Honeywell Searchpoint Optima Plus User Manual
Operating Instructions
Searchpoint Optima Plus
Infrared Point Gas Detector
MAN0551 Issue 07 - 09/08
2108M0501
TOTAL ENVIRONMENTAL SOLUTIONS
Ensure that you read and understand these Operating
Instructions BEFORE installing or operating any part of the
Searchpoint Optima Plus.
Please pay particular attention to the Safety Warnings.
WARNINGS
1. For installations in the UK, 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 BS5345: Part 1: 1989. Specic requirements
for ameproof (Type 'd'), intrinsically safe (Type 'i')
and increased safety (Type 'e') protection are given
in BS 5345: Part 3: 1979, BS 5345: Part 4: 1977 and
BS5345: Part 6: 1978 respectively.
For installations in North America, the National
Electrical Code (NFPA 70 - 1990) or later issues
should be strictly observed.
Elsewhere the appropriate local or national
regulations should be used.
2. The Code of Practice regarding SELECTION,
INSTALLATION, USE AND MAINTENANCE
OF APPARATUS FOR THE DETECTION AND
MEASUREMENT OF COMBUSTIBLE GASES
(OTHER THAN FOR MINING APPLICATIONS OR
EXPLOSIVES PROCESSING AND MANUFACTURE)
must be complied with. Refer to BS6959:1988 in the
UK or the appropriate local or national regulations.
3. Operators must be fully aware of the action to be
taken if the gas concentration exceeds an alarm
level.
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TOTAL ENVIRONMENTAL SOLUTIONS
CAUTIONS
1. Use only approved parts and accessories with the
Searchpoint Optima equipment.
2. To maintain safety standards, a planned maintenance
programme is strongly recommended. This
maintenance programme should take account of all
operational conditions and requirements. Maintenance
and service operations should only be performed by
personnel qualied to work upon Searchpoint Optima
Plus.
3. In order to maintain electrical safety, the unit must
not be operated in atmospheres with more than 21%
oxygen.
IMPORTANT NOTICES
1. Honeywell Analytics Limited can take no responsibility
for installation and/or use of its equipment if this is not
done in 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/or operated. If in doubt, the user should
contact Honeywell Analytics Limited for advice.
3. If further details are required which do not appear in
this manual, contact Honeywell Analytics Limited or
one of their agents.
4. The Searchpoint Optima System is certied for and
intended for use in potentially hazardous areas.
Install and use the Searchpoint Optima System in
accordance with the latest regulations.
Honeywell Analytics Limited reserve the right to change
or revise the information supplied in this document
without notice and without obligation to notify any person
or organisation of such revision or change.
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HELP US TO HELP YOU
Every effort has been made to ensure the accuracy in the
contents of our documents, however, Honeywell Analytics
Limited can assume no responsibility for any errors or
omissions in our documents or their consequences.
Honeywell Analytics Limited would greatly appreciate being
informed of any errors or omissions that may be found in the
contents of any of our documents and to this end we include
the form opposite for you to photocopy, complete and return
to us so that we may take the appropriate action.
