Spectrex SafEye 300 Series User Manual Download

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300 Series

Open-Path Gas Detection System

User Guide

Document Ref: TM794200, Rev Ad March 2019

8200 Market Blvd, Chanhassen, MN 55317, USA

Phone: +1 (973) 239 8398 Fax: +1 (973) 239 7614

Website:

www.spectrex.net

Email:

[email protected]

Summary of Contents for SafEye 300 Series

Page 1: ...ath Gas Detection System User Guide Document Ref TM794200 Rev Ad March 2019 8200 Market Blvd Chanhassen MN 55317 USA Phone 1 973 239 8398 Fax 1 973 239 7614 Website www spectrex net Email spectrex csc rmtna emerson com ...

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Page 3: ...e or will have responsibility for using maintaining or servicing the product The detector is not field repairable due to the meticulous alignment and calibration of the sensors and the respective circuits Do not attempt to modify or repair the internal circuits or change their settings as this will impair the system s performance and void the SPECTREX product warranty Warranty SPECTREX agrees to e...

Page 4: ... Rev Date Revision History Prepared by Approved by Aa August 2018 First Release Michal Heller Udi Tzuri Ab December 2018 Second Release Michal Heller Udi Tzuri Ac February 2019 Third Release Michal Heller Udi Tzuri Ad March 2019 Fourth Release Michal Heller Udi Tzuri ...

Page 5: ...Optical Path 14 2 3 4 Microprocessor Based 15 2 3 5 Gas Sensitivity 15 2 3 6 Gas and Mixture Selection and Setting 16 2 3 7 HART Protocol 16 2 3 8 Modbus RS 485 17 2 4 Product Marking 17 2 5 Models and Types 17 2 6 Description 18 2 6 1 Light Source Unit 19 2 6 2 Detector Unit 20 3 Operation Mode 21 3 1 Normal Mode 21 3 2 Fault Mode 21 3 3 Alignment Mode 21 3 4 Zero Calibration Mode 1mA Output 22 3...

Page 6: ...4 3 Mechanical Specifications 36 4 4 Environmental Specifications 37 5 Installation Instructions 39 5 1 Introduction 39 5 2 General Considerations 39 5 2 1 Personnel 39 5 2 2 Tools Required 39 5 2 3 Site Requirements 39 5 2 4 The Source and Detector 40 5 2 5 Guidance Tips for Gas Detector Locations 40 5 3 Preparations for Installation 40 5 4 Mounting for Duct Installation 41 5 4 1 Duct Mount Set 4...

Page 7: ...3 Function Check of Unit 62 7 2 4 Maintenance Records 62 8 Troubleshooting 63 Appendix A Wire Selection Tables 65 A 1 General Instructions for Electrical Wiring 65 Appendix B Wiring Option Configurations 67 A 2 RS 485 Communications Network 69 Appendix C Outline Drawings 71 Appendix D Special Conditions to Comply with SIL 2 Requirements 73 A 3 Safety Relevant Parameters 73 A 4 Guidelines for Confi...

Page 8: ... Source Terminal Board 28 Figure 7 Drilling Layout Dimensions for Duct Installation 43 Figure 8 Detector Light Source and Duct Mount Installation Scheme 45 Figure 9 Duct Mount Installation Outline Drawing 46 Figure 10 Telescope Alignment Set 48 Figure 11 Detector with Cover removed 51 Figure 12 Light Source Open View 54 Figure 13 Detector Wiring Diagram 67 Figure 14 4 20mA Source Output 68 Figure ...

Page 9: ...screte Reading of 4 20mA at Different Detector Modes 25 Table 6 Light Source Terminals 28 Table 8 Sensitivity Levels Options 301 SIL 30 Table 9 Detection Distance Range 33 Table 10 Sensitivity Range 33 Table 11 Dry Contact Relays 35 Table 12 Detector Source Weight and Dimensions 37 Table 14 Duct Mount Kit 41 Table 15 LED Signal Adjustment 61 Table 16 Maximum DC Resistance at 68 F for Copper Wire 6...

