Honeywell Searchzone Sonik Ultrasonic Operating Manual
Gas Detection
SEARCHZONE SONIK
Technical Manual
1 Preface
1.1Introduction
Searchzone Sonik™ is a hazardous area certified advanced ultrasonic gas leak detector for detecting pressurized gas leaks. It provides
local visual status indication as well as 420 mA with HART® and Modbus® outputs as standard. It has a Bluetooth® interface for
configuration and maintenance using the Searchzone Sonik App on a suitable Bluetooth enabled smartphone or other suitable Android
device (mobile device).
The Searchzone Sonik detector is ATEX and IECEx approved for use in either Zone 1 (gas) or Zone 21 (dust) hazardous areas as well as
being cULus approved for use in Class I Division 1 or Class II Division 1 locations. See Certification and Approvals section of this manual
for a list of certificates.
The Searchzone Sonik detector is available in painted Stainless Steel. It has two cable entries for easy wiring with either M25 or
3/4” NPT cable entries, dependent on the version.
1.2Disclaimer
The Searchzone Sonik detector is designed to detect an airborne acoustic ultrasonic signature produced by escaping high pressure gas.
The detector is not designed to identify the presence of any particular type of gas. It will detect the dangerous release of high pressure
gas, whether toxic or flammable for the purpose of protecting people, plant and the environment. Honeywell shall not be liable to pay
for any gas leak investigation or service call carried out or arranged in response to an alarm. 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. Please note that product designs may change from time to time and the images in this manual should only be used as a
guide.
21 Preface
1.3Scope
This user manual describes how to install the Searchzone Sonik detector and how to commission and operate it in order to ensure
optimal performance.
1.4How to Use This Manual
The manual is structured to cover the instrument, installation (mechanical and electrical), set-up and commissioning, operating and
maintenance. This manual is available in PDF format .
1.5Copyright & Trademarks
This document is the copyright of Honeywell.
Searchzone Sonik is a Honeywell trademark.
1.6Patents
The Searchzone Sonik advanced ultrasonic gas leak detector uses patented sensing technology. Focus Mode, an operating mode of
Searchzone Sonik is patent pending.
1.7Revision History
Revision Comment Date
Issue 1 A05126 November 2018
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
Table of Contents
1 Preface 2
1.1Introduction 2
1.2Disclaimer 2
1.3Scope 2
1.4How to Use This Manual 2
1.5Copyright & Trademarks 2
1.6Patents 2
1.7Revision History 2
2 Safety and Information 8
2.1Warnings and Cautions 8
2.2Important Information 9
2.3Organisational Measures for Functional Safety 9
31 Preface
3 Overview and Introduction 10
3.1Description of Product 10
3.2Description of Function 10
3.3Applications 10
3.4Sensor Technology Description 10
3.5Environmental Factors 10
3.5.1 Introduction to Background Noise and Interference 10
3.6Range and Field of Coverage 11
3.6.1 Standard Mode 11
3.6.2 Focus Mode 12
3.7Description of Gas Leak Detection Using Ultrasound 12
3.8Mounting Accessories and Flexibility 12
3.9Commissioning and Maintenance Tools 13
3.10Available Accessories 14
4 Siting Considerations 15
4.1Safety Case Framework 15
4.2Siting the Detector 15
4.2.1 Mounting Position 16
4.2.2 Mounting Angle 16
4.3Accidental Impact 16
4.4Change in Site Infrastructure 16
4.5Transient Background Noise 16
4.6Location Survey 16
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4.7Bluetooth Considerations 17
5 Mechanical Installation 18
5.1Visual Check after Transportation 18
5.2Description 18
5.3Main Parts 19
5.4Mounting Searchzone Sonik 20
5.5Pole Mount Installation 22
5.6Wall Mount Installation 24
5.7Assemble Cable Glands 25
5.8Connect Cable Glands to the Searchzone Sonik 25
5.9Detector Attachment 26
5.9.1 Detector removal 26
5.10Connect Wires to PCB Terminals 28
5.11Sunshade Installation 30
41 Preface
6 Electrical Installation 31
6.1Power Supply Requirements 31
6.1.1 Internal Battery Cell 31
6.2420 mA Current Loop 31
6.3Relays 32
6.4Connections / Wiring Diagram 32
6.4.1 Terminal Wiring Description 33