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CONTENTS
Section Page
1. INTRODUCTION 10
1.1 General 10
2. INSTALLATION VARIATIONS 14
2.1 ATEX Units 14
2.2 UL and CSA Units Only 15
3. INSTALLATION 17
3.1 Unpacking 17
3.2 Siting and Orientation 17
3.3 Installation Guide 18
3.4 Attachments and Options 22
3.4.1 General 22
3.4.2 Standard Weather Protection 22
3.4.3 Sunshade/Deluge Protection 22
3.4.4 Storm Bafe 23
3.4.5 Dust Barrier 23
3.4.6 Calibration Cap 24
3.4.7 Gassing Cover 24
3.4.8 Flow Housing 25
3.4.9 Remote Gassing Cell 26
3.4.10 Junction Box Adaptor Plate 27
3.4.11 European Duct Mounting Kit 28
3.4.12 US Duct Mounting Kit 31
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CONTENTS
Section Page
4. ELECTRICAL CONNECTIONS 35
4.1 General 35
4.2 Analogue Connection 40
4.3 Digital Connection 40
4.4 +24V Power Connection 41
4.5 Earth Connection 41
5. COMMISSIONING 46
5.1 General 46
5.2 Commissioning Procedure using SHC-1
and Multimeter 47
5.2.1 Electrical Commissioning and Tests 47
5.2.2 Gas Response Testing 48
5.2.3 System Level Testing 49
5.2.4 Final Commissioning 51
5.3 Commissioning Procedure with Multimeter
Only 52
5.3.1 Electrical Commissioning and Tests
(Multimeter) Only 52
5.3.2 Gas Response Testing (Multimeter)
Only 54
5.3.3 System Level Testing 55
5.3.4 Final Commissioning (Multimeter) 56
5.4 Control System Setup 57
5.5 Functional Response Checking and
Calibration 57
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CONTENTS
Section Page
6. CALIBRATION 59
6.1 General 59
6.2 SHC-1 Hand-Held Interrogator 60
6.2.1 Connecting the Hand-Held
Interrogator 61
6.2.2 Hand-Held Interrogator Operating
Modes 62
6.2.3 Other Hand-Held Features 66
6.3 Calibrating the Controller 70
6.4 Calibrating the Sensor 73
7. ROUTINE CHECKS 81
7.1 General 81
7.2 Inspection and Functional Response Check
Procedure 81
7.2.1 Response Check Using Gassing Cover
and %LEL Concentration Gas 83
7.2.2 Response Check Using Remote
Gassing Cell & High %VV Gas 87
7.3 Inspection and Testing of Units Installed
in Ducts 92
7.4 Removal and Retting of Flow Housing 94
7.4.1 Removal of Flow Housing 94
7.4.2 Retting of Flow Housing 94
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CONTENTS
Section Page
8. FAULT FINDING 97
8.1 Troubleshooting 97
8.2 Diagnosis of Warning and Fault Messages 103
9. REPLACEMENT OF HAND-HELD
INTERROGATOR BATTERY 111
10. ORDERING DETAILS 113
11. SPECIFICATION 117
11.1 Searchpoint Optima Plus Specication 117
11.2 Cross Interference to Other Gases and
Vapours 124
11.3 Hand-Held Interrogator SHC-1
Specication 125
11.4 SHC Protection Device 126
11.5 Termination Unit DVC100 Specication 127
11.6 DX Termination Units Specication 128
12. CERTIFICATION DETAILS 130
13. WARRANTY 137
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Optical Block
WindowHeaterMirror
Heater
Gas Measuring Path
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1. INTRODUCTION
1.1 GENERAL
Searchpoint Optima Plus is designed for use in potentially
hazardous areas where it provides gas and vapour
detection which is free from poisoning and independent
of the presence of oxygen. The gas measuring parts of
Searchpoint Optima Plus are illustrated below.
Searchpoint Optima Plus uses the dual wavelength infrared
absorption principle to detect hydrocarbon gases and
vapours in various concentration ranges. The instrument
measures the number of molecules of the target gas in the
light path, which depends on the concentration of the target
gas. In addition to the relatively long and open measuring
chamber, Searchpoint Optima Plus can be tted with a short
enclosed ow through-cell as part of the chassis.
This is tted with separate inlet and outlet ports and
allows the application of high concentrations of gas for
test purposes.
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1. INTRODUCTION
Searchpoint Optima Plus is a micro-processor controlled,
Infrared Gas Detector with comprehensive built-in self-
diagnostic and fault nding facilities. An analogue 4 to
20mA output and digital communications are provided as
standard. Full two way communication allows calibration
and advanced self checking procedures to be used. To take
advantage of these features a Hand-Held Interrogator unit
may be connected to a Termination Unit or via the SHC
Protection Device to other junction boxes.
