po...

Page 31: ... blocks and clamps is as follows Mounting stud Adjustment clamp Pivot block 5 Tighten the adjustment clamp s grubscrews until they just grip the unthreaded part of the stud 6 Fit the pivot block to the mounting bracket using a self locking clamp nut and washer M12 or M20 The correct orientation for the pivot blocks and mounting brackets is as follows Self locking clamp nut and washer Mounting brac...

Page 32: ...ws until they just grip the unthreaded part of the unit s mounting stud 9 Fit the unit to the pivot block using a self locking clamp nut and washer M12 or M20 Do not fully tighten the nut At this point position the units on their mountings so that their optical windows face each other as shown Ensure that the adjustment clamp s stub lever is approximately centrally positioned between the pivot blo...

Page 33: ...nd Commissioning If the units are to be installed with junction boxes other than DVC100 DX100 DX100 M types ensure that the boxes have a M20 cable gland entries for BASEEFA units or 3 4 NPT for UL and CSA b terminals for five wires and an earth 2 Remove the M20 blanking plugs if fitted and attach the Searchline Excel Transmitter and Receiver cables to their junction box Fit the locking rings if su...

Page 34: ...ver and the alignment procedure repeated The Handheld Interrogator is then attached to the Receiver to finally commission the equipment and depending on the type of Receiver may need to be used to assist in fine tuning the alignment The procedure can be performed by a single technician Each gas detector unit features a mounting assembly that allow both coarse and fine mechanical adjustment in the ...

Page 35: ...errogator see Appendix C Spare Parts Optional SHC Protection Device see Appendix C Accessories Spare Parts see Note 8 Appropriate plastic test filters see Chapter 5 section 5 1 2 3mm hex Allen key with additional 5mm key for mid long range gas detectors 19mm spanner with additional 30mm spanner for mid long range gas detectors Notes 1 Ideally carry out the alignment procedure on a clear day 2 Get ...

Page 36: ...screws should need to be tightened Further tightening later on will affect the fine adjustment and should be avoided Note The unit can still be moved by the adjustment screws 3 7 4 Accurate Alignment The procedure for accurately aligning the Transmitter and Receiver units is the same Before making any adjustments consult the following table to ensure that the correct type of telescope is used with...

Page 37: ...e telescope assembly This telescope assembly consists of a telescope and mirror assembly attached to a datum mount that features a latching mechanism It can be used with either the Trident or non Trident types of Excel units When used with the non Trident Excel the alignment may also need to be fine tuned and then verified using the SHC1 Handheld Interrogator The latches are used to lock the whole...

Page 38: ...ting latch assembly Cowl Latch 2 off c Locate the latch mounting hooks behind the back of the unit 2 3 3 d Rotate the telescope to a comfortable viewing position and then secure the latches as indicated by arrow 3 A horizontal viewing position is the easiest to interpret Now align the units by continuing with step 5 3 INSTALLATION AND OPERATION ...

Page 39: ...the datum mount the telescope can be rotated to a convenient viewing position To remove the telescope assembly reverse the following mounting procedure a Align the telescope s two datum mount bayonet slots with the two locating pins on the cowl of the unit as shown Bayonet slot 2 off Mirror assembly Bayonet locating pin 2 off Datum mount Locking handle Alignment telescope Excel unit Telescope view...

Page 40: ...compression springs After attaching the telescope assembly align the units by continuing with step 5 5 Align the Excel unit using the two sets of assembly adjustment screws so that the cross hairs viewed through the alignment telescope are centred on the window of the other Excel unit Cross hairs Mirror Distant Excel unit Telescope viewfinder Before alignment View the image with the eye placed app...

Page 41: ...djusters as they have been factory set Clamp nuts Mounting bracket adjusting screw 2 off Adjustment clamp lock screw 2 off Pivot block adjusting screw 2 off Adjustment clamp lock screw 2 off Clamp nuts Mounting bracket adjusting screw 2 off Adjustment clamp lock screw 2 off Pivot block adjusting screw 2 off 6 Iteratively tighten and loosen each pair of adjustment screws sequentially in the horizon...

