FDS303
MULTI SPECTRUM IR
FLAME
DETECTOR
SAFETY & TECHNICAL MANUAL
Ref: 3303.0001
micropackfireandgas.com
2
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
This documen t is strictl y private an d confidential, reproduction withou t Micropack approval is pro hibited. © Micropack Enginee ring Ltd, 2018
HELP US TO HELP YOU
Every effort has been made to ensure the accuracy in the contents of our documents; however,
Micropack (Engineering) Ltd can assume no responsibility for any errors or omissions in our
documents or their consequences. This document has been processed through Micropack’s QA
procedures pertaining to ISO9001:2015 certification.
Micropack (Engineering) Ltd would greatly appreciate being informed of any errors or
omissions that may be found in our documents. To this end we include a form, given in
Appendix B, for you
to photocopy, complete and return to us so that we take the appropriate
action. Thank you.
CONTENTS
1
Introduction
4
1.1 Features 4
2
Safety Instructions
5
2.1
Specific conditions of use
5
2.2
Cautions
6
2.3
Important Safety Notices
6
2.4
EN 54-part 10 Limitation of use
7
3
Installation
8
3.1
Detector Enclosure
8
3.2
Mounting & Orientation
9
3.3
Wiring Procedure
11
3.3.1
0-20mA Output
12
3.3.2
Relay Output
13
3.3.3
Internal Inter-connections
14
3.4
Installation Checklist
15
3.4.1
Mechanical
15
3.4.2
Electrical
16
4
System Design Guidelines
17
4.1
Power Supply
17
4.2
Cable Selection
17
4.2.1 DC Power 17
3
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
This documen t is strictl y private an d confidential, reproduction withou t Micropack approval is pro hibited. © Micropack Enginee ring Ltd, 2018
5
Application Guidelines
19
5.1
Positioning Requirements
19
5.2
Detection Coverage
20
5.3
Exposure to Flare Radiation
20
5.4
Optical Contamination
20
5.5
Enclosed Areas
20
5.6
Detector Sensitivity
20
5.7
Detector Alarm Delay
20
6
Maintenance and Commissioning
22
6.1
Procedure
22
6.2
Functional Testing
24
7
Fault Finding
25
7.1
Removal of the Electronics
25
7.2
Replacement of the Electronics
25
7.3
Diagnostics
25
7.4
LED Indication
26
7.5
Power Fault
27
8
Technical Specification
28
8.1
Electrical Specification
28
8.2
Mechanical Specification
28
8.3
Environmental Specification
29
8.4
Certification and Approvals
29
8.5
Operating Specification
29
Appendix A
Acronyms, Terms & Abbreviations
30
Appendix B
Help us to help you 31
Appendix C
Field of View 32
Appendix D
FM Approval Performance Report
33
Appendix E
Offshore Certification 35
Appendix F
IEC 61508 Failure Rate Data 36
4
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
This documen t is strictl y private an d confidential, reproduction withou t Micropack approval is pro hibited. © Micropack Enginee ring Ltd, 2018
1
Introduction
This Safety and Technical Manual applies to FDS303 Hardware Version 1.0 and above.
The MICROPACK FDS303 is a flame detector that has unsurpassed false alarm
immunity for a Multi Spectrum IR flame detector.
The Micropack flame detection range are the safest and most advanced flame
detectors on the market today. Our worldwide installed base has proven that the
Micropack technology is robust, even in the harshest of environments.
FDS303 flame detectors identify flame using certified flame recognition software.
FM Approvals ensures that our flame recognition software is fit for purpose through
rigorous research and testing to a range of fires fuelled by different fuel types and
various potential false alarm stimuli.
The FDS303 has been designed for use in standalone operation.
1.1 Features
• The FDS303 has a 90o cone of vision with a range of 60 metres to a 0.1m2 pan
fire of heptane.
• Three detection sensitivity settings allowing the user to select the sensitivity that
is most suitable for their application.
• Superior false alarm immunity to common sources of unwanted alarms such as
Hot Process and Hot Work.
• Advanced optical verification test assuring readiness to perform when needed.
• Outputs include both relay contacts and 0-20mA.
• Separate termination chamber for ease of installation
• Certified Flame Simulator verifies operation from distances of 3 to 8 metres.
• FDS303 can operate via a standard 3 or 4 wire termination
• Microprocessor controlled heated optics increases resistance to moisture and
ice.
5
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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2
Safety Instructions
For the correct and effective use of this equipment, to maintain safety and avoid
hazards it is essential that you read and understand these instructions fully and act
accordingly BEFORE installing, operating or maintaining the equipment.
PAY ATTENTION TO ALL SAFETY WARNINGS AND CAUTIONS
2.1 Specific conditions of use
This equipment is certified and intended for use in potentially hazardous areas. Install and use
the equipment in accordance with the latest regulations.
The end user shall close any unused
entries using suitably certified blanking elements to maintain the housing’s type
of protection.
For European (ATEX) installations IEC/EN60079-14 ‘Electrical Installations in Hazardous Areas’ and
ICE/EN60079-17 ‘Inspection and Maintenance in Hazardous Areas’ should be strictly observed.
The Multispectrum IR flame detector type FDS303 is to be installed in places where there is a low
risk of mechanical damage.
For installations in North America the National Electrical Code (NEC) should be strictly observed.
In other countries the appropriate local or national regulations should be observed.
The equipment must be properly earthed to protect against electrical shock and minimise
electrical interference.
Do not drill holes in any housing or enclosure as this will invalidate the explosion protection.
