Spectrex Series 200 User Manual

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Series 200

Open-Path Gas Detection System

User and Maintenance Manual

TM 792100, Rev. D, May 2004

UL Approved

E209870, Class I Group C and D

218 Little Falls Rd., Cedar Grove, NJ 07009 USA;

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

Web -Site: www.spectrex-inc.com ; Email: spectrex@spectrex-inc.com

ATEX (Cenelec) Approved

Ex II 2 G, EExd IIB +H2 T6 EExde IIB +H2 T6

The SafEye monitoring system described in this document is the property of Spectrex, Inc.

No part of the hardware, software or documentation may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any

language or computer language, in any form or by any means, without prior written permission of Spectrex, Inc.

While great efforts have been made to assure the accuracy and clarity of this document, Spectrex, Inc. assumes no liability resulting from any omissions in this document, or from misuse of the information obtained herein. The information in this document has been carefully checked and is believed to be entirely reliable with all of the necessary information included. Spectrex Inc. reserves the right to make changes to any products described herein to improve reliability, function, or design, and reserves the right to revise this document and make changes from time to time in content hereof with no obligation to notify any persons of revisions or changes. Spectrex, Inc. does not assume any liability arising out of the application or any use of any product or circuit described herein; neither does it convey license under its patent rights or the rights of others.

Warning:

This manual should be carefully read by all indiv iduals who have or will have responsibility for using, maintaining or servicing the product.

The Source and Detector are not field-repairable due to the meticulous internal alignment and calibration of the sensors and the respective circuits. Do not attempt to modify or repair the internal circuits or change their settings, as this will impair the system's performance and void the Spectrex Inc. Product warranty.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

TABLE OF CONTENTS

1. Scope............................................................................................................................1

1.1 Product Overview...................................................................................................1

1.2 Document Overview................................................................................................1

2. Technical Description ...............................................................................................2

2.1 Features....................................................................................................................2

2.2 Applications.............................................................................................................2

2.3 Principle of Operation............................................................................................2

2.3.1 Definitions of Terms ..........................................................................................3

2.3.2 Spectral Finger Print ..........................................................................................3

2.3.3 Optical Path........................................................................................................3

2.3.4 Microprocessor Based........................................................................................ 3

2.3.5 Gas Sensitivity...................................................................................................4

2.3.6 Gas and Mixture Selection and Setting.............................................................. 4

2.4 Product Marking.....................................................................................................5

2.5 Models and Types...................................................................................................5

2.6 Description.............................................................................................................. 6

2.6.1 Flash Source Unit............................................................................................... 6

2.6.2 Detector Unit (Figure 3).....................................................................................7

3. Operation Mode..........................................................................................................9

3.1 Normal Mode...........................................................................................................9

3.2 Fault Mode...............................................................................................................9

3.3 Alignment Mode...................................................................................................... 9

3.4 Zero Calibration Mode (1mA Output).................................................................9

3.5 Mode Selection.......................................................................................................10

3.6 Visual Indications LEDs.......................................................................................10

3.7 Output Signals.......................................................................................................11

3.7.1 4-20mA Current Output................................................................................... 11

3.7.2 Relays............................................................................................................... 12

3.7.3 RS-485 Interface.............................................................................................. 12

3.8 Terminals...............................................................................................................13

3.8.1 Detector Terminal ............................................................................................ 13

3.8.2 Flash Source Terminals .................................................................................... 15

3.9 System Setup..........................................................................................................16

3.9.1 Detector Setting................................................................................................ 16

3.9.2 Flash Source Setting ........................................................................................ 19

4. Technical Specifications .......................................................................................20

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

4.1 General Specifications ..........................................................................................20

4.2 Electrical Specifications........................................................................................21

4.3 Mechanical Specifications ....................................................................................22

4.4 Environmental Specifications .............................................................................. 23

5. Installation Instructions.........................................................................................24

5.1 Introduction........................................................................................................... 24

5.2 General Considerations ........................................................................................24

5.2.1 Personnel.......................................................................................................... 24

5.2.2 Tools Required ................................................................................................. 24

5.2.3 Site Requirements ............................................................................................ 24

5.2.4 The Source and Detector.................................................................................. 24

5.2.5 Guidance Tips for Gas Detector Locations...................................................... 25

5.3 Preparations for Installation................................................................................25

5.4 Mounting for Standard Open-Path Installation ................................................ 26

5.4.1 Swivel Mount Kit............................................................................................. 26

5.4.2 Swivel Installation (Figure 7) .......................................................................... 26

5.4.3 Tilt Mount Kit .................................................................................................. 28

5.4.4 Detector / Source Installation (Figure No. 8 and 9)......................................... 30

5.5 Mounting for Duct Installation............................................................................ 30

5.5.1 Duct Mount Set (Figure 11, 12) ....................................................................... 30

5.5.2 Duct Alignment Set (Figure 13) and Accessories............................................ 31

5.5.3 Duct Installation - Surface Preparation (Figure 10)......................................... 31

5.5.4.Duct Mount Installation (Figures 11,12) ......................................................... 33

5.5.5 Duct Mount Alignment (Figures 12,13) .......................................................... 36

5.6 Detector Wiring (see appendix D if EExde version used).................................38

5.6.1 Conduit/Cable Installation............................................................................... 38

5.6.2 Harness Connection (Figure 14)...................................................................... 39

5.6.3 Detector Terminal Wiring ................................................................................ 41

5.7 Flash Source Wiring .............................................................................................42

5.7.1 Power Supply................................................................................................... 42

5.7.2 Harness Connection (Figure 14)...................................................................... 42

5.7.3 Terminal Wiring (Table 6)............................................................................... 42

6. Operating Instructions ...........................................................................................44

6.1 SafEye Operation..................................................................................................44

6.2 Alignment of Unit (Figures 16 through 17) Using Swivel Mount.....................44

6.3 Alignment of Unit (Figure 8, 9) Using Tilt Mount.............................................47

6.4 Powering on the system........................................................................................48

6.5 Safety Precautions.................................................................................................48

6.6 Zero Calibration....................................................................................................48

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

III

6.7 Functional Check of Unit.....................................................................................49

7. Maintenance Instructions......................................................................................50

7.1 General Maintenance............................................................................................50

7.2 Periodic Maintenance...........................................................................................50

7.2.1 Routine Optical Surface Cleaning ................................................................... 51

7.2.2 Signal Verification........................................................................................... 51

7.2.3 Function Check of Unit .................................................................................... 52

7.2.4 Maintenance Records....................................................................................... 52

8. Troubleshooting.......................................................................................................53