Page 42: ...b section 3 7 5 Commissioning the Gas Detector This process consists of the following steps Connect the Handheld Interrogator to the gas detector Power up the gas detector and check set the mode of the Interrogator for operation with the installed Excel gas detector Set the gas detector real time clock Complete the alignment process Finish up Connecting the Interrogator Connect the SHC1 Handheld I...

Page 43: ...ed for this procedure Carry out the following procedure to connect using the protection device 1 Isolate all power supplies 2 Remove the cover of the junction box 3 Hard wire the flying lead of the SHC Protection Device to the communications link terminals in the box as shown 4 Connect the Interrogator to the IS connector on the end of the SHC Protection Device Powering Up 1 Apply power to the Exc...

Page 44: ...ion 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 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 ...

Page 45: ...pad 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...

Page 46: ...minimum and maximum path length entry options for each gas detector are Gas Detector Type Minimum Range m Maximum Range m Step Size m 40m Range 5 40 1 120m Range 20 120 1 200m Range 20 200 1 9 When finished press Enter on the keypad A self test routine is started and the display shows the following message Self Test Please Wait When the test is successfully finished the following message is displa...

Page 47: ...lescope assembly If this type of alignment telescope was used with a Trident type Excel gas detector there is no need to further optimise the alignment using the SHC1 Handheld Interrogator When the SIG and TGT bar graphs are displayed on the SHC1 screen SIG will always be greater than TGT and installation can proceed to the next stage by pressing Enter and following step 12 Latch style Trident typ...

Page 48: ...plane and simultaneously rotating them inopposite directions h Repeat this for the other pair of grub screws i Press Enter and the signal levels are checked With the SIG level is greater than the TGT level the signal check should pass and the screen should display the following message Signals OK Notes 1 If SIG is less than the TGT value the following message is displayed Low Signal Enter to Retry...

Page 49: ...when any menu option is selected that modifies the unit s configuration 3 Disconnect the Interrogator from the gas detector reversing the process described at the beginning of section 3 7 5 3 8 SYSTEM CONTROLLER CALIBRATION This procedure is used to set up the system controller using the Searchline Excel gas detector A chosen fixed output signal is sent from the Excel gas detector to the system co...

Page 50: ...s to normal operation 12 Turn off the Interrogator and disconnect it from the gas detector 3 9 INSTALLATION CHECKS TESTS The following information is for the guidance of personnel carrying out installation checks tests on Searchline Excel In general it should be noted that Searchline Excel should only be installed by fully trained personnel trained by Zellweger Analytics or an authorised Zellweger...

Page 51: ...K TEST TRANSMITTER Mount Rigidity Mount Rigidity Vibration Vibration Excess heat Excess Heat Supply Voltage Supply Voltage Earthing Earthing RFI EMC RFI EMC Contaminants Contaminants BEAM OBSTRUCTIONS BLOCKS cont TEST FILTER LEL m Response LEL m Pass Fail 4 200 mA LOOP INTEGRITY Pass Fail Untested FAULT WARNING LOG Clear Faults Warnings cont INSTALLATION SATISFACTORY Yes No SIGNED INSTALLED BY PRI...

Page 52: ...ENELEC UL CSA FM Mount Rigidity Check that the units have been mounted securely to the supporting structure Check that the supporting structure is sufficiently rigid to maintain alignment in the anticipated operating conditions A maximum angular movement of 0 5o is allowable As an approximate guideline a sufficiently rigid mount supporting structure will only move a few millimetres not more than 6...

Page 53: ... 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 g...

Page 54: ...on etc If there is a realistic possibility that they could cause a significant problem enter a brief description e g Personnel in corridor Loading bay vehicles Test Filter After completing the installation procedure enter the DISPLAY mode and test the gas detector response with a plastic test filter Enter the nominal value of the test filter the unit s displayed response and mark the Pass or Fail ...

Page 55: ... operating environment which in the trained installer s opinion could or will result in unreliable operation mark the NO box Reasons for declaring an installation unsatisfactory could include excessive movement vibration of unit s mounting 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...

Page 56: ...4M0506 Customer Notified Make sure that the relevant customer operator is notified of the installation problem s Mark box accordingly System Status Upon leaving note the gas detectors status i e operational or nonoperational 3 INSTALLATION AND OPERATION ...