6.4.2 Searchzone Sonik Connection for mA loop Configuration as Current Source 34
6.4.3 Searchzone Sonik Connection for mA Loop Configuration as Current Sink 35
6.4.4 Searchzone Sonik Connection for mA Loop Configuration as Isolated Output 35
6.5Cabling Recommendations 35
6.6Earthing Recommendations 36
6.7Modbus 36
7 Commissioning and Configuration 37
7.1First Time Switch On 37
7.1.1 Pre-power Check 37
7.2Operating Function Verification 37
7.3Communication 37
7.3.1 Bluetooth® 37
7.4Settings and Configuration 37
7.5Delay Time 38
7.6Background Noise Rejection 38
7.7Performance Verification 38
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8 Operation 39
8.1Operation 39
8.2Status Signalling 39
8.2.1 Visual Status Indicator 39
8.2.2 mA Loop Status 40
8.2.3 Relay Signalling 40
8.3Normal Operation 40
8.4Operation During Fault 40
8.5Operation During Alarm 41
8.5.1 Pre-alarm 41
8.5.2 Alarm 41
8.5.3 Overload 41
9 Mobile App 42
9.1General User Access 42
51 Preface
9.2Terminology 42
9.3Communications 43
9.3.1 Company Account Management 43
9.3.2 Creating a New Company Account 43
9.4Connecting to Detectors 47
9.4.1 How to Connect to a Searchzone Sonik Detector 47
9.4.2 Making an Ad Hoc Connection to the Detector 49
9.5Detector Overview 50
9.5.1 Detector Status 50
9.5.2 Detector Inhibit 51
9.6Detector Alarm History 52
9.7Detector Maintenance 53
9.7.1 Event Log 53
9.7.2 Set Maintenance Flag 54
9.7.3 Output Test 55
9.7.4 Diagnostics 56
9.8Detector Settings 58
9.8.1 Firmware Version 59
9.8.2 Background Levels 60
9.8.3 Editing Detector Settings 61
9.9How to Change Application Settings 64
9.9.1 Detector Registrations 64
9.10User Management 65
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10 Communications 67
10.1HART® 67
10.1.1 Searchzone Sonik HART Interface 67
10.2Menu Structure 68
10.3Commissioning using HART Communications 72
10.3.1 User Configuration 73
10.3.2 Configure Warning, Inhibit and Over-range Signal Levels 73
10.3.3 Configure Device Identification Information 74
10.3.4 Test 4-20 mA Loop Integrity 75
10.3.5 Configure Internal Alarm Threshold 75
10.3.6 Clear Alarm Latch 75
10.4Maintenance using HART Communications 76
10.4.1 Inspection 76
10.4.2 Proof Test (Gas Leak Challenge) 77
61 Preface
10.4.3 Investigation of Faults or Warnings 77
10.5Modbus 78
10.5.1 Programming the Host 78
10.5.2 Addressing Conventions and Register Values 78
10.5.3 Modbus Cables 78
10.5.4 Modbus Electrical Connections 79
10.5.5 Modbus Termination Resistor 79
10.5.6 Modbus Multi-Drop Mode 79
10.5.7 Modbus Protocol 79
10.5.8 Modbus Registers 80
11 Maintenance 84
11.1Inspection and Cleaning 84
11.2Periodic Proof Test using a Canister of Compressed Air 84
11.3Suggested Maintenance Schedule 84
11.4Response to Fault 85
11.5Product Life Expectancy 85
12 Problem Solving 86
12.1Introduction 86
12.2Problem Solving 87
13 Certification and Approvals 89
13.1Hazardous Locations 89
13.2ATEX Certification 89
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13.3IECEx Certification 89
13.4CSA Certification 90
13.5cULus Certification 90
13.6Labelling 91
13.7EU Declaration of Conformity 91
13.8RoHS 91
13.9China RoHS 92
13.10WEEE 92
13.11EMC 92
13.12RED 92
13.13REACH 92
13.14FCC 92
13.15IC 93
13.16Export Compliance Classification 93
71 Preface
13.17Wireless Approvals 93
13.18Bluetooth® 93
14 Ordering Information 94
15 Specifications 95
15.1Short Form Table 95
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2 Safety and Information
2.1Warnings and Cautions
WARNING
1. Installation must be in accordance with the recognized standards of the appropriate authority in the
country concerned. For Europe see EN 6007914 and EN 60079292.
2. Installation, operation and maintenance of the unit must meet requirements on safety and operation in
hazardous areas.
3. The equipment is NOT intended to be mounted onto surfaces which may act as sources of heating or
cooling.
4. Do NOT operate the unit outside the temperature range stated in the Specification section.
5. Do NOT open the front enclosure. Doing so will invalidate the warranty.
6. Operators should be fully aware of the action to be taken in the event of an alarm.
7. Do NOT modify or alter the construction of the product as essential safety and certification
requirements may be invalidated.