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Page 11: ...ple optics and dual spectrum reference sensor the SafEye can maintain operation in up to 90 signal obscuration and 2 degree of misalignment SafEye has a fast response detection time of no more than 2 seconds This feature enables an adequate time to take appropriate safety measures This manual consists of a full description of the detector and its features It contains instructions on the installati...

Page 12: ...ion Chapter 3 Operation Mode the detector s operation modes user interface and indications Chapter 4 Technical Specifications the detector s electrical mechanical and environmental specifications Chapter 5 Installation Instructions including wiring and mode setting Chapter 6 Operating Instructions and power up procedures Chapter 7 Maintenance Instructions and support procedures Chapter 8 Troublesh...

Page 13: ...n alignment and calibration Designed to meet SIL 2 approval by TÜV Programmable configuration 2 2 Applications The SafEye system may be used to monitor flammable gas concentration in various applications such as fence line monitoring and area monitoring in processing facilities air intakes and duct installations found in various industries including Petrochemical pharmaceutical and other chemical ...

Page 14: ...velength selected according to its specific spectral absorption or fingerprint There are 3 IR sensors 2 signals and 1 reference The detection process involves 2 separate filters 1 transmitting radiation that is absorbed by a particular gas and 1 that is not sensitive to it 2 3 3 Optical Path The presence of hazardous airborne vapors gases or aerosols in a monitored area is detected when the define...

Page 15: ...ength all hydrocarbon materials have a strong absorption peak This peak enables the detector to achieve regular sensitivity LEL m 2 5 LEL m or 1 LEL mLEL mLEL mLEL mLEL could be selected using RS485 Winhost or HART communication However since the desired detection information is air flammability and the actual measurement is radiation absorption around the 3 4µ spectral band the detector has a dif...

Page 16: ... 3 LPG 60 propane and 40 butane Gas 4 99 methane and 1 propane and is for use in detecting methane mixture with heavier gases where the methane component can vary between 100 and 95 It is also good for protecting areas where a leak can be either pure methane or pure propane The 4 internal gas calibrations cover most of the flammable gas detection applications Actual selections should be made by th...

Page 17: ...ct web page will display all the detector s parameters and confirm that the installation has been completed successfully It is also required to perform the necessary zero calibration function For more details refer to Manual TM899050 2 4 Product Marking The SafEye 300 Series open path gas detector and source unit are designed to meet FM per Class I Div I Groups B C and D Class II Div I Groups E F ...

Page 18: ... System User Guide Figure 1 P N Definition for the 300 Series 2 6 Description The system comprises 2 main units the light source and the detector The SafEye system detects gases over an open path transmitted from the light source to the detector ...

Page 19: ... March 2019 19 2 6 1 Light Source Unit The light source unit emits IR radiation pulses in a collimated beam for maximum intensity to the detector unit The model number is OPS LI0DFAL Figure 2 Figure 2 Light Source Reflector Type ...

Page 20: ...r to be processed by the internal microprocessor When the signals drop below a prescribed level the internal microprocessor will compensate for them This will allow the signal to be maintained even in severe weather conditions The data is sent to the output interface section The signals can be sent to a standard control panel or to a central computer The Series 300 detector model no OP IL000DFAL i...

Page 21: ...tion causing the problem is removed or resolved This mode will occur after a delay of 60 sec from the moment of the fault This delay is important to eliminate momentary obscuration due to objects people passing through the beam Low Voltage Fault 0mA Output In this case detection is disabled due to low voltage being supplied to the detector The detector returns to proper operation only when proper ...

Page 22: ...eather conditions Zero calibration must be performed after installation re alignment and window cleaning using magnetic mode selection 3 5 Mode Selection A magnetic mode selector is used to change to alignment and calibration modes by placing the magnet on the side of the detector Figure 16 3 6 Visual Indicator LEDs There are 2 indicators LEDs located in the detector s front window referred to as ...

Page 23: ...n Green 0mA 80 60 Orange Green 0mA 60 or less Red Orange 0mA After 20 seconds the color represents the signal intensity See Note 2 See Note 1 See Note 1 0mA Standby mode Green Green Both LEDs flash alternately at a rate of 2Hz 0mA Calibration mode See Note 3 Off Off 0mA Notes 1 The number of flashes shows the intensity of the received signals while the color represents the gain see Table 3 The lef...