Page 57: ...S DETECTOR DESCRIPTION Transmitter Mounting plate Mounting cell Conduit Junction box type DVC100 shown Receiver Double glazed retro reflector Path 0 5m 5m The Cross Duct Searchline Excel gas detector consists of a Transmitter and Receiver which are fixed to a mounting block and a separate retro reflector The Transmitter and Receiver are mounted on a cast metal block mounting cell that houses a bea...

Page 58: ...gth and the double pass of the beam across the duct 4 2 3 Retro Reflector Using a retro reflector panel has a number of advantages for a Cross Duct gas detector Because the infrared beam crosses the duct twice it will be absorbed twice by any gas present This makes the gas detector more sensitive to gas than a single pass gas detector Sensitivity to vibration or misalignment is greatly reduced The...

Page 59: ...r to the optical axis of the Transmitter Receiver assembly 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 Depending on the duct width the Cross Duct Excel will tolerate up to three degrees of angular misalignment of the mounting plate or 15 degrees tilt of the retro reflector It is not advisable to install the C...

Page 60: ...umed to be 24V 2 All connections along the cable are sound and have zero resistance 4 3 4 Unpacking Carefully unpack the equipment observing any instructions that may be printed on or contained within the packaging Check the contents for damage and against the packing note for deficiencies In the event of damage or loss in transit notify the carrier and Zellweger Analytics Limited or your local ag...

Page 61: ...h 5 9 8 in 1 52 m m Height with sensor 10 6 3in 2 70m m 11 1 3in 2 82m m with O sensor fitt 2 2 3 1U NI T DI M EN SI ON S W idt h 5 51 in 1 40 m m He igh t 5 9 0 in 1 50 m m De pt h 5 98 in 1 52 m m He igh t wi th se ns or 1 0 63 in 2 70 m m 11 1 3in 2 82 m m wi th O se ns or fitt ed 5 51 in 1 40 m m He igh t 5 9 0 in 1 50 m m De pt h 5 98 in 1 52 m m He igh t wi th se ns or 1 0 63 in 2 70 m m 11 ...

Page 62: ...high temperature Identify the mounting holes using the following drawing and table Identity Quantity Size Used for A 4 M6 tapped Mounting cell mounting B 8 6 5mm Mounting plate to support bar mounting C 2 14mm Clearance for support bar fixing nuts D 1 10mm Drain for mounting cell E 1 25mm Cross Duct optical measurement path F 3 M6 tapped DVC100 mounting G 4 M6 tapped BARTEC terminal box fixing H 2...

Page 63: ... holes diameter 7mm in the positions marked G on the Transmitter Receiver 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 One at a time insert the two mounting ...

Page 64: ...s that the Transmitter s beam hits the centre of the retro 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 Insertthetworetro reflectorpanelsupportbarsthroughtheapertureandattachthemtotheinside of the duct Check that the threaded holes in the support bars line up with the holes drilled in the ...

Page 65: ... section 3 3 1 as they also apply to the Cross Duct Excel Because the Transmitter and Receiver operate from a common supply the field cabling requirements are different For Cross Duct Excel the field cabling conductors should have sufficient cross sectional area to ensure that the minimum supply voltage applied to the gas detector is 18V at a current of 720mA This corresponds to a maximum round lo...

Page 66: ...shers where necessary to maintain ingress protection rating 3 Fit approved blanking plugs to all unused cable entries 4 Make appropriate electrical connections as shown in the subsequent diagrams 5 The mounting plate must be bonded to a protective earth either through contact with the duct wall if it is itself suitably earthed or by direct connection Note Suitable crimps or ferrules must be fitted...

Page 67: ...e earth bonding arrangement must ensure that the maximum peak voltage between the unit case earth and any field cable conductor is less than 350V Voltages in excess of this can cause permanent damage to the unit s RFI protection filters Safety protective ground 4 5 4 Connections using Non DVC DX100 DX100 M Junction Box BRN Earth Terminal Cable Earth Shield Ex d or Ex e Junction Box Flying lead tem...

Page 68: ... EXCEL GAS DETECTOR 1 Switch on the Handheld Interrogator 2 Check that the Handheld Interrogator displays Excel as the operating mode as it powers up If not select CHANGE MODE from the main menu and use the and keys to select Excel 3 Select CALIBRATE from the Main menu Press the and keys on the keypad to navigate through the menu options 4 Press on the interrogator keypad to display the calibrate ...