8. Installation, set-up and maintenance must be conducted only by trained personnel. Refer to the
manual at all times.
9. Access to the interior of the product, when carrying out any work, must be conducted only by trained
personnel.
10. In order to maintain electrical safety, the unit must NOT be operated in atmospheres of more than
21% oxygen.
11. The plastic transport cap supplied must be replaced with suitably certified closers (such as glands or
stopping plugs) prior to commissioning. Failure to do so presents a potential source of ignition. One
certified stopping plug is supplied as standard.
12. Do NOT rely on the local visual indicator for safety related purposes.
82 Safety and Information
CAUTION
If the time in which a user logs in to the Searchzone Sonik App in the online mode exceeds 1 year,
it will be necessary to establish an Internet connection to the mobile device and log in to the App in
order to refresh the detector’s security certificate.
Items of Disposal
Enclosure Painted 316 Grade Stainless Steel
Standard Adjustable
Mounting Bracket
Sunshade Plastic / Stainless Steel (optional)
This symbol indicates that this product and/or parts of the product may not be treated as
household or municipal waste. Waste electrical products (end of life) should be recovered/
recycled where suitable specialist WEEE disposal facilities exist. For more information about
recycling of this product, contact your local authority, our agent/distributor or the manufacturer.
Stainless Steel
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2.2Important Information
This manual is for use with the Honeywell Searchzone Sonik advanced ultrasonic gas leak detector only.
Honeywell Analytics can take no responsibility for installation and/or use of its equipment if not done so in accordance with the
appropriate issue and/or amendment of this Manual.
The reader of this Manual should ensure that it is appropriate in all details for the exact equipment to be installed and/or operated. If in
doubt, contact Honeywell Analytics for advice.
The following types of notices are used throughout this Manual.
WARNING
Identifies a hazardous or unsafe practice which could result in severe injury or death to personnel.
CAUTION
Identifies a hazardous or unsafe practice which could result in minor injury to personnel, or product or
property damage.
92 Safety and Information
Note
Identifies useful/additional information.
Every effort has been made to ensure the accuracy of this document, however, Honeywell Analytics can assume no responsibility for any
errors or omissions in this document or their consequences.
Honeywell Analytics would greatly appreciate being informed of any errors or omissions that may be found in the content of this
document.
For information not covered in this document, or if there is a requirement to send comments/corrections about this document, please
contact Honeywell Analytics using the contact details given on the back page.
Honeywell Analytics reserve the right to change or revise the information supplied in this document without notice and without
obligation to notify any person or organization of such revision or change. If information is required that does not appear in this
document, contact the local distributor/agent or Honeywell Analytics.
2.3Organisational Measures for Functional Safety
Refer to the Searchzone Sonik Safety Manual for more information.
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103 Overview and Introduction
3 Overview and Introduction
3.1Description of Product
The Searchzone Sonik is an advanced ultrasonic gas leak detector for use in hazardous areas. It detects high pressure gas leaks within
the protection area, in order to provide an early alert to a hazard. While the Searchzone Sonik does not indicate the type of gas, it will
respond to any high pressure gas leak within the coverage area and so will protect against the release of dangerous gases, whether they
be toxic or flammable.
With conventional gas detectors, the escaping gas has to reach the detection point or line between a transmitter/receiver pair. The
Searchzone Sonik ultrasonic gas leak detector recognizes sound emitted by the leak from a distance, without the released gas having to
reach the detector.
3.2Description of Function
The Searchzone Sonik detects pressurised gas leaks by sensing the airborne acoustic ultrasonic sound pressure wave and signature
produced by the escaping gas. The detection method uses a robust patented piezo-based sensor which will function in extreme weather
conditions, on and offshore. With no moving parts and no sensor cover required, the Searchzone Sonik can withstand adverse conditions
including pressure wash-down. The detector does not require field calibration, only periodic bump testing, which can be accomplished
from ground level. Interfacing for set-up, commissioning and maintenance can be achieved wirelessly using the Searchzone Sonik App,
running on a suitable Bluetooth-enabled mobile device.
3.3Applications
The Searchzone Sonik detector is ideal for detecting gas leaks from units such as metering skids, compressors, pumps, valves and
pipework flanges in complex and congested distribution, process and transmission systems.
3.4Sensor Technology Description
The Searchzone Sonik detector employs an advanced ultrasonic sensor module that is robust and reliable even in harsh environmental
and operational conditions. The sensor module has a very long life in these adverse conditions and does not require field calibration.