Appendix A - Wire Selection Tables .......................................................................55

Appendix B: Wiring Option configurations ...........................................................57

Appendix C: Outline Drawing ...................................................................................61

Appendix D - Mounting the “EExde approved” version....................................67

LIST O F FIGURES

Figure 1: Flash Source – Reflector Type ............................................................................6

Figure 2: Flash Source – Lens Type...................................................................................7

Figure 3: Detector .............................................................................................................. 8

Figure 4. Detector’s Wiring Diagram.............................................................................. 13

Figure 5. Detector Terminal Board .................................................................................. 14

Figure 6. Flash Source Terminal Board ........................................................................... 15

Figure 7. Detector/Flash Source and Swivel Mount Assembly for Standard Installation 27

Figure 8. Tilt Mount Assembly.......................................................................................... 28

Figure 9. Detector/Source and Tilt Mount Assembly ....................................................... 29

Figure 10. Drilling Layout Dimensions for Duct Installation.......................................... 32

Figure 11. Detector/Flash Source and Duct Mount Installation scheme ......................... 34

Figure 12. Duct Mount Installation - Outline Drawing ................................................... 35

Figure 13. Telescope Alignment Set ................................................................................. 37

Figure 14. Detector with Cover (removed)....................................................................... 40

Figure 15. Flash Source - Open View .............................................................................. 43

Figure 16. Alignment and Mode Selection ....................................................................... 45

Figure 17. SafEye Flash Source/ Detector Alignment...................................................... 45

Figure 18. Detector’s Wiring Diagram............................................................................ 57

Figure 19. 4- 20mA Source Output.................................................................................... 58

Figure 20. Typical 4 Wire Controller ............................................................................... 58

Figure 21. RS-485 Networking......................................................................................... 59

Figure 22. Detector Outline Drawing With Swivel Mount.............................................. 61

Figure 23. Source Outline Drawing (65 dia Lens Type) With Swivel Mount.................. 62

Figure 24. Source Outline Drawing (80 dia Lens Type) With Swivel Mount.................. 63

Figure 25. Source Outline Drawing (Reflector Type) With Swivel Mount ...................... 64

Figure 26. Detector and Tilt Mount Outline Drawing .................................................... 65

Figure 27. Source and Tilt Mount Outline Drawing ....................................................... 66

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Figure 28: Flame Detector Assembly - Wiring Diagram ................................................. 68

Figure 29: OPTION A Detector Assembly - Wiring Diagram ....................................... 69

Figure 30: OPTION B Detector Assembly - Wiring Diagram ........................................ 69

IST OF TABLES

Table 1: Model Selection Guideline for SafEye Series 200 IR Type ..................................5

Table 2. LED Status Indication......................................................................................... 10

Table 3. Alignment Indication LED Color........................................................................ 11

Table 4. Standard (default) 4-20mA Current for the Gas Channel.................................. 12

Table 5. Discrete reading of 4-20mA at different detector’s modes................................. 12

Table 6. Flash Source Terminals ...................................................................................... 15

Table 7. SW1 DIPswitches Configuration ........................................................................ 16

Table 8. Flash Source Flash Rate Configuration ............................................................. 17

Table 9. Gas Type Calibration Setup................................................................................ 17

Table 10. SW2 DIPswitches Configuration...................................................................... 18

Table 11. SW3 DIPswitches Configuration...................................................................... 19

Table 12. Flash Source rate setting................................................................................. 19

Table 13: Detection Distance Range ................................................................................ 20

Table 14: Dry Contact Relays........................................................................................... 21

Table 15. Detector/ Source Weight & Dimensions ........................................................... 22

Table 16. Swivel Mount Kit............................................................................................... 26

Table 17. Tilt Mount Kit.................................................................................................... 28

Table 18. Duct Mount Kit ................................................................................................. 30

Table 19. LED Signal Adjustment..................................................................................... 51

Table 20. Maximum DC resistance at 68°F for copper wire............................................ 55

Table 21. Wiring length in feet (meter)............................................................................. 55

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

1. Scope

1.1 Product Overview

The SafEye 200 Series IR Open-Path Gas Detector employs an advanced Flash Source and integrated electronics package to provide high quality and

performance, fast respon se, line of sight gas monitoring. SafEye detects ambient combustible gases at LEL.m concentrations over a path

length of up to 459-ft. (140 m), even in harsh environments where dust, fog, rain, snow or vibration can cause a high reduction of signal. Due to its unique

combination of triple optics and dual-spectrum reference sensor, the SafEye can maintain operation in up to 90% signal obscuration and ±1 degree of misalignment. SafEye has a fast response detection time of no more than 5 seconds. This feature enables an adequate time to take appropriate safety measures.

The SafEye Source and Detector unit enclosures are ATEX certified EExd flameproof or EExde with additional separate EExe terminal box connected to the

unit. This manual consists of a full description of the Detector and its features. It

contains instructions on the installation, operation and maintenance. The system is intended to be used by qualified personnel.

1.2 Document Overview

This manual describes the Detector and its features and provides instructions on the installation, operation and maintenance.

This manual is divided into separate sections as follows: Section 1. Section 2.

Section 3. Section 4.

Section 5. Section 6. Operating Instructions and power-up procedures. Section 7. Section 8. Appendix A.

Appendix B. Appendix C.

Scope - a general introduction and overview of the product and the Manual, with a brief description of its content.

Technical Description - the Detector’s theory of operation. Operation Mode - the Detector’s operation modes, user interface and

indications. Technical Specifications - the Detector’s electrical, mechanical and

environmental specifications.

Installation Instructions , including wiring and mode setting. Maintenance Instructions and support procedures.

Troubleshooting Wiring Selection Tables for electrical wire selection according

to installation configuration. Wiring option Configurations - wiring diagrams for installation.

Detector and Source Outline Drawing

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

2. Technical Description

2.1 Fea tures

• Long Range Gas Detection up to 459ft (140m)

• Simultaneous detection of C1-C8 flammable gases

• High Sensitivity and fast response to Hydrocarbon gases

• Continuous operation in extreme and harsh environmental

Conditions

• Solar blind and immune to industrial environments

• Withstands extreme vibration conditions

• Interfaces with most commonly used control panels

• Standard 4-20mA and Dry Contact Relays Outputs

• RS-485 Output for PC Communication Network for a maximum of 64

systems

• Simple one person installation, alignment, and calibration

• ATEX Approved - EX II 2 G, EExd IIB + H2 T6; EExde IIB + H2 T6

• UL Approved – E209870 Class I, Group C and D

• Programmable configuration

2.2 Applications

The SafEye system may be used to monitor flammable gas concentration in various applications, such as:

• Petrochemical, pharmaceutical and other chemical storage and production areas.