There are several different types of termination unit available:
Termination Unit Certication Output
DVC Type Termination Units
DVC100 (I) MK2 ATEX Isolated 4-20mA
DVC100 (M) MK2 ATEX Isolated 4-20mA and MODBUS
DX Type Termination Units
DVC100 (I) UL Isolated 4-20mA
DX100 (M) UL Isolated 4-20mA and MODBUS
Searchpoint Optima Plus contains no moving parts and
is available in a robust Stainless Steel explosion proof
enclosure which has a M25 (ATEX) or 3/4 NPT (UL and CSA)
mounting thread. The unit operates over a wide temperature
range and has a high degree of protection against dust
and water ingress. It is designed to operate in the most
arduous conditions and is supplied with a choice of weather
protection assemblies.
Searchpoint Optima Plus can be In-Duct Mounted, used
in Sampling Systems, is easily condence checked and
may easily replace an existing sensor. Provided that
existing cabling has three appropriately rated cores and the
installation is correctly screened and earthed, it should not
be necessary to replace the eld cables or junction boxes. (A
current to bridge converter may be required if the controller
cannot be congured to accept 4-20mA signals).
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1. INTRODUCTION
No special tools are required for installation. Correct
function of the detector as installed can be easily conrmed
using a Hand-Held Interrogator. Maintenance amounts to
occasional cleaning, zeroing and response checking for
condence.
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Existing Junction Box
Existing Cable
Optima
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2. INSTALLATION VARIATIONS
2.1 ATEX UNITS
Replacing existing Sensor
using existing Junction Box
and Cable (where suitable).
New Junction Box.
New Installations.
Optima
Optima
DVC Termination Unit
When used for calibration
and diagnostics purposes
the Hand-Held Interrogator
SHC-1 allows digital
communication with the
Optima. It is connected
to the Optima via the IS
Socket on the Termination
Unit DVC100 or via the
SHC Protection Device for
other junction boxes.
SHC-1
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3/4 NPT
Optima
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2. INSTALLATION VARIATIONS
2.2 UL AND CSA UNITS ONLY
UL and CSA Installations using
Explosion Proof
Junction Box.
Note: The Junction Box must be suitable for the hazardous
location in which the Optima is installed, check with the
Junction Box manufacturers literature as to suitability of
the box.
Optima
15
Field
Cable /
Conduit
Top
DX
Termination
Unit
Handheld
Interrogator
Socket
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3. INSTALLATION
WARNING
The Code of Practice regarding selection, installation
and maintenance of electrical apparatus for use in
potentially explosive atmospheres must be complied
with at all times.
Notes:1. The flying leads of the Searchpoint Optima Plus
must be mechanically protected and terminated
within a suitable terminal or junction facility.
2. When the detector is terminated in a hazardous
area a suitable UL listed enclosure must be used
(where appropriate).
3.1 UNPACKING
Carefully unpack the equipment, observing any instructions
that may be printed on or contained in the packaging, and
check the contents for transit damage.
3.2 SITING AND ORIENTATION
Searchpoint Optima Plus must
be mounted horizontally, as
this greatly reduces the risk of
obscuration due to build up of
dirt and moisture on the optical
surfaces.
Ensure the area immediately
surrounding the sensor is free
from objects that could hinder
the free ow of air around it.
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3. INSTALLATION
For monitoring lighter than air gases, Searchpoint Optima
Plus should be mounted above the area requiring protection.
For monitoring heavier than air gases it should be mounted
below the area to be protected.
When monitoring for heavier than air gases and mounting
the detector close to the oor, give consideration to the
potential of general site debris to build up on the detector.
Whether Searchpoint Optima Plus is installed in a
sheltered or an exposed location, it will require some form
of protection around the optics. The standard weather
protection combined with the sunshade/deluge protection
provides a high degree of protection of the detector, suitable
for many outdoor environments. Detectors operating in very
exposed locations where torrential rain or driven sea-spray
is routinely encountered can benet from the additional
protection provided by the Storm Bafe (2108D0280).