The sensor detects the ultrasonic sound pressure waves, which are longitudinal vibrations that propagate through the air. Upon entering
the sensor structure, the sound pressure waves create a voltage across the transducer, which is then amplified and processed using
advanced detection algorithms. The patented piezo-based ultrasonic sensor module is robust with minimal failure modes.
3.5Environmental Factors
The leak detection range is limited by the atmospheric absorption of the ultrasound. This absorption increases with frequency. The
Searchzone Sonik will detect specified gas leaks typically up to 20m in all conditions. Background noise levels also have an effect
on the detection range. Process equipment which generates ultrasonic noise will need to be considered when setting the detection
thresholds of the detector, which can cater for high, medium and low levels of background noise. The detection range of the detector will
be maximal at lower levels of background ultrasonic noise. Typical sources of background noise include rotating machinery, clanking
chains, steam whistles and other steam release mechanisms, air horns as well as intentional gas releases.
Note
Ice build-up on the face of the sensor will cause an increase in sensitivity, which may lead to an increase in nuisance alarms. When
mounting in locations where ice build-up is likely, take necessary precautions in protecting the unit against such build-up and/or setting
of alarm levels.
3.5.1Introduction to Background Noise and Interference
The frequency of the noise being produced by the source will also have a bearing on the measurement range since the attenuation
co-efficient of sound in air increases with frequency. This not only affects the sound pattern generated by a gas leak but also that
generated by other sources of ultrasonic noise and they differ. The Searchzone Sonik detection is optimized to detect gas leaks in real
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113 Overview and Introduction
world conditions. The sound pressure level generated by a high pressure gas leak is dependent upon the pressure, the leak diameter, and
upon the gas density. The Searchzone Sonik detector is designed to detect hazardous high pressure leaks.
As a guide, the following table indicates typical maximum detection ranges that can be achieved for various levels of background
ultrasonic noise.
Detection Threshold Level 64 dB (Low) 74 dB (Mid) 84 dB (High)
Standard Detection Mode 24 m 12 m 7 m
Focus Detection Mode 7 m 5 m 3 m
Note
Due to variances sound level intensity generated across the measured frequency range and angular positioning of the detector.
The above values may vary up to 50%.
The values in the table above were achieved with a methane leak, mass flow rate of 0.1 kg/s at an environment of 20°C, 50 %RH and a
standard atmospheric pressure of 1013 hPA.
Note
The Background Levels feature, available in the Searchzone Sonik mobile App, can be used to validate and check that the current
detector settings are appropriate. Refer to section 9.9 Detector Settings for more information.
3.6Range and Field of Coverage
The Searchzone Sonik detector has a dynamic range of 40dB to 140 dB giving a detection range of typically 20m on-axis radius
(background noise dependant). The field of detection coverage (FoC) is +/90 degrees in both horizontal and vertical planes measured
on-axis to the face of the detector’s sensor.
The detection algorithms (Standard or Focus) differentiate between leak signatures and typical noise source signatures in both time and
frequency domains. The polar plots in the Figures 3 and 4 below show the typical detection areas for both Standard and Focus modes.
Refer to the table in section 3.5.1 for typical ranges that can be achieved for both Standard Mode and Focus Mode.
3.6.1Standard Mode
Use Standard Mode for larger areas which are subject to lower levels of background noise and where nuisance alarms sources are not
expected.
Figure 3.Angular Field of Coverage in
Standard Mode (% of Range)
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3.6.2Focus Mode
Use Focus Mode for closer areas which are subject to high levels of background noise and where nuisance alarm sources are expected.
123 Overview and Introduction
Figure 4.Angular Field of Coverage in
Focus Mode (% of Range)
3.7Description of Gas Leak Detection Using Ultrasound
A high pressure gas leak is a broadband continuous phenomenon. This gas leak ultrasound signature is detected in the presence of
other ultrasound noise sources using advanced detection algorithms. The detection algorithms differentiate between leak signatures
and typical noise source signatures in both time and frequency domains.
3.8Mounting Accessories and Flexibility
The Searchzone Sonik detector is supplied with the Standard Adjustable Mounting Bracket that can be simply installed prior to the
fitting of a Searchzone Sonik detector. The 3-axis adjustment allows the detector to be aimed precisely and has graduated angles
marked on the adjustments. The Standard Adjustable Mounting Bracket allows simple fixing onto a range of surfaces as well as poles,
struts, plates and other plant infrastructure. It is manufactured from high quality Stainless Steel.