Page 24: ...n page 24 3 7 Output Signals The SafEye system provides the following outputs Standard 4 20mA port Three dry contact relays Optional RS 485 output for PC communications 3 7 1 4 20mA Current Output The 4 20mA output can provide the detector status measurement in 1 of the 2 following methods It can be measured proportionally default showing a continuous reading of the exact gas concentration see Tab...

Page 25: ...0mA at Different Detector Modes Current Reading Mode LEL m Setting 301 0 0 5mA Fault 2 or low voltage 2 0 5mA Fault 1 4 0 5mA Standby 0 14 0 5mA Warning 1 19 0 5mA Alarm 1 5 3 7 2 Relays The detector includes 3 relays Fault relay Alarm relay Accessory relay Fault relay contacts are normally energized closed and opened when in fault condition 3 7 3 RS 485 Interface The RS 485 input output sends com...

Page 26: ...er Guide 3 8 Terminals Terminal outputs are described for the detector and the light source 3 8 1 Detector Terminal Terminal wiring Figure 4 displays a schematic diagram of the terminals and Figure 5 shows their location Figure 4 Detector Wiring Diagram ...

Page 27: ...Terminals TM794200 Rev Ad March 2019 27 Description 1 Detector Cover 2 Terminal Board 3 Terminal Screw 4 Securing Cable Figure 5 Detector Terminal Board ...

Page 28: ...tion System User Guide 3 8 2 Light Source Terminals Figure 6 shows the terminals board and Table 6 describes their use Figure 6 Light Source Terminal Board Table 6 Light Source Terminals Light Source Terminal Number Description 1 VIN 2 RTN ...

Page 29: ...oftware Refer to Manual TM899050 for programming instructions 3 9 2 Detection Setup Function See Detector Default Setup on page 31 for default settings 3 9 2 1 Gas Calibration Four gas types can be selected for maximum compatibility to the required measured gas es Gas Type for Model 301 Methane Mixture 92 methane 4 ethane 4 propane default LPG 60 propane 40 butane Mixture 99 methane 1 propane ...

Page 30: ... level Accessory relay is activated at alarm level Alarm latching No latching function at alarm relay Alarm relay is latched Latching reset can be performed by momentary power disconnection or when detectors are set to alignment mode 4 20 mA mode Continued reading of the 4 20mA per the gas concentration level see Table 1 SafEye 300 IR type Model Information Discrete reading of the 4 20mA output ac...

Page 31: ...he customer requirement at the factory or at the customer facility using a software host or a handheld unit The standard setup is as follows Detector Default Setup SafEye 301 Gas type 2 Full scale sensitivity 2 5 LEL m BG zero calibration Enabled Accessory relay Warning Alarm latching No 4 20mA Continuous Beam block during alarm No latch ...

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Page 33: ...l No 301 Distance ft 2 11 5 Distance m 0 6 3 5 Response Time Typically 2 sec max 5 sec Spectral Response 3 0 4 0µm Sensitivity Range Table 9 Sensitivity Range Field of view Line of Sight Alignment tolerance 2 Drift Long term 5 of full scale Temperature range 40 F 40 C 185 F 85 C Immunity to false alarms Does not produce false alarms due to hydrocarbon flames and IR radiation sources Sensitivity 30...

Page 34: ...A is a source configuration The maximum permitted load resistance is 600ohm There are 2 options for 4 20mA Continuous reading default see Table 4 Discrete reading see Table 5 4 2 2 Communications Network The detector is equipped with an RS 485 communication link that can be used in installations with computerized controllers Communication is compatible with the Modbus protocol This protocol is sta...

Page 35: ...n When in the Alarm or Warning status the appropriate relay is closed Fault relay is normally energized closed and the contact will be closed When it is in Fault status the relay is opened 4 2 4 HART Protocol The HART protocol is a digital communications signal at low level on top of the 0 20mA This is a bi directional field communications protocol used to communicate between intelligent field ins...

