MSA FL500 UV/IR, FL500-H2 Operating Manual
Operating Manual
FL500 UV/IR, FL500-H2 Flame Detector
Order No.: 10193213/04
CR 800000038336
MSAsafety.com
WARNING!
Read this manual carefully before using and maintaining the device. The device will perform as designed
only if it is used and maintained in accordance with the manufacturer's instructions. Otherwise, it can fail to
perform as designed and persons who rely on this device for their safety could sustain serious injury or
death.
The warranties made by General Monitors with respect to the product are voided if the product is not
installed, used and serviced in accordance with the instructions in this manual. Protect yourself and your
employees by following the instructions.
Read and observe the WARNINGS and CAUTIONS inside. For any additional information relative to use or
repair, call 1-949-581-4464 during regular working hours.
26776 Simpatica Circle
Lake Forest, CA 92630
USA
Phone 1-949-581-4464
For your local contacts please go to our website MSAsafety.com
©
General Monitors 2020. All rights reserved
Contents
1 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Liability Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.1 Limited Express Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.2 Sole Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.3 Exclusion of Consequential Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Continuous Optical Path Monitoring (COPM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 LED Operation Mode Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2.1 Field of View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2.2 Environmental Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5 Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.1 TB2, Alarm High Relay Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.2 TB2, Alarm Low Relay Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.3 TB1, Fault Relay Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.4 Alarm Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.5.5 Analog Output, Modbus and HART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.6 Cable Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.7 Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.8 Chassis Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.9 Fire Cards or Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.10 Cable Termination in a Nonhazardous Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
US
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.1 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Changing Device Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.1 Using the DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.2 Using Modbus or HART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Sensitivity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3.1 TL105 Test Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3.2 Alarm Test Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 Regular Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Cleaning the Optical Window and Reflectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
FL500 UV/IR, FL500-H2 Flame Detector
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7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.1 Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.2 Returning the Device for Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.3 Removing the Device from Service Permanently . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.4 References and Other Sources of Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.1 System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2 Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.3 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.4 Environmental Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9 Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10 Ordering Information
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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FL500 UV/IR, FL500-H2 Flame Detector
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Safety Regulations
1 Safety Regulations
1.1 Correct Use
WARNING!
Do NOT install or operate the device until you read and understand the instructions in this manual.
Only qualified personnel are approved to operate and do maintenance on the device.
Do NOT remove the cover from the device when the device is in operation or in an explosive atmo-
sphere.
Install a conduit seal within 18 in. (46 cm) of the device enclosure.
Repair or alteration of the device beyond the scope of the maintenance instructions in this manual
or by anyone other than General Monitors or General Monitors-approved service personnel can
cause incorrect operation of the device and put persons who use this device for their safety at risk
of serious injury or death.
An approved electrician must do electrical wiring.
All wiring must satisfy the requirements of the applicable National Electrical Code (NEC),
Canadian Electrical Code (CEC), and local electrical safety codes.
Make sure that field connections to the FL500 are applicable for the location and obey the wiring
requirements of the NEC, CEC, and local electrical safety codes.
Do not install or operate a device that is damaged.
Install the device in a location away from conditions (such as high-pressure steam) where electro-
static charge can collect on nonconducting surfaces. This equipment uses an external nonmetallic
coating. If extreme levels of electrostatic charge collect, ignition can occur.
Make sure that there is no physical blockage from permanent objects such as structures and
equipment or temporary objects such as personnel and vehicles in the sensor's field of view.
If there is physical blockage in the sensor's field of view, the device cannot accurately monitor the
area for flame.
Make sure that there is no ice, dirt, or debris on the optical window. Blockage of the optical window
can result in a Fault condition.
During a Fault condition, the device does not monitor the area for flame.
Keep the device safe from vibration and mechanical shock, which can cause damage.
Do NOT connect or disconnect equipment when power is supplied to the device. Doing so can
result in serious damage to the equipment. The warranty does not apply to equipment that is
damaged in this way.
The device has components that can be damaged by electrostatic discharge (ESD). When you do
work with the device wiring, be careful to touch only the connection points. The warranty does not
supply coverage for components that are damaged by ESD.
Use ONLY a damp cloth to clean the device. Otherwise, electrical shock or ignition from ESD can
occur.
Failure to obey these warnings can result in serious injury or death.
US
For dimensional information about the flameproof joints, contact General Monitors.
FL500 UV/IR, FL500-H2 Flame Detector
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Safety Regulations
Specific Conditions of Safe Use
• Potential electrostatic charging hazard; use only a damp cloth for cleaning.
• Contact General Monitors if dimensional information of flameproof joints is needed.
• Field connections to the FL500 shall be appropriately certified for the location and installed in
accordance with wiring method requirements of the local electrical code as applicable.
1.2 Liability Information
General Monitors accepts no liability in cases where the product has been used inappropriately or not
as intended.
The selection and use of this product must be under the direction of a qualified safety professional
who has carefully evaluated the specific hazards of the jobsite where it will be used and who is
completely familiar with the product and its limitations. The selection and use of this product and its
incorporation into the safety scheme of the jobsite is the exclusive responsibility of the employer.