Ensure that the enclosure lid is fully tightened and locked into position before energising the
equipment.
Do not open the enclosure in the presence of an explosive atmosphere.
All permits and proper site procedure and practices must be followed and the equipment must
be isolated from the power supply before opening the enclosure in the field.
Operators must be properly trained and aware of what actions to take in the event of a fire being
detected.
Cable to be used for installation is to be selected with a temperature rating of greater than 25
degrees Celsius above the maximum ambient temperature. The metric cable entries are fitted
with an internal stop. This will result in threads of the cable gland being visible. Do not over
tighten.
6
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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2.2 Cautions
Use only approved parts and accessories with this equipment.
Do not attempt to replace the window as the Sapphire and the front cover are individually
matched pairs to meet the stringent requirement of the Hazardous area certification.
The threaded portions of the detector are flame paths. These threads and the flame paths
are not to be repaired.
To maintain safety standards, commissioning and regular maintenance should be performed
by a qualified person.
2.3 Important Safety Notices
Pay attention to the guidelines given throughout this document.
If in any doubt about the instructions listed within this manual, then please contact Micropack
(Engineering) Ltd. Micropack (Engineering) Ltd takes no responsibility for installation and/or use
of its equipment if this it is not in accordance with the appropriate issue and/or amendment of
the manual. Micropack (Engineering) Ltd reserve the right to change or revise the information
contained herein without notice and without obligation to notify any person or organisation of
such action.
Only those parameters and configurations highlighted with the FM diamond ( ) have been
tested and approved by Factory Mutual.
Warning
Do not open the detector assembly in a hazardous area. The detector
contains limited
serviceable components and should only be opened by trained
personnel.
Caution
The wiring procedures in this manual are intended to ensure functionality of the device under
normal conditions. Due to the many variations in wiring codes and regulations, total compliance
to these ordinances cannot be guaranteed. Be certain that all wiring complies with the all local
ordinances. If in doubt, consult the authority having jurisdiction before wiring the system.
Installation must be done by trained personnel.
Caution
To prevent unwanted actuation or alarm, extinguishing devices must be inhibited/isolated prior
to performance testing or maintenance.
Detector Orientation
Detectors should be mounted with the earth stud directly below the lens.
7
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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Detector Positioning
Detectors should be positioned to provide the best unobstructed view of the area to be
protected.
The following factors should also be taken into consideration:
• Identify all high-risk fire ignition sources. Ensure that enough detectors are used to
adequately cover the hazardous area.
• Locate and position the detector so that the fire hazard(s) are within both the field of
view and detection range of the device.
• For best performance, the detector should be mounted on a rigid surface in a low
vibration area.
• Extremely dense fog or blizzard conditions could eventually block the vision of the
detector.
• For indoor applications, if dense smoke is expected to accumulate at the onset of a
fire, mount the detector on a side wall (approximately 1 to 2 metres) below the ceiling.
• The FDS303 has three sensitivity settings, which may be changed via a Micropack
application.
• The Detector carries out continuous internal hardware diagnostic testing to ensure
correct operation is relayed to the control system.
• The FDS303 is not designed to annunciate diagnostic failure of signal returns via
external wiring. Control systems and fire panels generally have fault monitoring for
such an eventuality.
2.4 EN 54-part 10 Limitation of use
The FDS303 is not approved for use in Oxygen-enriched atmospheres.
As the FDS303 responds to flame. It cannot be used in locations where flare stacks are within its
field of view or a reflected view is present without triggering alarms.
As the FDS303 responds to CO
2
Emissions of a flame the FDS303 cannot detect non-Hydrocarbon
fires, such as those using pure hydrogen, Silane and Sulphur as fuel.
The sensitivity of the FDS303 is reduced by obscurants such as smoke, fog and other
airborne particulates. The FDS303 may be blinded by extremely dense obscurants.
Arc welding should not take place within 10m of the FDS303 when using the highest
sensitivity setting.
8
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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3
Installation
The FDS303 design has been developed to allow simple installation. The detector comprises two
key components, the detector enclosure and the detector internal assembly. The detector
assembly located in the front of the enclosure should not be removed except by trained
personnel. Unauthorised removal or disassembly of the detector assembly will invalidate the
warranty. Only the rear end cap can be removed for terminal access.
3.1 Detector Enclosure
The detector electronics are housed in an enclosure certified for use in hazardous areas. For the
exact certification and conditions of use see certification label on the device, or the example
drawing below:
The enclosure comprises the front window cover including the window Part Number
3303.8004, the rear enclosure cover Part Number 2301.6009, the enclosure body Part Number
2301.6007, certification rating label see above Part Number 3303.6006.01, and the mounting
bracket Part Number 2301.6012.
9
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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3.2 Mounting & Orientation
The mounting bracket allows the detector’s vertical orientation to be adjusted from 0 to 45° and
allows a horizontal rotation of +/-45° when mounted from above.
Figure 1: Detector Mounting Bracket
10
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
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Figure 2: Ceiling Mount
Figure 3: Wall Mount
Firm, vibration free mountings are essential for trouble free operation of optical systems and
the
detector should be fixed to a rigid mounting. When mounting on a wall in this orientation
allow for the cable gland and cable as this may restrict the downward rotation of the detector.
11
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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3.3 Wiring Procedure
The wiring terminals are in the rear section of the detector enclosure and are accessible by
removal of the end cap.
The front section of the enclosure should only be accessed by trained personnel.
The terminal schematic detailed below shows the view looking inside the detector following
removal of the end cap.