In areas where a high pressure jet may be used at close
range to wash down the surrounding location, it is advisable
to t some means of extra peripheral shielding,
Bafe or a shield plate.
eg. Storm
Accessories and attachments that can be used to improve
ease-of-use, performance and reliability in particular
installations are described in Section 3.4.
3.3 INSTALLATION GUIDE
Note: Installation of Searchpoint Optima Plus does not require
the unit to be opened. There are no user serviceable
parts inside the unit. Do not attempt to open or
dismantle the unit.
(1) Ensure that the correct attachments and accessories
for the application have been tted (see Section 3.4).
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3. INSTALLATION
(2) Check that the unit's 4-20mA current ouput is of the
correct type for the control card that it is connected to.
(Output type is on a label attached to white lead.)
Control card I/P: SINK Optima O/P: SOURCE
Control card I/P: SOURCE Optima O/P: SINK
(3) Secure the junction box onto the mounting surface,
using the Junction Box Adaptor Plate if required.
Searchpoint Optima Plus must be installed with it's
long axis horizontal in order for the standard weather
protection to operate correctly and to prevent water
from settling on the optical surfaces (see below).
The Optima unit should therefore only be screwed into
a threaded entry that is in a vertical wall of the junction
box.
3 7
(4) Feed the unit's wires carefully through the chosen
junction box entry and offer up it's threaded boss to
the entry. Screw the unit into the junction box until
it is secure and the semi-circular pattern of holes on
the front of the weather protection are on the bottom
(see below). For M25 entries, the boss should go right
through the wall and a locking nut should be tted;
whilst for 3/4 NPT entries, the boss should lock off on
the taper. If getting the holes in the right orientation
requires more rotation than is readily achievable,
remove the weather protection and rotate it through
180 degrees.
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3. INSTALLATION
(5) Using a multimeter, check that the voltages on the
+24V, and 4-20mA connections with respect to 0V are
less than +32V DC and that there is no 110V or 230V
AC around.
(6) Wire up the unit's electrical connections in
accordance with Section 4, taking note of the general
recommendations upon electrical installation.
(7)
Ensure that all cable entries are either used or plugged
in strict accordance with the relevant certication
requirements and local codes of practice.
(8) Verify the correct installation and operation of the unit
using the SHC-1 handheld interrogator. If a Termination
Unit has been used, testing can be performed without
the need for a hot work permit. Alternatively, if a basic
junction box has been used, electrical connections can
be made to the terminals inside the box using the SHC
adaptor. This will ordinarily require a hot work permit.
CAUTION
1. Searchpoint Optima Plus is certied and specied
for operation in ambient temperatures from -40°C
to +65°C. Operation of the unit outside of this
temperature range invalidates the certication and
the warranty. The unit records a non-erasable fault
log entry if it is operated at temperatures outside of
it's certied range.
If the ambient temperature that the unit could be
exposed to is likely to go outside of the certied
range it is recommended that the unit be located
elsewhere. The use of sampling systems can be
highly effective, especially in applications where
high temperatures are involved.
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3. INSTALLATION
2. Searchpoint Optima Plus is specied for operation
in environments where the rate of change of unit
temperature is less than 3°C / minute. Exceeding
this rate of change of temperature will cause the unit
to report a fault and may cause permanent damage.
If the conditions experienced by the unit are likely
to cause it to exceed this rate of change it is
recommended that additional preventative measures
are taken. The use of sampling systems is highly
effective; whilst shielding the unit from the prevailing
air ow can also be of benet.
3. Searchpoint Optima Plus has been vibration tested
to the levels specied in EN61779. If the vibration
levels on the installation exceed this, the unit's
reliability and integrity of operation will be degraded.
Do not install units in locations where the vibration
exceeds this level.
4. All optical gas detectors are eventually affected by
the build up of contaminants / condensation upon
their optical surfaces, normally resulting in faults
or warnings. In order to minimise the faults and
warnings caused by this it is recommended that
detectors are located as far away as is possible
from sources of airborne contaminants and steam /
condensation. Alternatively, the tting of shields or
the Storm Bafe (2108D0280) should be considered.