• Flammable and toxic chemical storage sites and hazardous waste disposal areas.

• Refineries, oil platforms, pipelines, refueling stations and fuel storage facilities.

• Hazardous loading docks, transportation depots and shipping warehouses Engine rooms

•

• Compressor and pumping stations

• Test cells

• LNG-LPG Systems

• Offshore Floating Production Storage and Shipping vessels (FPSO), and

fixed oil rigs.

2.3 Principle of Operation

The SafEye system detects gases through a dual spectral range monitoring, analyzing the absorption of radiation caused by gases in the atmosphere and

comparing it (ratio) to background atmospheric absorption.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

2.3.1 Definitions of Term s

The following list defines gas concentrations measurement terms that are used in this manual:

LEL Lower Explosive Limit - The minimum concentration of a substance

(gas/vapor) in air mixture that can be ignited. This mixture is different for every gas/vap or, measured in % of LEL.

LEL.m Integral of Concentration in LEL units (1 LEL = 100% LEL) and the

operation distance, or path length, in meters (m).

2.3.2 Spectral Finger Print

Each hazardous material is detected at a specific wavelength selected according to its specific spectral absorption or "finger print". There are three IR sensors: two signals and one reference. The detection process involves two separate filters, one transmitting radiation that is absorbed by a particular gas and one that is not sensitive to it.

2.3.3 Optical Path

The presence of hazardous airborne vapors, gases, or aerosols in a monitored area is detected when the defined substance crosses/enters the optical path

between the radiation source unit and the detector. Hazardous gases /vapors present in the atmosphere cause absorption of the

radiation pulse in the optical path between the radiating source and the detector unit at some specific wavelengths. This causes a change in the signal intensity

received by the detector, which is translated into an output related to the detector’s measuring scale.

The system analyzes the defined open path at the spectral bands specific to the materials being monitored. The Automatic Gain Control (AGC) unit compensates for environmental disturbances such as fog, rain, etc., through a constant comparison with its dual spectral beam.

2.3.4 Microprocessor Based

The incoming signals are analyzed by the built in microprocessor. A sophisticated mathematical algorithm calculates between the various functio ns of the detected signal thresholds. Statistics, ratio algorithms, data communications, diagnostics and other functions are performed.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

2.3.5 Gas Sensitivity

The SafEye IR Model uses wavelengths around 3.4µ spectral band to measure air flammability potential between the source and detector. At this wavelength, all hydrocarbon materials have a strong absorption peak. This peak enables the detector to achieve both regular sensitivity of 0-5 LEL.m or high sensitivity of 0-2 LEL.m according to functions set up. However, since the desired detection information is air flammability and the actual measurement is radiation absorption around the 3.4m spectral band, the detector has a different sensitivity to different gases or gas combinations.

This difference in sensitivity is irrelevant if in the protected area the gas composition is known. However, if in a protected area the gas composition can vary substantially, then the difference in sensitivity should be considered in determining the Detector calibration.

2.3.6 Gas and Mixture Selection and Setting

At the 3.4µ spectral band of the SafEye, the least sensitive gas is pure (100% vol) methane and the most sensitive gases are various mixtures of Methane with

heavier alkanes where the Methane percentage is less than 90%. For pure Ethane the sensitivity is close to the high sensitivity gases and for pure Propane

it lies somewhere between the two extremes. Every SafEye has 4 built-in gas calibration settings that can be changed by function set up The setting for each Safeye is detailed on the calibration datasheet provided with each unit.

The calibration settings are designed for use in various applications:

Gas 1 - Pure methane and is for use in methane storage and piping

applications

Gas 2 - 92% methane, 4% propane and 4% ethane (default) Universal oil

and gas production mixture to be used in all cases where methane concentration in the mixture does not exceed 98%. It can also be

used for pure Ethane applications. Gas 3 - Pure propane and is good for prop ane/butane detection. Gas 4 - 99% methane and 1% propane and is for use in detecting

methane mixture with heavier gases where the methane

component can vary between 100% to 95%. It is also good for

protecting areas where a leak can be either pure methane or pure

propane.

The four internal gas calibrations cover most of the flammable gas detection applications. Actual selections should be made by the user in consultation with experts to provide for safety requirements. However, for special cases where none of the four calibrations are appropriate, Spectrex, through local agents can advise how to calibrate a SafEye Detector to any specific gas.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

2.4 Product Marking

The SafEye 200 Series open path gas Detector and source unit are certified to:

1. ATEX Ex II 2 G per SIRA 00 ATEX 1161 & 1165 EExd IIB +H2 T6 and EExde IIB +H2 T6 Amb. Temp. -40°C to +55°C

2. UL E209870 Class I, Group C and D

2.5 Models and Types

This manual includes information for SafEye Series 200 models. Table 1 identifies the detector model options in reference to the required gas type and

detection range.

Table 1: Model Selection Guideline for SafEye Series 200 IR Type

Distance Model

Ft. m.

202 9.8- 39.4 3-12 OP-IF100x OPS-FI0x Yes Yes 203 33- 131 10-40 OP-IF100x OPS-FI1x No Yes 204 49- 197 15-60 OP-IF100x OPS-FI2x No Yes 226 98- 295 30-90 OP-IF100x OPS-FI3x No Yes 227 164-459 50-140 OP-IF101x OPS-FI3x No Yes

For standard installation add “S” suffix. For duct installation add “D” suffix. For St. St. version add “St” suffix after the “D” or the “S” suffix.

Detector* Flash

Source*

* Notes

Option for Duct Mount

Option for St.St Enclosure

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

2.6 Description

The system comprises two main units; the Flash Source and the Detector. The SafEye system detects gases over an open path transmitted from the Flash Source to the Detector.

2.6.1 Flash Source Unit

The Flash Source unit emits IR radiation pulses, in a collimated beam (for maximum intensity) to the detector unit. The source is available in three different

types as follows:

1. Reflector type, model OPS -FI0x (Figure 1)

2. 65 dia lens type, model OPS- FI1x (Figure 2)

3. 80 dia lens type, model OPS- FI2x and model OP-SFI3x (Figure 2)

Figure 1: Flash Source – Reflector Type

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

a. 80 dia Lens b. 65 dia Lens

Figure 2: Flash Source – Lens Type

2.6.2 Detector Unit (Figure 3)

The detector's sensors receive the transmitted pulsed radiation signals from the Flash Source. The signals are then amplified and fed into an analog to digital signal converter to be processed by the internal microprocessor.