Page 69: ...ed If the mechanical installation is satisfactory Excel can be initialised 12 Press on the keypad and the display shows Press Enter to Initialise Unit 13 Press and the display will show the following message whilst the unit is initialising Processing Data Please Wait When the gas detector has completed initialisation the following message is displayed for three seconds Unit Initialised The display...

Page 70: ...r windows and the beamsplitter Remove the top cover from the mounting cell The cover is retained by 3 x M4 captive bolts and a chain attaches the lid to the mounting cell when opened There are no electrical hazards inside the mounting block and a hot work permit is NOT required Note It is strongly recommended that the Excel gas detector is inhibited use the Handheld Interrogator and select Calibra...

Page 71: ...xpected reading can be calculated from Gas reading 100 LEL 2 x duct width 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 are due to a number of factors such as variation in air pressure flow rate and tolerances in the gas composition Test Gas Duct Width Expected Reading Expected Reading...

Page 72: ...5 section 5 2 4 8 PROBLEM SOLVING Any problems encountered with the Cross Duct Excel are likely to be similar to those affecting the Open Path version See Chapter 6 for a problem solving guide The beam from the Transmitter is invisible but during normal operation the Transmitter can be heard ticking at 4Hz In addition when cleaning the optical surfaces include the beamsplitter and the retro reflec...

Page 73: ...g disturbed it is important to inhibit the analogue output The quickest way to inhibit the Excel output is to select DISPLAY from the Calibration menu 3 Clean any dust or dirt from the Searchline Excel windows using soapy water or window cleaner and a soft cloth 4 Using the SHC1 Handheld Interrogator release the Searchline Excel signal output The output can be released by pressing ESC followed by ...

Page 74: ...ed thetypicalvalueforcross sensitivityisnotsufficientlypreciseto enable valid calibration checks to be performed using the Gassing Cell however response tests can be easily performed with the plastic Test Filters as described in section 5 1 2 WARNING Take the necessary precaution to ensure safety when dealing with these high concentration gases The gassing cell supplied by Zellweger Analytics Part...

Page 75: ...useful signal in the short path of the gassing cell 5 4 DISPLAY GAS READING This procedure displays details about the current gas gas table Carry out the following procedure 1 Connect the SHC1 Handheld Interrogator to the gas detector See Connecting the Interrogator to the Searchline Excel Gas Detector in section 3 7 6 2 Switch on the SHC1 Handheld Interrogator See Powering Up in section 3 7 6 3 S...

Page 76: ...y camera store 5 6 OPERATIONAL MAINTENANCE FM As required as a criterion for the FM Performance Approval routine operational verification is recommended once within a three month period and is required once within a six month period using one of the following methods WARNING The following procedure will indicate a gas reading Ensure all required personal have been notified prior to starting and co...

Page 77: ...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 information before contacting Zellweger Analytics Installation Check Sheet See Chapter 3 Any error message Displayed on the Handheld Interrogator screen Any error code Displayed on the Handheld Interrogator screen Fault Probl...

Page 78: ...ny obstruction if present Transmitter or Receiver 1 Connect SHC1 Interrogator to unit and check signal misaligned levels 2 If signal levels are low use the telescope and SHC1 Interrogator to optimise Receiver alignment 3 If signal levels remain low after re aligning Receiver check the Transmitter alignment using the telescope 4 Re zero the unit after alignment See Appendix A 5 3 4 Output is 3mA He...

Page 79: ...rogator battery low Check the Interrogator battery and replace if low See Appendix A Section A 4 3 Interrogator The installation has failed to 1 Check that the signal levels reaching the Receiver are Installation meet the acceptable criteria greater than 0 7 and less than 1 5 Failed message of the Instrument Assisted 2 Check that the correct range has been entered for the when attempting Alignment...

Page 80: ...expected to gas units to plastic test filters See section 5 1 2 test filters 1 Check that the response to the test filters is within the limits stated in this handbook See section 5 1 2 2 Check that the value being used for response testing corresponds correctly to the target gas that the unit has been calibrated for Receiver misaligned 1 Use the telescope and Interrogator to optimise Receiver ali...

Page 81: ...its warranty Such equipment Temperature 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 Incorrect supply voltage 1 Check that the 24V supply voltage reaching the unit report reaching unit it should be between 18...