LEGEND:
- Adjusting range in the vertical axis (A) = 0° to 90°
- Adjusting range in the horizontal axis (B) = 45° to +45°
- Adjusting rotational range (C) = 45° to +45°
- Graduated adjustment in 5 degree steps
- Graticule for easy setting
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133 Overview and Introduction
A
C
B
Figure 5.Standard Adjustable
Figure 6.Adjustment ranges
Mounting Bracket
3.9Commissioning and Maintenance Tools
The Searchzone Sonik Mobile App is an Android-based application downloadable from Google Play. It connects via Bluetooth to the
Searchzone Sonik detectors and is the primary tool for installation, commissioning and maintenance.
The HART and Modbus protocols provide additional means of communicating with Searchzone Sonik for the purpose of installation,
commissioning and maintenance.
Searchzone Sonik Mobile App
Installation/
Commissioning
Engineer
Bluetooth
HART
Modbus
Plant Management System
Figure 7.Searchzone Sonik communication diagram
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Plant Operator
3.10Available Accessories
The Standard Adjustable Mounting Bracket and a Plastic Sunshade are provided as standard. The following items are available as
optional accessories. Refer to the Ordering Information section of this manual for more information:
1. Large Adjustable Mounting Bracket
2. Stainless Steel Sunshade
3. Hazardous Area Mobile Phone
4. Searchzone Sonik App
143 Overview and Introduction
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154 Siting considerations
4 Siting Considerations
When designing an installation for a Searchzone Sonik detector it is important to give due consideration as to where it is to be located,
what potential sources of problems that may be encountered in the intended location and how the detector is to be mounted.
Users are strongly recommended to consult with experts who are experienced in site mapping and siting of ultrasonic gas leak detectors
when determining final positioning.
4.1Safety Case Framework
In compliance with IEC 61508, IEC 61511 and EEMUA recommendations, the Safety Case Framework is used as a method of
reducing risks at hazardous installations to acceptable levels. The framework is based on the concept of Layers of Protection which is
widely recognized by the process industry and clearly defined in industry safety standards.
Considering the application of all types of the protection layers − some layers are preventative (e.g., emergency shut down), while
some are there to mitigate the impact of an incident should it occur (e.g., fire and gas protective systems or plant emergency response
systems). Other layers of protection can counter occurrence of incidents in the first place (e.g., plant and physical asset protection,
constraint and boundary management, operator training, and asset management); while others can provide detection and alerting, and
associated guidance (e.g., operator alarms, early event detection, and integrated operator procedures). Layers can either be automated,
such as emergency shut down (ESD) equipment, or require human interaction such as operator responses to process alarms. Some
layers offer easily quantifiable risk-reduction benefits but require that the risks all be identified before. And still others are less tangible
and offer subtler benefits.
An Advanced Ultrasonic Gas Leak Detector will generally be used as part of a Gas Detection and Mitigation layer. Ultrasonic gas leak
detectors complement point and open path gas detectors as they detect the gas leak by sensing the sound pressure level created by a
high pressure gas leak. Ultrasonic gas leak detectors are affected by environmental conditions but not significantly by wind.
4.2Siting the Detector
CAUTION
1. Do NOT install in areas where detector can be struck by falling objects.
2. Do NOT site the detector where maintenance may impact, misalign or damage the detector.
3. Avoid installing on a vibrating infrastructure.
4. Install the detector a minimum of 1 m away from potential source of gas leak. Point the detector
30 degrees away from the potential source of gas leak.
5. A detector installed a minimum of 3 m away from a potential source of gas leak may be aimed directly
at it.
6. Do NOT operate the detector outside of the allowed temperature range. Refer to the Specification
section of this manual for more information.
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4.2.1 Mounting Position
It is recommended that Searchzone Sonik is placed close to the area to be protected to maximise the detection performance. For best
performance, use the following location principles when determining final positioning of the detector:
• Avoid situations were a leak plume is presented directly to the face of the detector. For best results, aim the detector at the potential
leak but at an angle of approximately 30 degrees off axis of the resultant plume.
• When monitoring a pipe containing the pressurized gas, mount the detector so that it ‘looks’ along the pipe.
• Avoid mounting the detector directly next to or over sources of ultrasonic noise e.g. compressor, gearbox, turbine, generator, etc.
• Do not install the detector next to pressurized air lines and fittings.
• Positioning the detector away from sources of unwanted ultrasonic noise will significantly reduce the risk of nuisance alarms.
4.2.2Mounting Angle
It is recommended that Searchzone Sonik is mounted pointing downwards by at least 30 degrees when used outdoors to allow the
sunshade to protect the sensor from the adverse environmental conditions.