Page 36: ...l O rings to prevent intrusions such as dust salt and sprays The circuit boards are conformal coated and protected from mechanical vibrations and a slight impact Approvals FM designed to meet Class I Div 1 Groups B C and D Class II Div 1 Groups E F and G SIL 2 designed to meet Per IEC61508 TÜV Electrical Modules Conformal coated Electrical Connection 2x3 4 14NPT conduits Water and Dust Tight IP66 ...

Page 37: ...ns The source and detector units compensate for adverse conditions while maintaining accuracy High Temperature Designed to meet MIL STD 810C Method 501 1 Procedure II Operating temperature 185ºF 85ºC Storage temperature 185ºF 85ºC Low Temperature Designed to meet MIL STD 810C Method 502 1 Procedure I Operating temperature 40ºF 40ºC Storage temperature 40ºF 40ºC Humidity Designed to meet MIL STD 81...

Page 38: ...ration Vibration Designed to meet MIL STD 810C Method 514 2 Procedure VIII Mechanical Shock Designed to meet MIL STD 810C Method 516 1 Procedure I Electromagnetic Compatibility EMC This product is designed to meet EMC directive 89 336 EC Radiated Emission EN61000 6 3 Conducted Emission EN61000 6 3 Radiated Immunity EN61000 4 3 Conducted Immunity EN61000 4 6 ESD EN61000 4 2 Burst EN61000 4 4 Surge ...

Page 39: ...des and practices and trained for gas detection maintenance should be employed Wiring should only be performed or supervised by someone with knowledge of electronics and in particular knowledge of wiring installation 5 2 2 Tools Required The SafEye system requires the following tools Set of screwdrivers Set of hex keys Allan wrenches supply with commissioning kit Voltage multimeter 5 2 3 Site Requ...

Page 40: ... the appropriate purchase order and record the P N and serial number of the source and detector units in the appropriate logbook Carefully unpack the following equipment observing any instructions printed on or contained in the packaging list Check the contents for any possible damage caused from shipping and handling In the event of damage or loss in transit notify the carrier and your supplier i...

Page 41: ... air intake as well as good sealing and accurate alignment capability see Figure 8 and Figure 9 5 4 2 Duct Alignment Set and Accessories Air duct installation has a limitation which is the disability of viewing the detector front and performing fine alignment through detector aiming such as performed in a standard installation As a result fine alignment of the detector mount should be performed be...

Page 42: ...The location of the central point of each duct hole 3 should be at the same distance from the surface edge This will provide that both detector and optical axis will be parallel to the air duct wall lines such that any blocking in the interior area will be prevented 2 Preparation of the surface Prior to hole drilling you should verify that the installation surface is straight clean and free of cor...

Page 43: ...Duct Installation TM794200 Rev Ad March 2019 43 Description 1 Air duct installation surface 2 Duct mount screw securing hole 3 Hole for detector light source Figure 7 Drilling Layout Dimensions for Duct Installation ...

Page 44: ...ully The internal plate screws should be inserted slightly into the base plate holes 3 Secure the base plate to the installation surface using 4 nuts and flat washers 4 4 Attach the window plate 5 by threading its holes on the base plate screws The window 7 protection ring of the plate should be facing outside Secure it with 4 nuts and flat washers 6 5 Alignment plate installation Screw together t...

Page 45: ...3 Base plate 11 Horizontal alignment nut and flat washer 4 Base plate securing nut and flat washer 12 Detector light source plate 5 Window plate 13 Detector light source 6 Window plate nut and flat washer 14 Horizontal adjustment locking screw 7 Window 15 Detector light source securing nut and flat washer 8 Alignment plate 16 Window nut Figure 8 Detector Light Source and Duct Mount Installation Sc...

Page 46: ...t and flat washer 3 Base plate 11 Horizontal alignment nut and flat washer 4 Base plate securing nut and flat washer 12 Detector light source plate 5 Window plate 13 Detector light source 6 Window plate nut and flat washer 14 Horizontal adjustment locking screw 7 Window 15 Detector light source securing nut and flat washer 8 Alignment plate 16 Window nut Figure 9 Duct Mount Installation Outline Dr...