Figure 4: Terminal Schematic
The detector has two types of alarm output available simultaneously
• 0-20mA (source non-isolated)
• Relay (Alarm & Fault)
Listed below are wiring options dependent on the functional requirements of the detector.
12
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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3.3.1 0-20mA Output
The following wiring connection diagram shows correct wiring of the detector when a 0-20mA
output is required.
Figure 5: 3 Wire Termination
Factory Fixed Values
Current Output
Event
0mA
Power/Detector Fault
1.5mA
Optical Fault
4mA
Healthy
18mA
Alarm
21mA
Over-range
Note:
The tolerance on the above outputs is +/- 0.3 mA dc current with a maximum loop
resistance of 500 ohms
13
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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3.3.2 Relay Output
The following wiring connection diagrams shows wiring the detector when a relay output is
required. Reversal of polarity across terminals 1 & 2 enables Micropack RS485 communication
on terminals 3 & 4. This communication protocol when used with Micropack applications allows
configuration changes to the detector.
Figure 6: Relay Configuration Termination
NOTE: EOL and Alarm resistors values are defined by the client and the
control system/fire panel which the detectors are being integrated into.
14
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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3.3.3 Internal Inter-connections
The following diagram shows the internal inter-connections of the alarm and fault relay contacts
and jumpers. Each field connection is listed on this diagram for clarity.
Figure 7: FDS303 Internal Inter-connections
15
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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3.4 Installation Checklist
Experience has shown that poor installation and commissioning practice may result in an
unreliable fire detection system that fails to meet the site performance targets. Before
installing the detector, it is important to consider where it is to be located and how it is to
be mounted. In order to maintain compliance with the EMC regulations it is essential the
electrical
installation be engineered correctly.
3.4.1 Mechanical
Notes When locating the detector consideration should be given to maintenance access to the
detector. The detector mounting should be secure and vibration free.
It is advisable to check the detection locations, prior to fabrication of the mounting
supports, as
changes are frequently made during construction at site which can affect
detector coverage.
The installation should allow space for subsequent detector removal, for maintenance or
repair,
to be easily achieved.
1
The detector should be fixed to a stable supporting structure using the mounting bracket
provided. The supporting structure must allow for horizontal adjustment of the detector
orientation. The support structure should be in place prior to detector installation.
Information
on mounting is available from Micropack (Engineering) Limited.
2
The threaded flame path of the enclosure cover and body must be protected from damage
during installation. Any such damage can destroy the validity of the enclosure.
3
The detector electronics shall be protected from mechanical damage and external sources
of EMI such as X-rays, RFI and electrostatic discharge. The detector should not face directly
towards
the sun.
4
Fit the mounting bracket to the support structure using 8mm bolts (not provided). The
detector (bracket) should be oriented to provide the desired coverage.
5
The detector enclosure body should be fitted to the mounting bracket. The bolts locate
into the bracket. Twist the enclosure to locate the bolts; these are then tightened using a
6mm Allen key.
6
Ensure the detector is orientated such that the earthing stud is directly beneath the lens.
7
Glanding should be carried out by trained personnel. The gland should be fitted in line
with installation standards for potentially explosive atmospheres that is 5 full threads
minimum with
the IP seal washer fitted at the bottom of the thread. This sealing
arrangement will result in a number of threads of the cable gland being visible. The gland
should be torqued between 15 to 20 N m (11 to 15 lb·ft).
16
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3.4.2 Electrical
Notes It is advisable to check the detection locations, prior to fabrication of the mounting
supports, as
changes are frequently made during construction at site. Detector cabling
must be segregated from cables carrying high-speed data or high energy and/or high
frequency signals and other
forms electrical interference. The detector requires a clear
unobstructed view of the local hazard. In order to avoid local obstructions, such as pipework and cable trays, a 2m helix should be allowed in the detector cabling. The detector
should only be fitted just prior to commissioning the detector. Experience shows that the
detector can be damaged due to cable testing
operations (Insulation Tests, etc.).
1
Isolate all associated power supplies. Ensure that they remain OFF until required for
commissioning.
2
The threaded flame path of the enclosure cover and body must be protected from
damage during installation. Any such damage can destroy the validity of the enclosure.
3
The electronics subassembly shall be protected from mechanical damage and external
sources of EMI such as X-rays, RFI and electrostatic discharge.
4
The enclosures external earth stud should be connected to a local earth point.
5
Remove the transit plug(s) from the enclosure body gland entries.
6
Fit approved cable glands.
17
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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4
System Design Guidelines
The following guidelines are intended to assist with the electrical design and engineering of
systems where it is intended that flame detectors will be used
.
4.1 Power Supply
The detector requires an absolute minimum supply voltage of 18Vdc, as measured at the
detector
terminals. The system power supply voltage and power distribution should be
arranged such
that on the longest cable run the detector(s) has a supply voltage of greater than
18Vdc.
4.2 Cable Selection
Cable to be used for installation is to be selected with a temperature rating of greater than 25
degrees Celsius above the maximum ambient temperature.
The metric cable entries are fitted with an internal stop. This internal stop has an IP washer
mounted directly above it. Ensure this is fitted to maintain the ingress protection. This will result
in threads of the cable gland being visible. Do not over tighten.
The installation and local regulations and standards determine the overall cable specification.
This section specifies suitable cable characteristics to ensure correct operation of the flame
detector.
4.2.1 DC Power
NOTE: Table 2 shows an absolute maximum for cable length; try not to approach this value.
DO NOT ground any cable shields at the detector housing.