4.3Accidental Impact
Situations where there is a significant probability of equipment, personnel or moving objects accidentally impacting Searchzone Sonik
detector should be avoided. If such locations cannot be avoided, measures including increase mechanical protection and warning
notices should be considered.
164 Siting considerations
4.4Change in Site Infrastructure
When there are changes in site infrastructure or configuration, which may introduce new sources of ultrasound, the customer should
review the existing configuration of Searchzone Sonik detectors and decide if it needs to be adapted to suit those changes.
4.5Transient Background Noise
Transient background noise from processes that release gas or steam under pressure (e.g., planned release of gas intended by the
operator) can cause unwanted triggering of an ultrasonic gas leak detector. These can be avoided by setting an alarm delay which is
longer than duration of that process operation.
4.6Location Survey
Points of consideration:
1) Assess the Risk Case
a. What is the risk?
b. What is the anticipated gas leak sound pressure level ?
c. What is the protection method?
d. What is the detection method in case of a leak?
e. How best to mitigate the risk?
2) Assess the environmental conditions before installation
3) Assess the potential sources of background noise in the area
If necessary measure these at the proposed ultrasonic gas leak detector install position
4) Assess the area to be covered by an ultrasonic gas leak detector with respect to:
a. Type of working environment
b. Local sources of ultrasounds
5) Choose an appropriate distance of the detector from the monitored area. Avoid installing the detector at or close to maximum range
to allow higher detection thresholds to be set, reducing the risk of false false alarms. See coverage diagrams specified in Overview
and Introduction section of this manual.
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174 Siting considerations
6) Choose Standard or Focus Mode with respect to the expected background noise levels and the nature of the risk to be covered.
Refer to the Overview and Introduction section of this manual for more information.
7) Choose the detector’s mounting position and angle, considering
a. Coverage
b. Ease of access
c. The direction of any potential leak. Refer to section 4.2.1 Mounting Position.
8) Ensure that the risk of physical impact, misalignment, or damage of the detector by human factor or uncontrollable events is avoided
4.7Bluetooth Considerations
1. Is use of Bluetooth permitted on the site?
2. Is the mobile device rated for operation in hazardous locations?
3. Is the Searchzone Sonik installed within 20 m from the place where operator will stand?
4. Is there direct visibility ensured between the Searchzone Sonik and the mobile device?
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5 Mechanical Installation
5.1Visual Check after Transportation
The Searchzone Sonik pack includes:
• The Searchzone Sonik Gas Leak Detector
• Standard Adjustable Mounting Bracket
• Plastic Sunshade
• One certified blanking plug
• Tool Kit
To ensure that the Searchzone Sonik unit was not damaged during transport, perform the following checks:
1. Check the packaging for damage before opening. If the packaging shows signs of tearing, breakage or other damage, immediately
inform the transport company and the supplier. Document the damage in an appropriate way (e.g., photographs).
2. Open the packaging carefully to avoid damaging the contents.
3. Examine the Searchzone Sonik detector for damage. If you find the detector to be damaged in any way, immediately inform the
transport company and the supplier. Document the damage in an appropriate way (e.g., photographs).
4. In the case of damage: a) Leave the detector in the original packaging
b) Do not attempt repair, or operate the detector until the damage claim has been resolved with the supplier.
185 Mechanical Installation
CAUTION
1. Installation, set-up and maintenance must be conducted only by trained and authorized personnel.
2. Do NOT open the front enclosure. The warranty of a unit, whose front enclosure has been opened, is invalidated.
3. Do NOT modify the front enclosure or component parts as this will compromise the hazardous location certification and
invalidate the warranty.
4. Do NOT modify the construction of the detector in any way as this will invalidate the warranty.
5. Open and close the wiring compartment cover with care to avoid deformation.
6. Installation, set-up and maintenance must be conducted only by trained and authorized personnel.
7. Avoid water and dust ingress when opening the wiring compartment to protect the unshielded electronic contacts.
8. Secure the detector when loosening bracket bolts. Unwanted release may cause injury.
9. Check mating surfaces prior to assembly (threads, O-rings). Ensure that they are clean and free of contaminants.
10. Check the O-rings prior to assembly, replace if damaged with genuine parts.
11. The Searchzone Sonik is supplied without cable glands. Ensure that all cable entry threads are sealed with an
appropriate plug to eliminate water ingress and thread damage. At installation, the cable entry transportation plugs
must be removed and replaced with suitable cable glands, thread adapters or blanking plugs to meet local hazardous
location requirements.
12. Check suitability of the blanking plug for its end use on site, ensure it meets local and national regulations.
13. Remove power from the Searchzone Sonik detector while installing wiring. Do NOT install wires or set up wiring with
power applied.