Page 82: ...ng Temp All 40 C to 65 C 40 F to 150 F Humidity All 0 99 RH Non condensing Pressure All 91 5kPa 105 5kPa 915 1055mBar non compensated Repeatability 0 4LELm 0 4LELm 0 4LELm 10 LEL LEL m 1metre width 2 5 LEL LEL m 1 5metre path Temperature 0 2LEL m zero 0 2LEL m zero 0 2LEL m zero 10 LEL LEL m zero Drift 40 C to 65 C 0 5LEL m 3LEL m 0 5LEL m 3LEL m 0 5LEL m 3LEL m 15 LEL LEL m 60 LEL Warm up Time Al...

Page 83: ... Pentane C5 H12 Hexane C6 H14 The Ethylene version of Excel is used to detect the following gases and vapours it will also respond to the hydrocarbons above but is only calibrated for the following Ethylene C2 H4 Propylene C3 H6 Butadiene C4 H6 Methanol CH3 OH Ethanol C2 H5 OH Note The Excel Ethylene version has not been evaluated as part of the performance testing relating to the FM approval and ...

Page 84: ... and Receiver BAS98ATEX 2165X Open Path Long Range Mid Range Transmitters BAS98ATEX 2299X UL Class 1 Groups B C D Class 1 Zone 1 AEx d IIB Hydrogen Amb 40 o C to 65 o C File No E91044 CSA FM Class 1 Div 1 groups B C D T5 and Class I Div 1 groups B C D T5 Exd IIC T5 Amb 40 to 65 o C Tamb 40 to 65 o C File No LR 48148 38 The Searchline Excel system has been designed built and tested to meet the late...

Page 85: ...900mm long see table of Conduit Technical Characteristics Cross Duct Transmitter EEx d IIC T5 40 to 65 C o EEx d IIC T6 40 to 40 C II 2G V max 32V o M20 gland EEx d EEx e Standard Junction Box EEx e or EEx d M20 gland EEx d EEx e Flexible Conduit 900mm long see table of Conduit Technical Characteristics M20 gland EEx d EEx e M25 gland EEx e or EEx d customer supply Receiver EEx d IIC T5 40 to 65 C...

Page 86: ... T6 40 to 65 C o V max 50V I max 5A Cable glands M20 M25 SHC1 Handheld Interrogator EEx ia IIC T4 40 to 40 C o Cross Duct M20 gland EEx d EEx e Flexible Conduit 900mm long see table of Conduit Technical Characteristics M20 gland EEx d EEx e IS Cable Length 15m max DVC100 Termination Unit EEx ia e m IIC T6 40 to 65 C o V max 50V I max 5A Cable glands M20 M25 SHC1 Handheld Interrogator EEx ia IIC T4...

Page 87: ...tant 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 Classification FRG04 Heavy Conductor Crush Classification FRG04 Heavy Flame Propagation Flame dies in less than 30 seconds after ignition source is removed Approvals Bureau Veri...

Page 88: ...6 8 CERTIFICATION Open Path Long Mid Range See Open Path Transmitter Short Range for label explanation Cross Duct See Open Path Transmitter Short Range for label explanation 8 2 4 2 Receivers Open Path See Open Path Transmitter Short Range for label details ...

Page 89: ...89 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8 CERTIFICATION Cross Duct See Open Path Transmitter Short Range for label explanation ...

Page 90: ...90 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8 CERTIFICATION 8 2 5 System Diagram ...

Page 91: ... practice customer supplied Cross Duct Transmitter Class I Div 1 Groups B C D and Class I Zone 1 AEx d IIB H2 Tamb 40 to 65 C o UL approved explosion proof junction box UL approved M20 NPT adaptor Solid conduit customer supplied must conform with the relevant US installation codes of practice 8 CERTIFICATION Note Later units 1 2 NPT threaded without adaptor Note Later units 1 2 NPT threaded withou...

Page 92: ...ss I Div 1 Groups B C D Tamb 25 to 40 C o SHC1 Handheld Interrogator Class I Div 1 Groups B C D Tamb 50 to 40 C o Receiver Class I Div 1 Groups B C D Class I Zone 1 AEx d IIB H2 Tamb 40 to 65 C o UL approved M20 0 75in NPT or M20 0 5in NPT adaptor IS Cable Length 15m max Solid conduit must conform with the relevant US installation codes of practice see Control Drawing 2104E0045 customer supplied 8...