When the signals drop below a prescribed level, the internal microprocessor will compensate for them. This will allow the signal to be maintained even in severe weather conditions. The data is sent to the output interface section. The signals can be sent to a standard control panel or to a central computer.

The Series 200 Detector is available in three basic types:

1. Model OP-IF000X for short-range installation

2. Model OP-IF100X for medium-range installation.

3. Model OP-IF101X for long-range installatio n.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Figure 3: Detector

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

3. Operation Mode

The SafEye system has three operation modes; Normal, Alignment and Zero Calibration.

3.1 Normal Mode

This mode is used for gas detection. The following status signals are possible: (see Table 2 for visual indications).

Normal - Signal received from gas detection is at safe levels. Warning - Gases have been detected at warning levels.

Alarm - Gases have been detected at alarm levels.

3.2 Fault Mode

There are three fault types:

• Fault 1 (2mA Output) – Non critical

If this occurs, it is due to blockage, poor alignment, very low signal or in the case of partial obscuration or full beam block and detection is no

longer possible. The Detector’s proper operation will be restored (Auto reset) during operation if the condition causing the problem is removed or

resolved. This mode will occur after a delay of 60 sec. from the moment of the fault. This delay is important to eliminate momentary obscuration

due to objects/people passing through the beam.

• Low Voltage Fault (0mA Output)

In this case, detection is disabled due to low voltage being supplied to the Detector. The Detector returns to proper operation only when proper voltage level restored.

Fault 2 (0mA Output) – Critical

In this case, the detection is disabled due to electrical / software operational failure or central device (memory, processor) fault. Such fault causes the Detector to cease operation.

3.3 Alignment Mode

This mode is used when the received signal needs to be measured (i.e. Installation & Periodic Maintenance). LED indications represent the received

signal strength for precise alignment. There is a temporary Standby Mode to give the option of switching from Alignment Mode to Calibration Mode.

3.4 Zero Calibration Mode (1mA Output)

This mode zeros the base level from which the Detector will read gas. It should only be performed when there are:

• No combustible gases present

• Clear path between the Flash Source and Detector

• Clear weather conditions.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Zero calibration must be done after installatio n, re-alignment and window cleaning, using magnetic mode selection

3.5 Mode Selection

A Magnetic Mode Selector is used to change to alignment and calibration modes by placing the magnet on the side of the detector (Figure 16).

3.6 Visual Indications LEDs

There are two indicators (LEDs) located in the detector’s front window, referred to as the right and left LEDs. They display red, orange and green light that can be either ‘On’ steady or flashing or ‘Off’

Table 2. LED Status Indication

Status Remarks Left LED Right

LED

Normal Green Off On 4 mA Warning See Note 4 Red Off On 14 mA Alarm See Note 4 Red Red On 19 mA Fault 1 Orange Off On 2 mA Fault 2 Orange Orange On 0 mA Low Voltage

Alignment Mode

Standby mode

Calibration mode

Orange Orange Both LEDs

First receives the intensity compared to the last calibration: The intensity is min. 80% of the last calibration intensity 80% - 60% Orange Green 0 mA 60% or less Red Orange 0 mA After 20 seconds the color represents the signal intensity (See Note 2). Green Green Both LEDs

See Note 3 Off Off 0 mA

Green

See Note 1 See Note 1 0 mA

Green

LED

Status

flash at rate of 2Hz

flash alternately

at a rate of 2Hz.

4- 20mA

Output

0 mA

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Notes: 1 The number of flashes shows the intensity of the received signals while the

color represents the gain ( see Table 3). The left LED shows the “tens” unit of the number while the right LED displays the “one” unit of the number of the

signal intensity. Each LED will flash 0 to 9 times (9 being the maximum possible signal intensity). When the left LED has reached its highest signal,

look at the right LED for fine adjustment.

Table 3. Alignment Indication LED Color

Left LED Right LED Gain

Red Red 3

Orange Orange 2

Green Orange 1 2 After 20 minutes at alignment mode the detector will return to normal mode. 3 After zero calibration is finished, the detector will return to normal mode and

the signal intensity will be saved for next alignment comparison.

4 The 4-20mA level in this Table refers to discrete indication option. A different

(continuous reading) option is described later in section 3.7.1

Green Green 0

3.7 Output Signals

The SafEye system provides the following outputs:

• Standard 4-20mA port

• Three dry contact relays

• Optional RS-485 Output for PC Communications

3.7.1 4- 20mA Current Output

The 4-20mA output can provide the detector status measurement in one of the two following methods:

1. It can be measured proportionally (default) showing a continuous reading of the exact gas concentration (see Table 4).

2. It can be a discrete indication according to the detector mode or the Warning or Alarm signal at a defined gas concentration. Setting of this

method can be done by SW3 -2 selection (see Table 5).

The 4-20mA functions as current source. The maximum permitted load resistance for the 4-20mA output is 600 ohms. The minimum permitted load resistance is 100 ohms.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Table 4. Standard (default) 4-20mA Current for the Gas Channel

Current Status and Description

0mA +0.5mA Fault 2 or Low Voltage 2mA ±0.5mA Fault 1 4mA ±0.5mA Zero reading - No gas detected 4-20mA Continuous measuring of gas concentration at a range

between 0 and 5 LEL.m or full scale

21mA Concentration is over the range limit (more than full scale

concentration).

Table 5. Discrete reading of 4-20mA at different detector’s modes

Current Reading Mode LEL.m Setting

0 +0.5mA Fault 2 or Low Voltage 2 ±0.5mA Fault 1 4 ±0.5mA Standby 0 14 ±0.5mA Warning 1 19 ±0.5mA Alarm 2.5

3.7.2 Relays

The detector includes three relays:

• Fault relay

• Alarm relay

• Accessory relay

Fault Relay contacts are normally energized closed, and opened when in Fault condition

3.7.3 RS-485 Interface

The RS-485 input/output sends complete data information to a PC and receives data or control commands from the PC. The communication with the PC is operated through this interface is executed only when used with appropriate host software.

The following PC minimal hardware requirements are as follows:

• 386 PC using DOS Ver. 5.0 or higher

• 1 M B RAM.