Table 2: Maximum Cable Lengths (24Vdc supply)
Installation
based on 24V
nominal supply
Number of
Flame Detectors
Maximum Power
(W)
Maximum Cable
Length (m) with
1.5mm2
Conductors
(12Ω/km)
Maximum Cable
Length (m)with
2.5mm2
Conductors
(7.6Ω/km)
Detector 1 12W @ 24Vdc 500 Metres 780 Metres
18
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Table 3: AWG Conversions
Cross Sectional Area (mm2) American Wire Gauge (AWG)
Typical Conductor Resistance
per km (3280 ft.)
DC Ω/km @ 20°C (Approx.)
0.5 22 36
1.0 18 19
1.5 16 12
2.5 14 7.6
19
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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5
Application Guidelines
In considering the application of the detector it is important to know of any conditions that may
prevent the detector from responding. The detector provides reliable response to Hydrocarbon
flames within its field of view, and insensitivity to common false alarm sources. Solid obstructions
or a direct view of intense light sources may result in a reduction in the coverage and/or a
reduction
in the detector sensitivity. Scaffolding or tarpaulins in the detector’s field of view may
reduce coverage. Contamination of the detector window may result in a reduction in sensitivity.
The detector has a 90° conical field of view. The location and orientation of the detector in
relation to the protected area determines the actual footprint.
Achieving the desired coverage
depends on congestion within the protected space, the location
of the detector(s) and the
distance of the detector from the hazard. It may be necessary to install
more than one detector
within an area to achieve adequate coverage.
The detector sensitivity, expressed as fire size at a distance, is determined by the radiant heat
output of the fire. This is a function of the fuel source, how it is released and distance from the
detector to the fire.
In common with other forms of flame detection the detector’s sensitivity is reduced and
potentially blinded by dense obscurants such as smoke, fog and other airborne particulates.
The detector is insensitive to arc welding; however, this should not be conducted within 10m of
the
detector.
5.1 Positioning Requirements
The following guidelines have been based on operational feedback, reflecting commonly
experienced problems which can be traced to a failure to observe the following:
• Ensure the mounting position is free from vibration or movement.
• Prevent accidental knocking or forcing out of alignment.
• Isolate as far as possible from local electrical interference sources.
• Ensure sufficient detection to achieve adequate coverage for all likely hazards.
• Minimise exposure to contamination of the detector face plate.
• Ensure ease of maintenance access to detector (i.e. direct ladder or scaffold
access).
• Do not allow the FDS303 to have direct view of hot surfaces.
• Ensure that the FDS303 has no direct view or reflected view of a friendly fire.
• The detector should be aimed downward by at least 10
o
to 20o.
All these issues are of crucial importance to a successful installation and they should be afforded
great attention during the detailed design, construction and commissioning phases of the work.
20
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5.2 Detection Coverage
Detector locations can be chosen from computer models or from site surveys. The detectors
should be aligned to view the intended hazard considering any obstruction and
congestion.
Software analysis of the actual detector coverage may be required to ensure adequate coverage
of the hazards. This analysis can also be used to optimise the number of detectors and the loop
configuration. The cones of vision are detailed in Appendix C.
5.3 Exposure to Flare Radiation
Flame detectors are frequently used where hydrocarbon fire hazards are expected; these are
quite often processing plants where a flare stack is in use nearby. The detector shall not have a
direct view of the flare or a reflected view of the flare.
5.4 Optical Contamination
There are many sources of contamination such as oil, water (deluge water, rain and sea-spray),
snow, ice, and internal misting. Excessive contamination of the detector faceplate may result in
an increased maintenance requirement and potentially reduce the detector’s sensitivity. Where
detectors are mounted at low level, care should be taken to avoid contamination (such as water
and oil) from equipment above the detector. Care should be taken in sighting the detector to
minimise the likelihood of such contamination. The detector is designed such that an optical
fault
is indicated after a confirmation period of 15 minutes, when half of the detection range
remains. This is indicated by the fault output and is evident by the yellow colour of the LED on
the face of the detector. The optical fault condition
indicates that the detector requires cleaning
or service. The optical fault indication is self-clearing.
5.5 Enclosed Areas
In enclosed areas, if dense smoke is expected to accumulate at the onset of the fire, the detector
should be mounted 1 to 2 metres below the ceiling level.
5.6 Detector Sensitivity
The detector’s response to a fire is a function of the fuel source and how it is released, fire size
and distance, orientation to the detector and local ambient conditions. The typical figures are
based on in-house tests except where marked with the FM logo these tests were conducted and
certified by Factory Mutual. As with all tests the results must be interpreted according to the
individual application considering all possible variables.
The detector sensitivity to different fuel sources is dependent on the Radiant Heat Output of the
flame, the detectors typical response is shown below (see table 4). The detector will only detect
Hydrocarbon fires.
5.7 Detector Alarm Delay
The detector can be factory configured with an alarm delay of up to 30 seconds. If this option is
selected, however, it invalidates the SIL 2 and FM certification shown within this manual.