Page 47: ...of installation surface hole on the opposite side Rotate the vertical and horizontal nuts Figure 9 Items 10 14 to achieve best results Provide stability for the plate by securing and releasing the opposite nuts or screws gently 4 Repeat step 3 until best results are achieved 5 Secure the screws and nuts tightly Figure 9 Items 9 11 6 Remove the alignment set carefully by unscrewing the nuts and scr...

Page 48: ...ounting for Duct Installation 48 SafEyeTM Open Path Detection System User Guide Description 1 Telescope plate 2 Detector light source securing screw hole 3 Telescope aim Figure 10 Telescope Alignment Set ...

Page 49: ...er remains attached to the detector swivel mount The housing slides under the cover and remains attached to it by a securing cable 8 Do not let the cover simply drop but rather support it until it hangs The terminal board 12 inside the detector cover is now revealed 5 Remove the protective plug 6 mounted on the detector conduit inlet 6 Pull the wires through the detector cover 2 and secure them fi...

Page 50: ... the 2 connector guide pins in the housing section with the correct openings in the housing section 14 Carefully slide the housing section onto the floating holes in the female D connector 15 Using the long handled hex key tighten the 4M6 1 0Px50 screws 14 16 Insert the 4 threaded plugs 13 ...

Page 51: ...2 Cover 10 SW3 3 Screw hole 11 SW2 4 Female D connector 12 Terminal board 5 Male D connector 13 Threaded plug 6 Conduit inlet plug 14 Socket head screw M6x1 0Px50 7 Ground terminal screw 15 Screw pan head No 4 40UNC 2Ax3 8 8 Securing cable 16 Cable tie Figure 11 Detector with Cover removed ...

Page 52: ...SPDT relay Terminals 6 and 7 are normally open and the contacts are closed when the detector is in the alarm status Terminals 7 and 8 are normally closed and the contacts are open when the detector is in the alarm status 5 4 8 4 Accessory Relay The Accessory output is normally open SPST relay Its contacts are at Terminals 9 and 10 It can be defined per user requirements see Appendix B Note To prot...

Page 53: ... 5 2 Harness Connection The instructions for this are identical to the detector see Figure 11 Refer to Harness Connection on page 49 5 5 3 Terminal Wiring The light source contains a terminal board see Table 6 Terminal wiring instructions are identical to the detector wiring instructions The light source consists of 2 wires only The positive supply power is connected to Terminal 1 and the common r...

Page 54: ...ing 54 SafEyeTM Open Path Detection System User Guide Description 1 Housing 5 Grounding wire 2 Cover 6 Securing cable 3 Conduit cable inlet plugs 7 Screw hole 4 Ground terminal screw 8 Figure 12 Light Source Open View ...

Page 55: ... 32VDC 4 After 60 seconds the left LED lights at green the current meter will indicate 4mA If it is the first operation after installation the LED may indicate any status Zero calibration should be performed after powering the system see Safety Precautions on page 55 6 3 Safety Precautions After powering up the detector requires minimal attention in order to function properly but the following sho...

Page 56: ... LEDs will flash alternately with a green color Switch from Standby to Calibration mode the LEDs will turn off Wait up to 60 seconds until it switches to Normal mode right LED green The detector reading is now set to Normal The 4 20mA output should indicate 4mA 6 5 Functional Check of Unit The SafEye system has been calibrated at the factory for the user s specific gas or vapor detection requireme...

Page 57: ... centered over the viewing window of the detector 3 Wait 20 seconds 4 Read the 4 20mA current Determine the difference between the reading taken with and without the functional check filter This difference is the 4 20mA current variance 5 Record the 4 20mA current variance in a maintenance logbook If the variance is more than a 30 change when compared to the previous check see delivery form repeat...

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Page 59: ...onditions and the applications used Proper maintenance will allow the SafEye system to retain maximum performance and reliability The optical surfaces of the source and detector viewing windows should be kept as clean as possible as it is an active device Alignment procedures must be performed each time that the source or the detector unit has been opened or moved for any reason The Signal Verific...