• 2 MB free hard disk space.

• 1.2 or 1.44 MB floppy drive

• Color VGA

• RS-485 Interface Card to be defined as COM1 or COM2. Isolated Adapter

is preferred.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

3.8 Terminals

Terminal outputs are described for the Detector and the Flash Source. For EExde versio n with separate EExe terminal section, see Appendix D

3.8.1 Detector Terminal

Terminal Wiring: Figure 4 displays a schematic diagram of the terminals and Figure 5 shows their location.

Figure 4. Detector’s Wiring Diagram

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1 Detec tor Cover 2 Terminal Board 3 Terminal Screw 4 Securing Cable 5 Conduits

Figure 5. Detector Terminal Board

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

3.8.2 Flash Source Terminals

Figure 6 shows the terminal board and Table 6 describes their use.

Figure 6. Flash Source Terminal Board

Table 6. Flash Source Terminals Flash Source Terminal Number

1 VIN 2 RTN

Description

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

3.9 System Setup

3.9.1 Detector Setting

The detector consists of the following DIPswitches, which enable the user to adapt the detector operation to specific application:

SW1 Function Selection Switch. Contains. 8 DIPswitches. Used for Calibration

of different gas selection, response time control and Relays response configuration (see table 7)

SW2 Address Selection Switch. Contains 8 DIPswitches. Used for Detector’s

address setting and 4- 20mA output configuration setting (see table 10)

SW3 Alarm Options Selection Switch. Contains 4 DIPswitches. Used for

Detector’s Alarm Latching configuration and 4-20mA level reading configuration (see table 11)

Function Selection Switch:

Table 7 describes SW1 DIPswitches position and the required function for setting the detector according to the necessary configuration

Table 7. SW1 DIPswitches Configuration

Switch

No.

1 Detection speed control bit

0 at “0” (see note 1 below)

2 Detection speed control bit

1 at “0” (see note 1 below)

3 Gas type control bit 0 at “0”

(see note 2 below)

4 Gas type control bit 1 at “0”

(see note 2 below)

5 Full scale sensitivity is 0-5

LEL.m

6 Zero calibration is

performed according to background

7 Accessory Relay is

activated at Warning level

8 Accessory Relay is

activated according to SW17 position

Off position On position Default

setting

Detection speed control bit 0 at “1” (see note 1 below) Detection speed control bit 1 at “1” (see note 1 below) Gas type control bit 0 at “1” (see note 2 below) Gas type control bit 1 at “1” (see note 2 below) Full scale sensitivity is 0-2 LEL.m Gas level detection performed without background Zero calibration Accessory Relay is activated at Alarm level (with the Alarm Relay) Accessory Relay is Activated at Power on continuously (used as End of Line)

on off on off off off

off

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Notes: 1 Detection flash rate can be selected by pre-setting of SW1-1 and SW1 -2

according to the following table. There are two bits, which provides four Flash Source rates. Same Flash rate should also be set at the Flash Source.

Table 8. Flash Source Flash Rate Configuration

bit # 0 position

(SW1-1)

off off 0.5 on off 1 off on 2

2 Four Gas types can be selected for maximum compatibility to Gas spectral

properties. The selection of the appropriate type is defined by pre-setting of SW1-3 and SW1- 4 according to the following table:

bit # 0 position

(SW1-3)

off off Methane Gas 1 on off Mixture Gas 2 off on Propane Gas 3 on on Mixture Gas 4

on on 4

Table 9. Gas Type Calibration Setup

bit # 1 position

(SW1-4)

Address Selection Switch

The Address selection Switch provides up to 64 different addresses for the detector upon a network installation. Each detector can be recognized at its specific address in RS485 network. The address should be determined by a presetting of SW2-1 to SW2- 6 switches.

SW2- 7 and SW2-8 should be always at on.

bit # 1 position

(SW1-2)

Detected Gas

Type

Attention!

Source flash Rate

(flashes/second)

Gas type as

defined in

Section 2.3.6

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Table 10 describes SW2 DIPswitches position and the required function for setting the detector according to the necessary configuration

Table 10. SW2 DIPswitches Configuration Switch

No.

1 Address bit 0 (LSB) 0 1 off 2 Address bit 1 0 1 off 3 Address bit 2 0 1 off 4 Address bit 3 0 1 off 5 Address bit 4 0 1 off 6 Address bit 5 (MSB) 0 1 off 7 4- 20mA direction

8 4- 20mA direction

Alarm Options Selection Switch

This switch is used for the following function setting:

• Selection of the Alarm status to be latched or to auto-reset after the Alarm

• Selection between two different 4-20mA reading modes, continuous

This switch also enables impedance matching to the serial link by providing a connection to a loading resistor through the switch.

Switch Definition Off

position

N/A 4-20mA output at source

setting (1)

N/A 4-20mA output at source

setting (2)

disappears. analog reading or discrete level reading which appropriate to the

detector’s status.

position position

On position Default

setting

on on

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Table 11 describes SW3 DIPswitches position and the required function for setting the detector according to the necessary configuration

Table 11. SW3 DIPswitches Configuration

Switch

No.

1 Non latching Alarm

2 Continuous reading

3 Non-latching Alarm

4 Normal Position

Off position On position Default

Alarm Relay latches. Latching reset

Relay

of the 4-20mA output reading

indications during Blocking Mode

(open)

can be provided by momentarily power disconnection or when the detector is set to alignment mode. Discrete Reading of the 4-20mA output according to the detector status (see table 5). Alarm indications are latched when the detector turns to Blocking Mode from Alarm position. Latching reset can be provided only if the detector turns to Normal Mode. Communication line termination for impedance matching

setting

off

3.9.2 Flash Source Setting

The Flash Source contains one DIPswitch, which enables the user to adapt the Flash Source rate to a specific application: The DIPswitch SW1 contains four switches which selects the rate as multiple of a base rate. Same flash rate should be set also at the detector. Table 12 defines the rate according to the switches selection.