5.2Description
The Standard Adjustable Mounting Bracket enables Searchzone Sonik to be fitted to a wide range of plant infrastructure and then
appropriately aimed to cover the area to be protected. It is manufactured in 316L Stainless Steel.
A Large Adjustable Mounting Bracket is available as option to suit installation on larger diameter poles.
Searchzone Sonik cable entries are 2 x M25 or 2 x ¾” NPT dependent on the version.
The two compartment design means that the sensing electronic module and wiring compartment are separate. There are no set-up
switches within the electronics.
Two pluggable connectors are provided within the wiring compartment. The connectors feature mechanical retention.
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5.3Main Parts
195 Mechanical Installation
4
3
1
2
5
Figure 8.Searchzone Sonik general view
LEGEND:
1. Searchzone Sonik Advanced Gas Leak Detector
2. Standard Adjustable Mounting Bracket to fit on a plate, pole or plant infrastructure
3. Sunshade
4. Antenna cover
5. Large Adjustable Mounting Bracket (optional)
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5.4Mounting Searchzone Sonik
Searchzone Sonik will normally be mounted at height, typically secured to a pole using the UBolts or Worm Drive Clips supplied in the
Pole Installation Kit (optional).
The supplied Standard Adjustable Mounting Bracket allows mounting on a plate, pole or other plant infrastructure. All bolts are captive
to avoid accidental loss during installation.
CAUTION
IMPORTANT: When tightening the pivot bolts, first, tighten the left-facing horizontal M10 bolt to fix the pivot in
its horizontal position. Second, tighten the right-facing horizontal M10 bolt. Tighten these bolts to a final torque of
30 Nm/22 lb.ft.
205 Mechanical Installation
126 mm (4.95")
165 mm (6.5")
165 mm (6.5")
126 mm (4.95")
105 mm (4.15")
Figure 9.Standard Adjustable Mounting Bracket general view and dimensions
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
126 mm (4.95")
215 Mechanical Installation
12
11
13
6 1
2
3
8
8
7
8 8
4 5 6
10
9
7
Figure 10.Standard Adjustable Mounting Bracket exploded view
LEGEND:
Position Description Pcs.
1 Standard Adjustable Mounting Bracket flange 1
2 Vertical pivot 1
3 Horizontal pivot 1
4 Keyed insert 1
5 Conical washer 1
6 Bolt M10x25 2
7 Captive Bolt M10x30 2
8 Nord lock washer M10 4
9 Bolt cover plate 1
10 Plate retention strap 1
11 Bolt M3x10 1
12 Nord lock washer M3 1
13 Retention strap screw 1
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
5.5Pole Mount Installation
For pole installation, use the optional Pole Mount Fixing Kit. Refer to the Ordering Information section of this manual.
1. For poles 50 to 101 mm (2 to 4 inches) in diameter use the supplied Standard Adjustable Mounting Bracket.
2. For larger poles 101 to 152 mm (4 to 6 inches) in diameter use the Large Adjustable Mounting Bracket (optional; Refer to
section 14 Ordering Information of this manual.)
3. Attach the assembled Standard Adjustable Mounting Bracket (or Large Adjustable Mounting Bracket) to the pole. Align the bracket
flange V-groove with the pole for a good fit. Fix the bracket with two U-bolts and four nuts with washers. Alternatively, fix the bracket
using the Worm Drive Clips. Refer to the figure below.
4. Unscrew both horizontal M10 bolts by 23 turns.
5. Adjust the pivot in horizontal position.
6. IMPORTANT: First, tighten the left-facing horizontal M10 bolt (refer to the figure below) to fix the pivot in horizontal position
(torque 30 Nm/22 lb-ft).
7. IMPORTANT: Second, tighten the right-facing horizontal M10 bolt (refer to the figure below) to fix the pivot in horizontal position
(torque 30 Nm/22 lb-ft).
CAUTION
225 Mechanical Installation
Use of the Worm Drive Clips is NOT recommended for installation on moving objects, e.g., gas carriers.
NOTE
All Mounting Bracket bolts are captive to ensure that they are not accidentally dropped during installation.
V-GROOVE
DETAIL
Left-facing
horizontal
M10 bolt
Right-facing
horizontal
M10 bolt
Figure 11.Standard Adjustable Mounting Bracket fitment to pole with U-bolts
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
235 Mechanical Installation
Horizontal M10 bolts
Figure 12.Standard Adjustable Mounting Bracket fitment using Worm Drive Clips
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
5.6Wall Mount Installation
For installation onto a wall, use M8 or M10 mounting bolts with washers (not supplied).