Changes and modifications not expressly approved by the manufacturer will void the user's authority
to operate the equipment.
1.3 Warranty
1.3.1 Limited Express Warranty
General Monitors warrants the product to be free from mechanical defects and faulty workmanship for
a period of two (2) years from the date of sale by General Monitors, provided that the product is maintained and used in accordance with General Monitors' instructions and/or recommendations. General
Monitors makes no warranty concerning components or accessories not manufactured by General
Monitors, but will pass on to the Purchaser all warranties of manufacturer.
This warranty is valid only if the product is maintained and used in accordance with General Monitors'
instructions and/or recommendations. General Monitors shall be released from all obligations under this
warranty in the event that repairs or modifications are made by persons other than its own or authorized
service personnel, or if the warranty claim results from accident, alteration, misuse, or abuse.
No agent, employee or representative of General Monitors has authority to bind General Monitors to
any affirmation, representation or modification of the warranty concerning the product.
THIS WARRANTY IS STRICTLY LIMITED TO THE TERMS HEREOF AND IN LIEU OF ALL OTHER
WARRANTEES, EXPRESSED, IMPLIED, OR STATUTORY INCLUDING, BUT NOT LIMITED TO, ANY
IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
US
1.3.2 Sole Remedy
It is expressly agreed that Purchaser's sole and exclusive remedy for breach of the above warranty,
for any tortious conduct of General Monitors, or for any other cause of action, shall be the repair or
replacement, at General Monitors' option, of any equipment or parts thereof, which after examination
by General Monitors is proven to be defective. Replacement equipment and/or parts will be provided
at no cost to Purchaser, F.O.B. Seller's Plant. Failure of General Monitors to successfully replace any
nonconforming equipment or parts shall not cause the remedy established hereby to fail of its essential purpose.
1.3.3 Exclusion of Consequential Damage
Purchaser specifically understands and agrees that under no circumstances will General Monitors be
liable to Purchaser for economic, special, incidental, or consequential damages or losses of any kind
whatsoever, including but not limited to, loss of anticipated profits and any other loss caused by reason
of non-operation of the goods. This exclusion is applicable to claims for breach of warranty, tortious
conduct or any other cause of action against General Monitors.
FL500 UV/IR, FL500-H2 Flame Detector
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2 Description
2.1 Overview
The following two models exist:
• FL500 UV/IR
• FL500 H
The models are not interchangeable.
The FL500 UV/IR is optimized for and to be used for hydrocarbon flame detection, whereas the FL500
H
is optimized for and to be used for hydrogen flame detection.
2
The FL500 ultraviolet/infrared (UV/IR) flame detector, referred to hereafter as the "FL500" or "device,"
uses a UV radiation-sensitive phototube and an IR detector to sense specific wavelengths in the
UV and IR spectral regions. The UV and IR detectors send signals about changes in the intensity of
UV and IR radiation to a microcomputer to activate Alarm Low, Alarm High, and Fault output. A flicker
discrimination circuit in the IR circuitry prevents false alarms caused by lightning, arc-welding, hot
objects, and other sources of radiation. The inherent flickering of a flame supplies the necessary
modulation to activate the IR circuit.
2
Description
Ultraviolet Region Infrared Region
UV Detector’s
Spectral
Sensitivity
Visible Region
Sun’s Radiation
Reaching Earth
IR Detector’s
Spectral
Sensitivity
Relative Energy
185 nm 260 nm
Fig. 1 Spectral Response of UV and IR Radiation Detectors
Wavelength
2.95 μm
(Hydrogen Detector)
If the device senses only UV radiation (such as arc welding) or only IR radiation (such as a large
modulating hot object), an alarm does not occur. If the device senses both UV and IR radiation in the
correct combination and intensity, as set by an algorithm in the microcomputer, the device identifies a
fire and sends the following output:
• 4 - 20 mA signal
• Immediate Alarm Low output
• Time-delayed Alarm High output
• RS-485 Modbus RTU output
• HART communication
4.35 μm
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FL500 UV/IR, FL500-H2 Flame Detector
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The FL500 has the following features:
• Compact unitized design
• Wide field of view
• Continuous optical path monitoring (COPM)
• 4 - 20 mA source or sink, alarm relays, and Modbus RTU RS-485 standard
• HART 7 communication
• False alarm prevention
Description
Fig. 2 FL500 UV/IR, FL500-H2 Flame Detector
The FL500 is compatible with the General Monitors TA402A trip amplifier, FL802 controller, and other
equipment that accepts 4 - 20 mA output. The device can be connected directly with alarm and
suppression devices or switched input modules through integral relays. If the HART protocol is used
with the FL802 controller, it is necessary to use the special HART signal (1.25 - 20 mA).
Because the FL802 controller is not CE marked, it cannot be supplied to the European
Union (EU).