Table 12. Flash Source rate setting

Switches position off = 0 ; on = 1 Flash Rate

(in seconds)

0.5 on off on off 1 off on on off + 2 on on on off 4 off off off on

SW1-1 SW1-2 SW1-3 SW1-4

Default Setting

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

4. Technical Specifications

4.1 General Specifications

Detected Gases: Detection Distance range:

Model No. 202 203 204 226 227 Distance (ft) Distance (m) Response Time

Response time: Spectral Response:

Field of View: Alignment Tolerance: Drift: Temperature Range: Immunity to false alarm:

Simultaneous detection of C1-C8 flammable gases

Table 13: Detection Distance Range

2.8-39 33-131 49-197 98-295 164-459 3- 12 10-40 15-60 30-90 50-140

2 Sec. 5 Sec. 5 Sec. 5 Sec. 5 Sec.

5 sec to T 90

3.0 - 4.0 micron 0-5 LEL.m (Standard) Sensitivity Range: 0-2 LEL.m (by dipswitch setting) Line of Sight ± 1° Long term ± 5% of full scale

-40°F (-40°C) to +131°F (+55°C) Does not produce false alarm and is not influenced by Solar Radiation, Hydrocarbon Flames and other external IR Radiation Sources.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

4.2 Electrical Specifications

• Operating Voltage : 18- 32 VDC

• Power Consumption

Detector 150 mA @ 24 VDC (200 mA Peak) Source 100 mA @ 24 VDC (220 mA Peak)

• Electrical input protection: The input circuit is protected against voltage -reversed polarity, voltage

transients, surges and spikes according to MIL-STD-1275A.

• Electrical Interface (see figure 4)

• Electrical outputs

A. 4-20mA Current Output :

The 4-20mA is source configuration. The maximum permitted load resistance is 600 Ohm.

Two 4- 20mA options:

• Continuous reading - default (See Table 4)

• Discrete reading

B. Communication Network:

The Detector is equipped with an RS 485-communication link that can be used in installations with computerized controllers. It enables continuous communicat ion with up to 64 Detectors.

C. Relays Output:

The Detector include up to three relays.

Table 14: Dry Contact Relays

Relay Type Normal Maximum Ratings

Alarm SPDT NO, NC 2A at 30VDC or 0.5 at 250 VAC Accessory SPST NO 5A at 30VDC or 250 VAC

Fault * SPST NC 5A at 30VDC or 250 VAC

* Fault Relay is normally energized, the contact will be closed, and when it is in Fault situation, the relay is opened.

(See Table 5)

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

4.3 Mechanical Specifications

Enclosure: The source and detector housings are made of either

anodized aluminum with less than 1% Mg with an epoxy enamel finish, or St.St. 316L enclosure with electro

polish finish The back covers are all sealed with special "O" rings to prevent intrusions such as dust, salt and sprays. The circuit boards are conformal coat ed and protected from mechanical vibrations and a slight impact.

Alignment Base is Stainless Steel 316L for all models.

Explosion Proof:

Electrical Modules: Electrical connection:

NEMA 250 type 6p Weight & Dimensions See Table 15

Table 15. Detector/ Source Weight & Dimensions

type and

application Lb Kg Lb Kg Inch mm

Detector for Duct Mount Detector for Standard Mount Source for Duct Mount. Source (reflector) 9.5 4.3 14.9 6.8 5.2x5.2x9 132x132x230 Source (lens Ö65) 10.1 4.6 16.1 7.3 5.2x5.2x9.3 132x132x239 Source (lens Ö 80) 10.8 4.9 16.7 7.6 5.2x5.2x10.9 132x132x279

ATEX (Cenelec)

UL FM

(Designed to meet)

Conformal coated. (Two options - specified at time of order)

2 X M25 (ISO) or 2 X 3/4” - 14NPT conduits. IP 66 and IP 67 Water and dust tight:

Al.

enclosure

8.1 3.7 13.4 6.1 5.2x5.2x4.7 132x132x120

8.8 4.0 14.4 6.55 5.2x5.2x9 132x132x230

8.5 3.9 13.8 6.3 5.2x5.2x4.7 132x132x120

enclosure

Ex II 2 G, EExd IIB + H2 T6

EExde IIB + H2 T6 Temp -40°F (-40°C) to 131°F (55°C) E209870, Class I Group C and D

hazardous Location Class I Div. 1 Group B, C, and D. Class II Div. 1 Groups E, F and G.

St.St.

Dimensions Detector/ Source

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

4.4 Environmental Specifications

The SafEye system is designed to withstand harsh environmental conditions. The Source and Detector units compensate for adverse conditions while maintaining accuracy.

• High Temperature : Designed to meet MIL-STD-810C, method 501.1 procedure II Operating temperature: +131 ºF (+55 ºC) Storage temperature: +149 ºF (+65 ºC)

• Low Temperature : Designed to meet MIL-STD-810C, method 502.1, procedure I Operating temperature: -4 ºF (-20 ºC) Storage temperature: -40 ºF (-40 ºC)

• Humidity :

Designed to meet MIL-STD- 810C, method 507.1, procedure IV Relative humidity of up to 95% for the operational temperature range.

• Salt and Fog:

Designed to meet MIL-STD- 810C, method 509.1 procedure I. Exposure to a 5% salt solution for 48 hours.

• Water and Dust :

IP67 per En60529 IP66 per En60529

Dust: Totally protected against dust. Liquids: Protected against immersion between 15 cm and 1m in depth.

Protected against all water jets from all directions.

• Shock and Vibration:

Vibration: Designed to meet MIL- STD-810C, method 514.2,

procedure VIII.

Mechanical Shock: Designed to meet MIL-STD-810C, method 516.1,

procedure I.

• Electromag netic Compatibility (EMC):

The detector is designed and approved according to the following EMC requirements: Electrostatic Discharge (ESD) IEC1000-4-2:1995 -1 Conducted emission EN55011, Class B Radiated emission EN55011, Class B Radiated immunity ENV50140:1994 (80-1000 MHz) EFT/B IEC801- 4: 1988

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5. Installation Instructions

The Detector and Flash Source units can be installed and maintained with the use of general -purpose common tools and equipment. The installation procedure has to be performed by suitably qualified personnel.

5.1 Introduction

This section does not attempt to cover all of the standard practices and codes of installation. Rather, it emphasizes specific points of consideration and provides some general rules for suitably qualified pers onnel. Special safety precautions are stressed wherever applicable.

5.2 General Considerations

5.2.1 Personnel

Only suitably qualified personnel, familiar with the local codes and practices, trained for gas detection maintenance should be employed. Wirin g should only be performed or supervised by someone with knowledge of electronics and in particular wiring installation.

5.2.2 Tools Required

The SafEye system requires the following tools:

• Set of screwdrivers

• Set of hex keys/Allan wrenches (supply with commissioning kit)

• Voltage Multimeter

5.2.3 Site Requirements

The installation position of the SafEye system must take into account if the gas being monitored is heavier or lighter than air, the prevailing wind directions and the individual site requirements . The site selected must give the Detector a direct view to the Source. The mounting point for each item should be secure and stable with minimal vibrations. Equipment should be either mounted in a position where it cannot be knocked out of alignment, or guarded from physical impact.