Page 60: ...ace with clean water ensuring no residue is left behind 5 Dry the glass with a clean dry and soft cloth 6 Enter into the maintenance logbook date name of person and company who performed the maintenance service 7 Turn on power to the SafEye detector and source 8 Perform signal verification see Signal Verification on page 60 9 Perform zero calibration see Zero Calibration on page 56 10 Perform func...

Page 61: ...th the previous alignment reading in the maintenance logbook 8 If the variance is more than 30 perform alignment see Operating Instructions on page 55 and zero calibration see Zero Calibration on page 56 Call a technician for service if the SIC is less than 66 and both LEDs flash red Table 13 LED Signal Adjustment Color left right Number to be added Red Red 0 Orange Orange 62 Green Orange 124 Gree...

Page 62: ...ted during the calibration check should be disconnected 7 2 4 Maintenance Records Record every maintenance operation performed on the source and or detector in a maintenance logbook The logs should include but not be restricted to the following The information identifying the measurement units The date of installation and contractor Entries for every maintenance operation performed to include at l...

Page 63: ...d 4 20mA indication level is 2mA Dirt has accumulated on the detector window or on the light source window Clean the optical windows see Routine Optical Surface Cleaning on page 60 One unit at least has been moved or tilted Perform realignment see Operating Instructions on page 55 Power is not supplied to the light source Supply power to the light source The optical open path beam is blocked Remov...

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Page 65: ... Table 15 to select wire gauge DO NOT connect any circuit or load to detector supply inputs Table 14 Maximum DC Resistance at 68 F for Copper Wire AWG mm2 Ohm 100ft Ohm 100m 26 0 12 0 15 4 32 14 15 24 0 16 0 24 3 42 11 22 22 0 30 0 38 1 71 5 60 20 0 51 0 61 1 07 3 50 18 0 81 0 96 0 67 2 20 16 1 22 1 43 0 43 1 40 14 1 94 2 28 0 27 0 88 12 3 09 3 40 0 17 0 55 10 4 56 6 64 0 11 0 35 Select number of ...

Page 66: ...ength in Feet Meters No of Detectors Recommended Wire Diameter Power Supply Range VDC 24 18 16 14 22 32 20 18 16 14 22 32 16 20 18 16 14 22 32 12 20 18 16 14 20 32 8 20 18 16 14 20 32 4 and less 20 18 16 16 14 20 32 Feet 164 328 492 656 820 Meters 50 100 150 200 250 Max length from power supply to last detector ...

Page 67: ...TM794200 Rev Ad March 2019 67 Appendix B Wiring Option Configurations Figure 13 Detector Wiring Diagram ...

Page 68: ...Wiring Option Configurations 68 SafEyeTM Open Path Detection System User Guide Figure 14 4 20mA Source Output Figure 15 Typical 4 Wire Controller ...

Page 69: ...le to connect up to 32 detectors in an addressable system with 4 wires only 2 for power and 2 for communication Using repeaters the number of detectors can be much larger 32 detectors for each repeater up to 64 on the same 4 wires When using the RS 485 network it is possible to read each detector status Fault Warning and Alarm For more details consult the factory Figure 16 RS 485 Networking ...

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Page 71: ...TM794200 Rev Ad March 2019 71 Appendix C Outline Drawings ...

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Page 73: ...application Relays alarm relays and accessory relays must be configured as the second alarm relay The contacts of both alarm relays must be connected in series SFF Fulfils the conditions of EN61508 for SIL 2 A 4 Guidelines for Configuration Installation Operation and Maintenance Alarm conditions complying with SIL 2 can be implemented in 1 of 2 ways Using 2 alarm relays and using the fault relay A...

Page 74: ...he 4 20mA signal current for values below 4mA and above 20mA A 4 3 Alarm Operation Using Relay Outputs Low Demand Only 1 alarm relay is needed High Demand The accessory relay has to be configured as the second alarm relay The contacts of both alarm relays have to be connected in series The fault relay error message has to be monitored by the connected controller The relay contacts must be protecte...

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Page 80: ...echnical Support For technical assistance or support contact 8200 Market Blvd Chanhassen MN 55317 USA Phone 1 973 239 8398 Fax 1 973 239 7614 Email spectrex csc rmtna emerson com Website www spectrex net ...

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