Page 93: ...93 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8 CERTIFICATION 8 3 3 Certification Label ...

Page 94: ...94 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8 CERTIFICATION 8 3 4 System Diagram With DX100 Termination Unit ...

Page 95: ...L OR ABNORMAL CONDITIONS A SOURCE OF POTENTIAL WITH RESPECT TO EARTH IN EXCESS OF 250V rms OR 250V d c 2 WIRING FROM THE HANDHELD CALIBRATOR SHC1 TO THE TERMINATION UNIT DX100 IS NOT TO EXCEED 15 METRES MAX 3 INSTALL EQUIPMENT INCLUDING FIELD WIRING IN ACCORDANCE WITH ARTICLES OF THE NATIONAL ELECTRICAL CODE FOR DIVISION 1HAZARDOUS LOCATIONS SENSOR ENTRY CONDUIT CONNECTION REQUIRED WITH SEAL NON H...

Page 96: ...ion box Conduit seal required see OEM J B details CSA approved M20 1 2 NPT threaded without adaptor Note Later units 1 2 NPT threaded without adaptor Flexible conduit customer supplied must conform with the relevant US and Canadian installation codes of practice conduit seal required within 30 of transmitter CSA Receiver Class 1 Div 1 Groups B C D T5 Exd 11C T5 Tamb 40 to 65 o C DX100 DX100 M CSA ...

Page 97: ...ATION CSA Receiver Class 1 Div 1 Groups B C D Class 1 Zone 1 AEx d IIB H2 Tamb 40 to 65 o C DX100 DX100 M CSA FM Termination Unit Class I Div 1 Groups B C D Tamb 25 to 40 o C SHC1 Handheld Interrogator CSA FM Class 1 Div 1 Groups B C D Tamb 50 to 40 o C FM Receiver Class 1 Div 1 Groups B C D 40 to 65 o C UL approved M20 0 5in NPT adaptor Note Later units 1 2 NPT threaded without adaptor Solid cond...

Page 98: ... MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8 CERTIFICATION CSA FM Certification Label Standard Transmitter Standard Receiver Long Range Transmitter Cross Duct Transmitter Cross Duct Receiver ...

Page 99: ...99 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8 CERTIFICATION ...

Page 100: ...100 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8 CERTIFICATION With DX100 M Termination Unit ...

Page 101: ...sic 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 Chapter 3 and Chapter 4 of this handbook A 2 OVERVIEW The interrogator consists of an LCD screen and four ...

Page 102: ...ttons are used to provide operator input in response to messages shown on the display This includes menu option selections and changing parameter values The four buttons are Up Move to the previous menu option list item or increase a displayed data value Down Move to the next menu option list item or decrease a displayed data value ESC Escape Quit the current menu level or operation and return to ...

Page 103: ... 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 Batter...

Page 104: ...d 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 Interrogat...

Page 105: ...ptions 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 W Version Displays the system software version and the current time and date Gas Reading Display the gas type and system status The display is in...

Page 106: ...re 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 Note The year 2000 is displayed as 00 A 5 3 Calibrate Menu This sub menu is used when installing and calibrating the system It has the following options Display Display system readings Install Direct the alignment and ...

Page 107: ...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 Install This choice is used to complete the alignment and commissioning operations after the system is mechanically and electrically installed It provides a sequential set of ...

Page 108: ...sage is displayed Path Length nnnn where nnnn The path length in metres The following ranges of path length can be entered for the system types System Type Minimum Range m Maximum Range m Step Size m Short Range 5 40 1 Medium Range 20 120 1 Long Range 20 200 1 Duct Mount 0 5 5 0 1 Self Test This starts the system self test process The following message is displayed Press Enter to Perform checks Th...

Page 109: ... current SIG level is larger than the TGT level The TGT signal level only ever increases If the current SIG level falls below the TGT level TGT will remain at its previous highest value In order to initialise the gas detector the SIG level must be brought back above the TGT level 5 If the SIG level is less than 50 of the expected level the bar graphs are not displayed Instead both SIG and TGT leve...