5.2.4 The Source and Detector

The appropriate Detector should be selected for the length of open path to be monitored. To allow for ageing of the Source and a reduction of the IR signal due

to adverse weather, we recommend using a Detector that is not at the limit of its operating range. As a guide, select a Detector that is installed at a distance from

the Source of not more than 75% of the specified operating distance. In severe weather conditions such as offshore oil production and exploration, this should

be reduced to 50%.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

The open path between the Source and Detector and the immediate surroundings should be kept clear of obscuration that might hinder the free

movement of air in the protected area or block the infrared beam.

5.2.5 Guidance Tips for Gas Detector Locations

Guidance Tips for Gas Detector locations in order to provide the best detection coverage:

1. Below potential leak source for heavier than air gases

2. Above potential leak sources for lighter than air gases

3. Near to leak sources along the expected leak trajectory, taking into

account prevailing wind directions

4. Between leak source and potential ignition sources

5. In area with expected heavy fog, rain or snow, consider the effect of long-

range installation and install the detector at shorter range with the maximum intensity model available.

5.3 Preparations for Installation

1. Upon receipt, verify the appropriate Purchase Order and record the Part

Number and Serial Number of the Source and Detector units in the appropriate Log Book.

2. Carefully unpack the following equipment observing any instructions

printed on or contained in the packaging list. Check the contents for any possible damage caused from shipping and handling. In the event of damage or loss in transit, notify the carrier and your Supplier immediately.

The System should include the following (in addition to this manual):

• Detector unit

• Source unit

• Two tilt or swivel Mounting Bases – one for the Detector and one for the

Flash Source.

• Telescope Kit

• Functional Fil ter

• Magnetic Mode Selector

Notes: 1 The Magnetic Mode Selector, the Calibration Filter and the Telescope Kit are

used during each SafEye’s installation and then removed. They can be reused for all other SafEye installations on the site. Therefore, only one set is provided for several detectors.

2 There are two different Telescope Kits:

For standard installation P/N 794110 For Duct installation P/N 794245

3 There are two different types of Functional Filter. One for standard mount

and the other for Duct Mount. Each type has five different models for different gas reading.

For standard installation P/N 794260 - 1 to 5 For Duct installation P/N 794220 - 1 to 5

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.4 Mounting for Standard Open- Path Installation

The following instructions are applicable for both the Light Source unit and the Detector unit. The detector may be mounted on special Swivel Mounts (see

5.4.1) or i. Tilt Mounts (see 5.4.3) ii. Duct mounts – (see5.5) iii. Also see appendix D if EExde version used

5.4.1 Swivel Mount Kit

Note

For Aluminum and St. St. detector enclosure use Swivel Mount:

• P/N 794765 for inches measure

• P/N 794765-1 for metric measure.

The Swivel Mounts models are made of St. St. 316L.

Table 16. Swivel Mount Kit

Item QTY Location

Swivel Mount 1 Screw 1/4”-20UNC or M 6 x 1P 4 Detector - Holding plate 1/4” Spring Washer 4 Detector - Holding plate

5.4.2 Swivel Installation (Figure 7)

1 Place the swivel mount Securing Plate (2) in its designated location and

secure it with four M6 or 1/4”-20UNC screws (9), placed 3 in. (76.2 mm.) apart.

Note

Skip this step if the mounting is already installed. Also detector removal for

maintenance purpose does not require Swivel Mount removal. 2 Unpack the detector carefully 3 Place the detector with its conduit inlets/electrical entries pointing down on

the holding plate of the swivel mount (10). Secure the detector by four 1/4”20UNC allen screws or M6 x 1P (8) with 1/4” spring washers from the swivel

mount kit (use No. 5 Hex Key for M6 screws, or 3/16” Hex Key for 1/4”20UNC screws).

4 Tighten the three locking 3/8”-24UNF screws (5) of the swivel mount ring until

the friction in the ball joint holds the detector in its position. Yet, still permits it to be moved by hand-applied force (use 3/16 Hex Key).

5 Point the detector towards the Flash Source and make certain that the view of

the area is not obstructed. Secure the detector in that position by tightening the locking screws of the swivel mount ring.

6 Repeat mounting and Swivel Mount installation described in this chapter for

installing the Flash Source.

The detector is now correctly located and ready for the electrical connection to the system prior to fine alignment.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1 Detector / Flash

Source Assembly

2 Swivel Mount

Securing Plate 3 Protective Front Cover 4 Swivel Mount

Alignment Plate 5 Swivel Mount Locking

Screws 6 Vertical Adjustment

Screws 7 Horizontal Adjustment

Screws 8 Detector Screws

9 Swivel Mount Plate

Securing Screws 10 Swivel Mount Holding

Plate

Figure 7. Detector/Flash Source and Swivel Mount Assembly for Standard Installation

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.4.3 Tilt Mount Kit

The Tilt Mount kit includes the items listed in Table 17 as follows:

Table 17. Tilt Mount Kit

Item Qty DWG

Tilt Mount 1 799220 Cap Socket 1 Screw 5/16 - 18 UNC - 2H 3/4” St.St. Spring Washer 1 Spring Washer 5/16” St.St. Detector Base Assembly 1 799110 Cap Socket Screw 4 Screw 1/4” - 20 UNC - 3A x 1/22 Spring Washer 4 1/4” St.St

Description 1 Tilt Mount 4 Spring washer 2 Detector Base 5 Holding Plate 3 Cap Socket

Figure 8. Tilt Mount Assembly

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description 1 Tilt Mount Holding Plate 7 Vertical fine alignment screw 2 Detector base 8 Horizontal fine alignment

tighten screw

3 Horizontal crude alignment tighten

screw 4 Horizontal fine alignment tighten screw 10 Telescope tightening bolt 5 Vertical fine alignment tighten screw 11 Detector / Source 6 Vertical crude alignment tighten screw

Figure 9. Detector/Source and Tilt Mount Assembly

9 Telescope

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.4.4 Detector / Source Installation (Figure No. 8 and 9)

1. Place the Tilt Mount holding plate (Item 1) in its designated location and secure it with (4) fasteners through four (4) holes dia. 8.5mm.