2.2 Continuous Optical Path Monitoring (COPM)
COPM does a check of the device's optical path (from the internal UV and IR detectors through an air
gap then the optical window) and related electronic circuitry every 2 minutes. If the optical window is
blocked by unwanted objects such as ice, dirt, or debris for two consecutive checks, the device activates the following Fault output:
• 2.0 mA signal
• Fault relay de-energizes
• Modbus signal
After a COPM Fault occurs, COPM occurs every 30 seconds until the Fault condition is removed.
When the Fault condition is removed, COPM continues every 2 minutes.
Because COPM does a check of the optical path every 2 minutes and two consecutive
checks must fail before a Fault occurs, it can be up to 3 minutes before the device identifies a blockage.
US
Refer to Section 5.2 "Cleaning the Optical Window and Reflectors" for maintenance instructions.
FL500 UV/IR, FL500-H2 Flame Detector
8
2.3 LED Operation Mode Definitions
The LEDs show the following modes of operation for the device.
Device Status Alternate Mode Standard Mode
No Power All LEDs OFF
Initial Power On All LEDs blink alternately for 10 s
Green LED = ON
Ready/Normal
Fault - COPM
Fault - Other
Alarm Low
Alarm High
Yellow LED = OFF
Red LED = OFF
Green LED = ON Green LED = OFF
Yellow LED = Blinking slowly (1 Hz)
Red LED = OFF
Green LED = ON Green LED = OFF
Yellow LED = ON
Red LED = OFF
Green LED = ON Green LED = OFF
Yellow LED = OFF
Red LED = Blinking slowly (1 Hz)
Green LED = ON Green LED = OFF
Yellow LED = OFF
Red LED = ON
Description
Green LED = ON with heartbeat
(5 s ON, 0.5 s OFF)
FL500 UV/IR, FL500-H2 Flame Detector
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9
3 Installation
WARNING!
Do not install or operate a device that is damaged.
Install the device in a location away from conditions (such as high-pressure steam) where electro-
static charge can collect on nonconducting surfaces. This equipment uses an external nonmetallic
coating. If extreme levels of electrostatic charge collect, ignition can occur.
Make sure that there is no physical blockage from permanent objects such as structures and
equipment or temporary objects such as personnel and vehicles in the sensor's field of view.
If there is physical blockage in the sensor's field of view, the device cannot accurately monitor the
area for flame.
Keep the device safe from vibration and mechanical shock, which can cause damage.
Failure to obey these warnings can result in serious injury or death.
3.1 Required Tools
• 5 mm Allen wrench (included with the device)
• Flat-blade screwdriver, maximum 1/8 in. width
• No. 2 Philips screwdriver
• 10 mm Allen wrench
• Adjustable wrench
Installation
3.2 Locations
Use the information in Section 3.2.1 "Field of View" and Section 3.2.2 "Environmental Factors" to
select the best location to install the device.
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FL500 UV/IR, FL500-H2 Flame Detector
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3.2.1 Field of View
Gas Performance:
HEPTANE
65°
60°
55°
45°
30°
15°
0°
20’
25’
30’
35’
40’
45’
50’
55’
60’
65’
70’
75’
80’
85’
90’
15°
30°
45°
55°
60°
65°
65°
60°
55°
45°
30°
15°
0°
20’25’30’35’
40’
45’50’
55’60’
65’70’
75’80’
85’90’
15°
30°
45°
55°
60°
65°
Horizontal High Med Low
Vertical High Med Low
Gas Performance:
HEPTANE
90’ 55’ 45’
55’ 45’
55’ 45’
90’
90’
75’
0°
± 15°
30°
- 30°
45°
75’- 60°
50’ 40’ 30’65°
50’ 40’ 30’- 65°
- 45°
60°
90’ 55’ 45’
55’ 45’
55’ 45’
90’
90’
75’
0°
± 15°
30°
- 30°
45°
60’- 60°
50’ 40’ 30’65°
50’ 40’ 30’- 65°
- 45°
60°
Installation
Fig. 3 Heptane Field of View
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FL500 UV/IR, FL500-H2 Flame Detector
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Installation
Gas Performance:
METHANE
65°
60°
55°
45°
30°
15°
0°
20’
25’
30’
35’
40’
45’
50’
55’
60’
65’
70’
75’
80’
15°
30°
45°
55°
60°
65°
65°
60°
55°
50°
45°
30°
15°
0°
20’
25’
30’
35’
40’45’
50’
55’60’
65’
70’75’
80’
15°
30°
45°
55°
50°
60°
65°
HorizontalHigh MedLow
Gas Performance:
METHANE
VerticalHigh MedLow
80’ 60’ 45’
80’
0°
± 15°
30°
- 30°
40°
80’- 45°
65’ 50’ 45’ 55°
65’ 50’ 45’- 55°
40’ 35’60°
35’ 35’- 60°
- 40°
45°
80’ 60’ 45’
80’ 50’
80’ 50’
35’
35’
65’ 45’
65’ 45’
0°
± 15°
30°
− 30°
40°
− 40°
45°
− 45°
50°
− 50°
55°
− 55°
50’ 35’
60°
60’ 35’
− 60°
Fig. 4 Methane Field of View
FL500 UV/IR, FL500-H2 Flame Detector
US
12
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