21
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Table 4: Typical FDS303 Response Characteristics High sensitivity (60 metres). For all
FM approved results see Appendix D
Fuel Fire Size Distance
Methane Fire 0.6m plume height 50m (165 feet)
Ethanol Fire
0.3m x 0.3m pan 42m (136 feet)
Diesel Fire
0.3m x 0.3m pan
50m (165 feet)
Crude Oil (heavy fuel oil) Fire
0.3m x 0.3m pan
50m (165 feet)
Wax Inhibitor (Clear 10) Fire
0.3m x 0.3m pan
50m (165 feet)
Anti-Foam (Surflo AF-300) Fire
0.3m x 0.3m pan
50m (165 feet)
Wood Stack Fire
0.3m x 0.3m crib
50m (165 feet)
n-heptane Fire 0.3m x 0.3m pan 60m (200 feet)
n-heptane Fire in direct sunlight 0.3m x 0.3m pan
60m (200 feet)
n-heptane Fire in modulated sunlight
0.3m x 0.3m pan 60m (200 feet)
n-heptane Fire in the presence of Arc welding
0.3m x 0.3m pan
60m (200 feet)
n-heptane Fire in the presence of a 500-Watt lamp 0.3m x 0.3m pan
60m (200 feet)
Gasoline Fire
0.3m x 0.3m pan
60m (200 feet)
JP4 Fire
0.3m x 0.3m pan
60m (200 feet)
Methanol Fire
0.3m x 0.3m pan
42m (136 feet)
22
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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6
Maintenance and Commissioning
6.1 Procedure
This maintenance schedule/ commissioning procedure is intended for guidance only. The actual
level of maintenance required will depend on the severity of the operating environment and
the likelihood of damage or the rate of contamination from oil, sea spray, deluge system etc. It
is advisable to regularly review maintenance reports and adapt the maintenance period to the
operating environment.
23
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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Step Periodic Inspection and Maintenance Suggested Interval
1 - 6
General Inspection and maintenance of the detector and faceplate. 6 Monthly
6 - 14
Specific inspection and maintenance of the detector enclosure. 12 Monthly
16
Detector function testing. 6 Monthly
1 – 5
15 - 17
Commissioning Procedure. Post Installation
Step
Activity
Key Points
1
Detectors that require maintenance / commissioning should be taken off
line and inhibited. Detectors which require to be opened will need to be
isolated electrically.
Ensure that panel wiring
and terminations
associated with all units
under test are in good
order.
2
Ensure that the detector mounting arrangements are secure and
undamaged.
3
Ensure that the detector enclosure is intact and undamaged.
4
Ensure that all associated cables and glands are correctly made up, secure
and undamaged.
5
Clean the enclosure faceplate (outside) with a mild detergent solution and
a soft cloth until the window is clear of all contamination. Wash the
window thoroughly with clean water and dry with a clean lint free cloth or
tissue.
Note: This MUST be carried out prior to initial powering of the device.
The FDS303 will carry out an automatic Optical Test Calibration at
this point.
Assess requirement for
opening the enclosure, for
maintenance or cleaning,
follow steps 6 to 14.
6
Open the detector enclosure if required, by removing the enclosure cover.
This exposes the enclosure flame path and detector lens.
Avoid damage to the flame
path, faceplate and lens.
7
Clean the enclosure cover and body flame paths with a dry clean cloth to
remove and contamination. If the flame path or threads are badly pitted
the components should be replaced.
8
Check the ‘O’ ring seal on the enclosure cover is not damaged or perished,
replace as required. Note the ingress protection is compromised if the seal
is not correct.
9
Clean the enclosure faceplate (inside) with a mild detergent solution and a
soft cloth until the window is clear of all contamination. Wash the window
thoroughly with clean water and dry with a clean lint free cloth or tissue.
10
Non–setting waterproof grease should be evenly applied to the flame path
on both the enclosure cover and body.
11
Clean the detector lens. This should be done with a soft, dry and clean
cloth.
Avoid touching the optics
or electronics.
12
Clean the detector enclosure faceplate. Use a degreasing agent on the
outside to remove deposits.
13
The enclosure cover must be screwed on to a minimum of 5 full turns or
until fully tight and secured using the locking screw provided.
14
Reinstate the detector back into service.
15
Ensure that inhibits are applied, then, using the flame test torch, function
test the detector. Note the detector LED indicator, within the detector
housing, changes colour to RED. Check the mA output is indicating 18mA.
Check the complete
display system for correct
function and indication.
16
Isolate the power to the detector and ensure a fault is initiated within the
control system. Check the Ma output is indicating 0mA.
24
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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6.2 Functional Testing
The detector can be function tested using the FS30x Flame Simulator, which has been specifically
designed to provide a convenient means of field testing the detector. Refer to the FS30x Flame
Simulator user manual for instructions on its use.
In the unlikely event of the detector failing to respond to the FS30x flame simulator please contact
Micropack (Engineering) Limited (info@micropack.co.uk
). Please ensure that the flame detector
and flame simulator are being used correctly in the first instance by referring to their manuals
Detector/simulator returns along with a written statement describing any fault should be sent
to the address listed below:
17
De-isolate the detector and ensure the status LED indicates green.
Reinstate the detector back into service. Check the mA output is indicating
4mA.
Micropack Engineering Repairs Ltd
c/o
Norcott Technologies
Ltd
Unit 1
Sunset Business
Centre
Widnes
Cheshire
WA8 0QR
25
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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7
Fault Finding
7.1 Removal of the Electronics
Warning there are no user replaceable parts within the electronic module. Any attempt to repair
or dismantle the electronic sub-assemblies will void the warranty. If any fault is suspected
within
the
electronics module the module is to be returned to Micropack for investigation and
repair if
required. Any faults should be reported to Micropack as per the instruction in section
6.2.
Removal of the electronics should only be performed by competent personnel. The following is
the procedure for removal of the electronic module: -
1. Loosen the Allen screw that secures the lens cap to the housing.
2. Un-screw the lens cap assembly and remove.
3. Gently un-screw the three screws indicated until they freely turn. Please note these
screws are not removable.
4. Grasp the two screws positioned at the bottom of the detector and pull the electronics
module out of its housing.