245 Mechanical Installation
Figure 13.Wall mount installation
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
5.7Assemble Cable Glands
Refer to the original manufacturer’s assembly instructions for the particular cable gland type. The wiring compartment is certified to be
able to use EX d or Ex e glands to suite local requirements. Leave a service loop in the cable as per site standard procedures.
NOTE
Use certified cable glands and blanking plugs as per local standards.
Figure 14.Example of cable gland
255 Mechanical Installation
5.8Connect Cable Glands to the Searchzone Sonik
1. Fit the cable glands to the Detector.
2. Fit a Stopping Plug to any unused cable entry.
3. Tighten the gland nuts and Stopping Plugs as per the manufacturer’s instructions.
Figure 15.Connect cable glands to the Detector
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
5.9Detector Attachment
1. Remove the bolt cover plate (refer to the figure below).
2. Attach the Searchzone Sonik to Standard Adjustable Mounting Bracket.
3. Hold in place and hand-tighten the vertical M10 bolt with washer. The Standard Adjustable Mounting Bracket is designed so that
Searchzone Sonik sits on the top spigot and is balanced to aid installation.
4. Aim the detector in the desired direction and hand-tighten the left-facing horizontal M10 bolt. Only hand fit the right-facing
horizontal M10 bolt at this stage.
5. Check the final positioning of the detector and make adjustments if necessary.
6. Tighten only the left-facing horizontal M10 bolt to a final torque of 30 Nm (22 lb ft).
7. Tighten the remaining bolts to a final torque of 30 Nm (22 lb ft).
8. Push home the bolt cover plate.
265 Mechanical Installation
Vertical M10 bolt
Bolt cover plate
Figure 16.Detector attachment
5.9.1Detector removal
1. IMPORTANT: First, loosen the right-facing horizontal M10 bolt by 23 turns.
2. IMPORTANT: Second, loosen the left-facing horizontal M10 bolt by 23 turns.
3. Set the vertical position of Detector to 0°.
4. Hold the detector body and loosen the vertical M10 bolt.
5. Remove the Searchzone Sonik from Standard Adjustable Mounting Bracket.
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
Left-facing horizontal M10 bolt
275 Mechanical Installation
Figure 17.Set the vertical position of Detector to 0°
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
5.10Connect Wires to PCB Terminals
285 Mechanical Installation
Wiring Compartment
Cover
Grub screw
Figure 18.PCB Terminals
CAUTION
Remove power from Searchzone Sonik before performing any electrical installation or maintenance.
CAUTION
The equipment features pluggable connectors that are mechanically locked into position. These are
not accessible by the user during normal operation.
1. Loosen the grub screw.
2. Unscrew the Searchzone Sonik wiring compartment cover.
3. Unscrew and remove the pluggable connectors.
4. Connect wires as per local procedures. The connectors are clearly identified. Refer to the diagrams and tables in the
Electrical Installation section of this manual for information on wiring.
5. Ensure that the O-rings on the detector body and in the end cap are properly fitted and not damaged.
6. Ensure that the threads of the wiring compartment cover are clean of dust and lubricated with a suitable anti-seize compound.
7. Screw on the wiring compartment cover.
8. Tighten the grub screw to a final torque of 1.1 Nm (0.81 lb-ft)
9. Ensure the horizontal M10 bolts are loosened by 23 turns.
10. Use the graduated adjustment and angle scale to aim the Detector to the required position.
11. IMPORTANT: First, tighten the left-facing horizontal M10 bolt to a final torque of 30 Nm (22 lb-ft).
12. IMPORTANT: Second, tighten the right-facing horizontal M10 bolt to a final torque of 30 Nm (22 lb-ft).
13. Fit the sunshade in place. Refer to section 5.11 Sunshade Installation for instructions.
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
Wiring Compartment
Cover
Grub screw
295 Mechanical Installation
Left-facing horizontal M10 bolt
Figure 19.Example position of 45°
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
5.11Sunshade Installation
1. Unscrew the antenna cover from the top of the detector.
2. Fit the standard (supplied) or stainless steel sunshade (optional) onto Searchzone Sonik.
3. Ensure the O-ring around the antenna is not damaged and is properly fitted.
4. Screw the antenna cover back onto the antenna.
5. Tighten the antenna cover to a final torque of 5 Nm (7 lb-ft).
305 Mechanical Installation
Figure 20.Sunshade and antenna cover
Searchzone Sonik − Technical ManualPN 2331M1220 Issue 1 11/2018
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