Page 110: ...level by making small adjustments in only one plane at a time e When the SIG level has been maximised in one plane make small adjustments in the other plane until SIG has been maximised in this plane f Repeat steps b to e until the SIG level has been maximised in both planes At this point SIG must be bigger than the initial TGT level and any adjustment either side of the current alignment must res...

Page 111: ... 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 following format Date DD MM YY dd mm yy where dd Day mm Month yy Last two digits of the year Notes 1 The time and date will not be updated unless both are entered and accepted without error 2 The year 2000 is displayed as 00 Cal Sensor This menu option zeros the system...

Page 112: ...n steps of 0 1mA After adjustment the output is forced to the set level and the following message is displayed Fixed mmmmm mA Press Enter where mmmmm Analogue output current previously set Normal mA This menu option returns the system to its normal analogue output state irrespective of its previous state If successful the following message is displayed for three seconds 4 20mA Released Show Status...

Page 113: ...ns 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 Faults This menu option displays operational faults when the system is in service 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 I...

Page 114: ... Excel log has become damaged Bad Temperature ERR_EXCEL_TEMPERATURE_LIMIT Unit 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_BLOCKED The infrared beam between the Transmitter and Receiver has become blocked Neg Gas Reading ERR_EXCEL_NEGATIVE_DRIFT Negative drift of gas detector ...

Page 115: ... user configuration parameters It has the following options Show Gas Show the gas related configuration parameters Show Config Show the user related configuration parameters Show Install Show the installation related configuration parameters Show Gas This option displays the useful gas table configuration parameters in the following way cccccccccccccccc vvvvvvvv where ccccccc Title of the configur...

Page 116: ...esponse 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 Install This option...

Page 117: ...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 SOLVING Interrogator problems that occur during communication wit...

Page 118: ...errogator device 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 Intrinsically safe apparatus in which the circuits themselves are incapable of causing ignition of a flammable gas Lower Explosive Limit LEL The volume of flammable gas or vapour in air below which an explosive gas atmosphe...

Page 119: ...raged LEL Units of measure are LEL m This reading is the average LEL concentration in the duct based upon the assumption that the gas concentration in the duct is uniform Effectively the reading is calculated as below Path Av LEL Number of LEL m in duct x 100 Duct Width m Example In a 1 metre duct a 10 LEL m reading will be signalled for 1 metre of 10 LEL gas or 0 5 metres of 20 LEL gas or 0 1 met...

Page 120: ...rument Assisted Alignment IP Ingress Protection IR Infrared IS Intrinsically Safe FM Factory Mutual LEL Lower Explosive Limit LR Long Range MR Medium Range NPT National Pipe Thread RFI Radio Frequency Interference SHC Sieger Handheld Calibrator SR Short Range UL Underwriters Laboratories ...

Page 121: ...11 2104B3101 2104B3301 Medium Range 2104B2131 2104B3111 2104B3311 Long Range 2104B2151 2104B3121 2104B3321 Open Path Receivers Current Sink Short Range 2104B2112 2104B3102 2104B3302 Medium Range 2104B2132 2104B3112 2104B3312 Long Range 2104B2152 2104B3122 2104B3322 Long Range UL 2104B2154 Cross Duct Transmitter Receivers Transmitter 2104B2530 2104B2601 Receiver Current Source 2104B2531 2104B2602 R...

Page 122: ...tro reflector double glazed pane for Short Range 2104D2534 Mounting plate Cross Duct Stainless Steel 2104D2505 Support strap Cross Duct mounting plate 2104D2506 Support strap Cross Duct retro reflector for Long Range 2104D2542 Support strap Cross Duct retro reflector for Short Range 2104D2541 Junction Boxes DVC100 Marine Excel 04220 A 1001 DX100 aluminium version of DVC100 CSA FM Certified 2104B23...

Page 123: ...est of the world Honeywell Analytics AG Wilstrasse 11 U11 CH 8610 Uster Switzerland Tel 41 0 44 943 4300 Fax 41 0 44 943 4398 sales zelana co uk Customer business center Americas Honeywell Analytics Distribution Inc 400 Sawgrass Corporate Pkwy Suite 100 Sunrise FL 33325 USA Tel 1 954 514 2700 Toll free 1 800 538 0363 Fax 1 954 514 2784 sales zelana com www honeywell com ...

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