7.2 Replacement of the Electronics
The following is the procedure for installation of the electronic module: -
1. Insert the electronic module with the centre sensor positioned at the top of the
housing.
2. Rotate the module clockwise and anti-clockwise until the locating pins click into
position.
3. Push the electronics assembly into the housing until the face plate is flush with the
front of the housing. Note: This should take minimum force if the locating pins are
in position.
4. Gently screw the three screws until they bottom. Note: Do not over tighten.
5. Grease and replace the lens cap.
6. Tighten the lens cap Allen locking screw.
7.3 Diagnostics
It is impossible to provide fault diagnostics for every possible detector fault. In all cases it is
advised that the following best practice is followed:
• Only make one change at a time (changing more than one thing makes diagnosis very
difficult).
• Check the most obvious possible cause first.
• Work systematically through the problem.
• Keep good notes on the original problem, each step taken, and the results observed.
26
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
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7.4 LED Indication
The detector LED indicator is used to reveal the detectors current state, as shown below:
Figure 9: FDS303 Fascia - Status LED
Table 5: LED Status Diagnostic Chart
LED Colour
Status
Indicator
Green
Healthy
Flashing LED 24V/0V Polarity Reversed
Steady OFF No Power/Major Internal Fault
Steady Yellow Fault
Red Alarm
One yellow flash at start up The FDS303 is set to low sensitivity (15 metres)
Two yellow flashes at start up The FDS303 is set to standard sensitivity (30 metres)
Four yellow flashes at start up The FDS303 is set to high sensitivity (60 metres)
27
FDS303 Safety and Technical Manual
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7.5 Power Fault
If the detector LED indicator is OFF or flashing then there may be a power supply fault, as shown
below:
Figure 10: Power Supply Diagnostic Chart
When investigating power supply faults, it is important to check that all voltages are within the
detectors operating range (18V to 32V) under full load conditions as the voltages measured
under
no load conditions can be misleading.
28
FDS303 Safety and Technical Manual
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8
Technical Specification
8.1 Electrical Specification
Parameter
Units
Min
Nominal
Max
Comment
Supply Voltage
Vdc 18 24 32 Inc. ripple
Supply Ripple Vpk-pk 1.0 1.0 1.0
Detector Power Consumption no Heaters W 3.0 3.5 4.0 In Alarm
Detector Power Consumption with heaters W 11 11.5 12 In Alarm
Detector shutdown voltage (low supply) Vdc <18
8.2 Mechanical Specification
Parameter
Units
Value
Comment
Enclosure
Overall Dimensions
mm
100 Diameter x 200 Length
Shipping Weight
Kg
2.5 6
Material
HE30 Aluminium
316SS
Coating
Colour
Red Epoxy Coated Finish
Cable Entries
mm/inches
M25, ¾ NPT
Other variants
on request
Terminal Wire Size
mm2
2.5
Ingress Protection
IP66 (NEMA 4X)
Mounting Bracket
See figure 1 Mounting Bracket Page 9
Support Fixings
mm
2 x M8
Vertical Adjustment
Degrees
0 to 45
Horizontal Adjustment
Degrees
0
Provided by
support
Axial (horizontal)
Rotation
Degrees
+/- 45
29
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
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8.3 Environmental Specification
Parameter
Units
Min
Min
Comment
Operating Ambient Temperature
o
C
-60
+85
T4
Storage Ambient Temperature
o
C
-60
+85
Relative Humidity
%RH 0 100
Non-condensing
8.4 Certification and Approvals
Parameter Authority/
Standard
Approval Certificate
Hazardous Area Certification
ATEX
Ex II 2 G Ex db II C T4Gb IP66
FM18 ATEX0004X
Area Certification Hazardous
NEC 505
Class1 Zone 1 A Ex db IIC T4
Hazardous Area Certification
NEC 500
Class 1 Div 1, Groups B, C, D T4
Hazardous Area Certification
IECEx
Ex II 2 G Ex db II C T4Gb IP66
FME18.0003X
American Fire Service Listing
FM
Class 3260,3810
European Fire Services
Listing
FM EN 54 Part 10 2002 1725-CPR-E0007
CE Marked (Emissions)
Element
EN61000-6-3:2007A1:2011
CE Marked (Immunity)
FM
EN50130-4 2011 A1:2014
IEC 61508
exida
Certified SIL 2 Capable
Class Guideline
DNV-GL
DNVGL-CG-0339
See Appendix E
8.5 Operating Specification
Parameter Units Min Max Comment
Detector Range (depth of field) m 2.0 60
Horizontal Field of View Degrees 90 90
Vertical Field of View Degrees 90 90
Detector Response Time Seconds 4.0 30
Power on reset delay Seconds 5 5
Optical Verification - - - Default - on
30
FDS303 Safety and Technical Manual
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FDS303 Flame Detector
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Appendix A - Acronyms, Terms & Abbreviations
Term
Description
AC
Alternating Current
ATEX
Atmosphere Explosive
AWG
American Wire Gauge
BS
British Standard
CCTV
Closed Circuit Television
CE
European Conformity
CO2
Carbon Dioxide
CSA
Canadian Standards Associated
dB
Decibel
DC
Direct Current
EMC
Electromagnetic Compatibility
EN
European Norm
FM
Factory Mutual
FOV
Field of View
HFT
Hardware Fault Tolerance
I or A
Electrical Current or Ampere
JB
Junction Box
Km
Kilometre
kW
Kilo Watt
LED
Light Emitting Diode
MEL
Micropack (Engineering) Ltd
mH
Milli Henry – Inductance
MOR
Meteorological Optical Range
NEC
National Electrical Codes
nF, pF
Nano Farad, Pico Farad – Capactiance
PC
Personal Computer (IBM PC Compatible)
R or Ω
Ohms (electrical resistance)
SFF
Safe Failure Fraction
SIL
Safety Integrity Level
V
Voltage
Vs
Versus
W
Watts (Wattage)
31
FDS303 Safety and Technical Manual
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Appendix B - Help us to help you
TO:
QA Department
Micropack (Engineering) Limited
Fire
Training Centre
School Hill, Portlethen
AB12 4RR
Tel: +44 (0) 1224 784055
Fax: +44 (0) 1224 784056
Email: info@micropack.co.uk
From:
Tel:
Fax:
Email:
I suggest the following corrections/changes be made to Section ……………
Marked up copies attached (as appropriate): Yes/No
Please inform me of the outcome of this change: Yes/No
For Micropack (Engineering) Limited:
Action by: __________________________________________________________________Date: ______________________
Response: ________________________________________________________________Date: ______________________
32
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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Appendix C - Field of View
Horizontal Field of view to a 0.1 m2 N-heptane pan fire with an alarm response. 100%= 60
metres for High sensitivity. 100%= 30 metres for Standard sensitivity. 100%= 15 metres for Low
sensitivity
.