Sources of contamination / condensation that have
caused particular problems where appropriate
measures were not taken include generator / turbine
exhausts, steam lines / vents, drilling operation
(oilmist and mud spray) and unltered HVAC
installations. In dusty atmospheres, regularly check
for the build up of dust on the detector (refer to
section 7 Routine Checks).
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3. INSTALLATION
3.4 ATTACHMENTS AND OPTIONS
3.4.1 General
There are a number of attachments and accessories
available for use with Searchpoint Optima Plus. When
specifying Optima Plus for a particular application, it is
recommended that the user contacts Honeywell Analytics
or their representatives to determine the attachments and
accessories required. Covers, barriers and bafes provide
protection from a wide variety of environmental conditions.
Gassing covers, cells and ow housings provide the means
of applying gas to the detector. Mounting plates and remote
gassing kits enable the detector to be installed in ducts or in
places where obtaining routine access is difcult.
3.4.2 Standard Weather Protection (2108D0276)
Provides the best compromise
between response time and
protection. Suitable for indoor,
outdoor and duct mounting
applications.
3.4.3 Sunshade/Deluge Protection (2108D0275)
Supplied as standard
for all outside
applications. Provides
additional protection
against heavy rainfall,
wash downs and
direct sunlight.
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3. INSTALLATION
The Sunshade/
Deluge protection
should be clamped
around the base of
the Standard Bafe
Weather Housing with
the longer overhang
extending beyond
the Standard Bafe.
Ensure the clamp
does not cover the
gas venting slot of the
Standard Bafe.
3.4.4StormBafe(2108D0280,NotIllustrated)
The storm bafe provides increased protection against
a variety of environmental conditions and effects. It is
particularly effective against torrential rain and driven
sea-spray and is recommended for exposed installations
in maritime locations or areas where monsoon or tropical
rain conditions are experienced. The storm bafe can be
benecial in installations where steam drifting over the
detector from nearby plant is a problem. The storm bafe
can also be useful in some duct applications where the
inlets are not ltered and where high ow rates result in dirt
build-up or excessive cooling / condensation effects. This
accessory will reduce the detector’s speed of response.
3.4.5DustBarrier(2108D0259,NotIllustrated)
Fits under the standard bafe weather housing to prevent
the ingress of dust or oil mist which could contaminate the
optical surfaces. It also protects the optics in very wet or
exposed locations. This accessory will reduce the detector’s
speed of response.
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3. INSTALLATION
3.4.6 Calibration Cap (2108D0272)
Used to achieve accurate
calibration of Optima Plus on the
bench. Requires all protective
covers and attachments to be
removed from the measurement
chamber except for the
dust barrier. The calibration
procedures are described in
Section 6.
CAUTION
The Calibration Cap is designed for temporary use on
Optima whilst performing calibration. If the calibration
cap is left tted it will prevent ambient gas from reaching
the detector's measurement chamber. Ensure that
operators are aware that calibration caps must not be
left tted. In order to reduce the likelihood of this mistake
going un-noticed, the calibration caps are coloured red.
3.4.7 Gassing Cover (2108D0258)
Provides a convenient means
of applying gas to Optima Plus
units in the eld. Suitable for
functional test and calibration
purposes. Fits over the standard
weather protection, covering the
gas inlet slots. Gas is introduced
into the weather protection via
an injection tube on the gassing
cover. Injected gas diffuses
through the dust barrier into the
measurement chamber.
The response check procedure
is described in Section 5.4.
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3. INSTALLATION
CAUTION
The Gassing Cover is designed for eld testing and
calibration operations. If the cover is left tted it will
prevent ambient gas from reaching the detector's
measurement chamber. Ensure that operators are aware
that gassing covers must not be left on detectors.
Gassing covers are coloured red to reduce the likelihood
of this mistake.