Vertical Field of view to a 0.1 m2 N-heptane pan fire with an alarm response. 100%= 60 metres
for High sensitivity. 100%= 30 metres for Standard sensitivity. 100%= 15 metres for Low
sensitivity.
33
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
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Appendix D - FM Approval Performance Report
Alarm Response to various stimuli
Stimuli
Low Alarm
Distance
Standard Alarm
Distance
High Alarm
Distance
N-heptane 0.1m2 pan fire
15 metres
30 metres
60 metres
Ethanol 0.1m2 pan fire
15 metres
30 metres
42 metres
JP4 0.1m2 pan fire
No test
30 metres
60 metres
Methane 0.6m plume fire
15 metres
30 metres
50 metres
100W incandescent Lamp steady state
No Alarm 0.9m
No Alarm 1.8m
No Alarm 1.8m
100W incandescent Lamp modulated
No Alarm 0.9m
No Alarm 1.8m
No Alarm 1.8m
Two 40W Fluorescent lamps steady state
No Alarm 0.9m
No Alarm 1.8m
No Alarm 1.8m
Two 40W Fluorescent lamps modulated
No Alarm 0.9m
No Alarm 1.8m
No Alarm 1.8m
500W Quartz Halogen lamp steady state
No Alarm 0.9m
No Alarm 1.8m
No Alarm 1.8m
500W Quartz Halogen lamp modulated
No Alarm 0.9m
No Alarm 1.8m
No Alarm 1.8m
190 Amp Electric arc welding
No Alarm 6.0m
No Alarm 8.0m
No Alarm 10m
3000W electric space heater steady state
No Alarm 1.8m
No Alarm 1.8m
No Alarm 1.8m
3000W electric space heater modulated
No Alarm 1.8m
No Alarm 1.8m
No Alarm 1.8m
1500W electric heater steady state
No Alarm 1.8m
No Alarm 1.8m
No Alarm 1.8m
1500W electric heater modulated
No Alarm 1.8m
No Alarm 1.8m
No Alarm 1.8m
Reflected Sunlight
No Alarm
No Alarm
No Alarm 1.8m
Reflected modulated Sunlight
No Alarm
No Alarm
No Alarm 1.8m
Low Sensitivity response to N-heptane 0.1m2 pan fire in the presents of False Alarm Stimuli
False Alarm Stimuli
Distance to false Alarm
Distance to Fire
100W incandescent Lamp steady state
0.9m
15 metres Alarm
100W incandescent Lamp modulated
0.9m
15 metres Alarm
Two 40W Fluorescent lamps steady state
0.9m
15 metres Alarm
Two 40W Fluorescent lamps modulated
0.9m
15 metres Alarm
500W Quartz Halogen lamp steady state 0.9m 15 metres Alarm
500W Quartz Halogen lamp modulated
0.9m
15 metres Alarm
190 Amp Electric arc wielding
6.0m
15 metres Alarm
3000W electric space heater steady state
1.8m
15 metres Alarm
3000W electric space heater modulated
1.8m
15 metres Alarm
1500W electric heater steady state
1.8m
15 metres Alarm
1500W electric heater modulated
1.8m
15 metres Alarm
Reflected Sunlight
N/A
15 metres Alarm
Reflected modulated Sunlight
N/A
15 metres Alarm
34
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Standard Sensitivity response to N-heptane 0.1m2 pan fire in the presents of False Alarm
Stimuli
High Sensitivity response to N-heptane 0.1m
2
pan fire in the presents of False Alarm Stimuli
False Alarm Stimuli
Distance to false Alarm
Distance to Fire
100W incandescent Lamp steady state
1.8m
60 metres Alarm
100W incandescent Lamp modulated
1.8m
60 metres Alarm
Two 40W Fluorescent lamps steady state
1.8m
60 metres Alarm
Two 40W Fluorescent lamps modulated
1.8m
60 metres Alarm
500W Quartz Halogen lamp steady state
1.8m
60 metres Alarm
500W Quartz Halogen lamp modulated
1.8m
60 metres Alarm
190 Amp Electric arc welding 8.0m 60 metres Alarm
3000W electric space heater steady state
1.8m
60 metres Alarm
3000W electric space heater modulated
1.8m
60 metres Alarm
1500W electric heater steady state 1.8m 60 metres Alarm
1500W electric heater modulated
1.8m
60 metres Alarm
Reflected Sunlight
N/A
60 metres Alarm
Reflected modulated Sunlight
N/A
60 metres Alarm
False Alarm Stimuli
Distance to false Alarm
Distance to Fire
100W incandescent Lamp steady state
1.8m
30 metres Alarm
100W incandescent Lamp modulated
1.8m
30 metres Alarm
Two 40W Fluorescent lamps steady state
1.8m
30 metres Alarm
Two 40W Fluorescent lamps modulated
1.8m
30 metres Alarm
500W Quartz Halogen lamp steady state
1.8m
30 metres Alarm
500W Quartz Halogen lamp modulated
1.8m
30 metres Alarm
190 Amp Electric arc welding
8.0m
30 metres Alarm
3000W electric space heater steady state
1.8m
30 metres Alarm
3000W electric space heater modulated
1.8m
30 metres Alarm
1500W electric heater steady state
1.8m
30 metres Alarm
1500W electric heater modulated
1.8m
30 metres Alarm
Reflected Sunlight
N/A
30 metres Alarm
Reflected modulated Sunlight
N/A
30 metres Alarm
35
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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Appendix E – Marine Certification.