3.4.8 Flow Housing (2108D0282)
For use in sampling system
applications.
The Flow Housing is fabricated
from solvent resistant Anodised
Aluminium.
The nozzles on the Flow Housing
are stainless steel with an outside
diameter of 6mm.
It is advised that sample gases and vapours are sucked
(negative pressure) rather than blown (positive pressure)
through this housing and that sample ow rates do not
exceed 2 litres per minute.
It is recommended that a ow failure indicator is tted
within the sampling system and the minimum ow rates are
suitable for the application and not less than 0.7 litres per
minute.
Note: response time will increase with a decreasing ow
rate.
The commissioning and calibration of an Optima equipped
with a ow housing is described in Sections 5 and 6.
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3. INSTALLATION
3.4.9 Remote Gassing Cell (2108B0240)
The Remote Gassing Cell (RGC) enables high
%V/V concentration gas to be applied remotely for
performing functional response checks (bump tests).
It is useful for units installed in ducts or in areas
where obtaining access is difcult. The RGC window
can be removed for cleaning.
Note:
During production, Optima Plus units are calibrated
with gas in the main measurement chamber, not in the
RGC. The RGC is not recommended for calibration
or high accuracy calibration testing purposes.
(The only exception to this is where units are being
used to measure high %V/V gases using the RGC as
a flow cell. In this instance, the units are production
calibrated with gas in the RGC.)
In order to avoid pressurisation effects, the ow rate should
be kept below 0.3 litres / minute.
The RGC option is factory tted.
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3. INSTALLATION
3.4.10 Junction Box Adaptor Plate (04200-A-1040)
The Junction Box Adaptor Plate provides a means of
increasing the spacing between the junction box's gland
entries and the mounting surface. This enables low gland
clearance junction boxes to be used without the Optima
Plus fouling on the wall / mounting surface. Junction boxes
which can be accommodated include the Hawke PL612 and
PJB1.
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3. INSTALLATION
3.4.11 European Duct Mounting Kit (04200-A-1015)
This kit enables Optima Plus to be conveniently mounted
inside a duct. Electrical connections are made to the
detector via a junction box which is mounted outside of the
duct. Using this kit, test gas can be non-invasively applied to
the detector via the gassing points provided.
250
Note 1: Dimensions
shown in mm.
250
125
63
63
125
188
250
Note 2: The cutout
250
in the duct should be
188
230mm x 230mm.
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Gassing
Points
Searchpoint
Optima
Duct
Mounting
Junction
Box
Bracket
Junction
Box
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3. INSTALLATION
Notes: 1. In order to make use of the gassing points provided,
the Optima unit must be fitted with the Remote Gassing
Cell (2108B0240).
2. In offshore HVAC ducts or ducts without inlet
filtering, the use of the Storm Baffle (2108D0280) is
recommended.
3. CSA approval only applies for flow rates less than 5
m/s and does not cover the use of the Storm Baffle.
The duct mounting kit is assembled and installed onto a duct
as below:-
(1) Cut a square 230mm * 230mm hole in the duct wall. Drill
the holes required to attach the mounting plate to the duct
wall.
(2) Place the Optima unit on the side of the mounting plate
where the threaded bushes protrude and feed the wires
through the central hole.
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3. INSTALLATION
(3) Locate the unit's boss in the central hole and feed the
unit's wires through the chosen cable entry on the junction
box.
(4) Screw the unit into the junction box until the assembly is
secure with the mounting plate trapped between the box and
the Optima.
(5) Cut off the seals on the ends of the gassing cell inlet
tubes.
(6) Attach the gassing tubing to the ends of the gassing cell
inlet tubes.
(7) Fasten the mounting plate to the wall of the duct,
ensuring that the seal is compressed.
(8) Wire up the unit in accordance with the electrical
connection details in Section 4.
(9) Ensure that all cable entries are either used or plugged in
strict accordance with the relevant certication requirements
and local codes of practice.
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