DNVGL Type Approval to Class Guide Lines DNVGL-CG-0339 Edition November 2016.
Certificate Number Pending.
Location Classes for FDS303 IR3 Flame Detector when used with mounting Bracket
Part Number 3100.0003.4
Green areas show FDS303 approved location classes.
COLUMN1 COLUMN 2
Type LOCATION WITHIN MAIN AREA
MAIN AREAS ON BOARD
Machinery
Spaces
Control Room
Accommodation
Bridge
Pump room, holds
rooms with no
heating
Open
Deck
Temperature
Inside cubicles, desks etc with temperature rise of 5°C
or more
B B B D D
All other locations A A A C D
Humidity
Locations were special precautions are taken to avoid
Condensation
A A A A A
All other locations B B B B B
Vibration
On Machinery such as integral combustion engines,
compressors, pumps including piping on such
machinery
B - - B B
Masts - - - - C
All other locations A A A A A
EMC (Electro-
magnetic
compatibility
All locations with specified main areas
A A B A B
Enclosure
Submerged application D - - D D
Below floor plates in engine room C - - - -
All other locations B A A B C
36
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
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Appendix F - IEC 61508 Failure Rate Data
IEC 61508: ed 2, 2010
Using reliability data extracted from the exida Electrical and Mechanical
Component Reliability Handbook the following failure rates resulted from the FDS303 FMEDA.
MAXIMUM DIGNOSTIC TEST INTERVAL – 15 minutes.
The useful lifetime of critical components is predicted to be
50 years (Ref: Report No.: MP 17/10-
145 R001 V1 R1).
Failure Category
Failure Rate (FIT)
Fail Safe Undetected 42
Fail Dangerous Detected 544
Fail Detected (detected by internal diagnostics) 488
Fail High (detected by logic solver) 13
Fail low (detected by logic solver) 43
Fail Dangerous Undetected 117
No Effect 1547
Annunciation Undetected 11
The FDS303 is classified as a Type B Element according to IEC 61508, having a hardware fault
tolerance of 0. Therefore, based on the SFF of 94.83% a design can meet SIL 2 @ HFT=0 when the
FDS303 is used as the only component in a SIF Sub-assembly.
Proof Testing
Step
Action
1
Bypass the safety function and take appropriate action to avoid false trip.
2
(Optional) Use RS485 communications to retrieve and diagnostics and take appropriate
action.
3
Use the test torch to force the FDS303 into alarm state. Verify that LED, alarm relay/020mA outputs indicate alarm (as required)
4
Wait for detector alarm signal to unlatch. Verify that the LED, alarm relay/0-20mA outputs
no longer indicate alarm.
5
Inspect enclosure for any leaks, visible damage or dirty optics.
6
Perform the periodic inspection and maintenance procedure from the FDS303 safety and
technical manual.
7
Remove the bypass and otherwise restore normal operation.
Proof testing should be carried out on a yearly basis, showing a probability of failure on demand
average (PFD
AVG
) of 6.82E-03. The following represents a suggested proof test.
Personnel carrying out commissioning, testing and maintenance on this device shall be
sufficiently competent and experienced to do so.
37
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535 Ref: 3303.0001
FDS303 Flame Detector
This documen t is strictl y private an d confidential, reproduction withou t Micropack approval is pro hibited. © Micropack Enginee ring Ltd, 2018
In the UK ,Europe and Asia
MICROPACK (Engineering) Ltd
Fire Training Centre, Schoolhill,
Portlethen, Aberdeen AB12 4RR
Tel: +44 (0)1224 784055
Fax: +44 (0)1224 784056
In the Americas
MICROPACK Detection (Americas) Inc
1227 Lakecrest Court, Fort Collins,
Colorado, 80526
Tel: +1 970 377 2230
MICROPACK (Engineering) Ltd
Fire Training Centre, Schoolhill, Portlethen,
Aberdeen AB12 4RR
Tel: +44 (0)1224 784055
Email: sales@micropack.co.uk
www.micropack fireandgas.com
In the Americas
MICROPACK Detection (Americas) Inc.
800 Town and Countr y Blvd
Suite 300
Houston, TX 77024
Tel: +1 832 431 3094
ISO 9001:2015 Certified
Doc Ref: 3303.0001 Rev 1.7
Subject to modifications. © 2018 Micropack (Engineering) Ltd.
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