2. Install the Detector Base Assy. (Item 2) on the Tilt Mount use cap socket screw (Item 3) and Spring Washer (Item 4).

Notes: 1 Skip steps 1 and 2 if the Tilt Mount is already installed. 2 Detector removal for maintenance purpose does not require Tilt

Mount removal

3. Place the detector, with its conduit/cable inlets pointing downwards on the detector base assy. of th e Tilt Mount (Item 2). Secure the detector with four 1/4”- 20 UNC - 3A x 1/2” screw with No. 1/4” spring washers to the Tilt Mount. Use 1/4” Hex Key for 3/16” screw.

4. Repeat 1 - 2 to install the Source

5.5 Mounting for Duct Installation

The following instructions are applicable for both the Source unit and the Detector unit. The detector may be mounted on a special Duct Mount. The Duct Mount enables the detector to be rotated up to ±3 degrees in the X-Y directions in order to provide fine alignment. For duct installation use Duct Mount P/N 794716. The Duct Mount Kit supplied with the item listed in Table 18 as follows:

Table 18. Duct Mount Kit

Item Qty

Duct Mount Set 1 Open & closed Wrench No. 10 key 1 per installation Closed No. 10 Key 1 per instal lation

5.5.1 Duct Mount Set (Figure 11, 12)

The Duct Mount set consists of Fitting Plates, Sealing Rings, Windowed plate, and securing elements combined with appropriate screws and nuts. It provides a reliable attachment of the detector to the air intake as well as good sealing and accurate alignment capability.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.5.2 Duct Alignment Set (Figure 13) and Accessories

Air Duct Installation has a limitation, which is the disability of viewing the Detector’s front and performing fine alignment through detector aiming such as

performed in standard installation. As a result, fine alignment of the Detector’s Mount should be performed before the detector assembly is mounted to it.

The Alignment Set solves this problem by enabling the installer to align the Detector Mount first, and then to install the Detector. The Alignment Set includes

a Mount that is identical to the Detector Mount Surface and a telescope that is installed in the middle of the Mount Surface. The Telescope is centered in the

Duct mount in a way that it is located in the same optical axis as the detector that will be mounted later in the same location.

The Accessories supplied with the kit includes one No.10 Key for installation and for alignment. One Accessories Set is supplied for each installation.

5.5.3 Duct Installation - Surface Preparation (Figure 10)

The following instructions are applicable for both the Flash Source unit and the Detector unit.

1. Check the Air Duct Installation Surface (1) stability. It should be as near as possible to a rig id girder connection in order to assure proper support to the mounting and the unit. Also the surface must be stable and free of vibrations.

2. Locate the best installation surface for the Detector/ Flash Source. The location of the central point of each Duct Hole (3) should be at the same distance from the surface edge. This will provide that both Detector and Source optical axis will be in parallel to the Air Duct wall lines such that any blocking in the interior area will be prevented.

3. Preparation of the surface: Prior to hole drilling, it should be verified that the Installation surface is straight, clean and free of corrosion.

Drilling and cutting: Mark the Location and dimensions of the Installation Figure 10 show surface drilling dimensions. Drill the Duct Hole (3) and the Screw

Holes (2) carefully.

Caution!

Since the installation is done in a potentially explosive, any workmanship in the installation area should be performed under

the appropriate rules and regulations.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1 Air Duct Installation Surface 2 Duct Mount Screw Securing Hole 3 Hole for Detector / Flash Source

Figure 10. Drilling Layout Dimensions for Duct Installation

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.5.4.Duct Mount Installation (Figures 11,12)

The following instructions are applicable for both t he Flash Source unit and the Detector unit.

1. Insert the first Internal Plate (1) through the Air Duct Hole. Hold it by hand and press the Base Plate Gasket (2) to the Installation Surface against the Internal Plate. The Internal Plate Screws should be inse rted into the Gasket holes and hold it from falling. Then remove your hand and repeat the process for the second Internal Plate.

2. Attach the Base Plate (3) to the Gasket (2) carefully. The Internal Plate screws should be inserted slightly to the Base Plate holes.

3. Secure the Base Plate to the Installation Surface using four Nuts and Flat Washers (4).

4. Attach the Window Plate (5) by threading its holes on the Base Plate Screws. The Window (7) Protection Ring of the plate should be directed outside. Secure it by four Nuts and Flat Washers (6).

5. Alignment Plate installation: Screw together the Internal Vertical Alignment Nut and the Washer (9) to the Base Plate Screws. Then thread the Alignment plate (8) on the screws. Connect the two External Alignment Nuts and Flat Washers (10) without fastening. The Plate is now connected.

6. Connect the Horizontal Alignment Screw with the Nut and Flat Washer (11) directed according the illustration. The Alignment Plate should be

held but set free for alignment.

At this point , the Duct Mount is ready for alignment.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1 Internal Plate 9 Internal Vertical Alignment Nut and

Flat Washer

2 Base Plate Gasket 10 External Alignment Nut and Flat

Washer

3 Base Plate 11 Horizontal Alignment Nut and Flat

Washer

4 Base Plate Securing Nut

and Flat Washer 5 Window Plate 13 Detector / Flash Source 6 Window Plate Nut and Flat

Washer 7 Window 15 Detector/ Flash Source Securing Nut

8 Alignment Plate 16 Window Nut

Figure 11. Detector/Flash Source and Duct Mount Installation scheme

12 Detector / Flash Source Plate

14 Horizontal Adjustment Locking Screw

and Flat Washer

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1 Internal Plate 9 Internal Vertical Alignment Nut

and Flat Washer

2 Base Plate Gasket 10 External Alignment Nut and Flat

Washer

3 Base Plate 11 Horizontal Alignment Nut and Flat

Washer

4 Base Plate Securing Nut and Flat

Washer

5 Window Plate 13 Detector / Flash Source 6 Window Plate Nut and Flat Washer 14 Horizontal Adjustment Locking

7 Window 15 Detector/ Flash Source Securing 8 Alignment Plate 16 Window Nut

Figure 12. Duct Mount Installation - Outline Drawing

12 Detector / Flash Source Plate

Screw Nut and Flat Washer

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.5.5 Duct Mount Alignment (Figures 12,13)

The following instructions are applicable for both the Flash Source unit and the Detector unit.

1. Connect the Telescope Plate (Figure 13, item 1) to the Duct Mount Alignment Plate (Figure 12, item 8). Insert each one of four Screws (Figure 12, item 15) from the Duct Mount side through the Hole (Figure 13, item 2), and s ecure it with Nut and Flat Washer (Figure 12, item 15).

2. Locate the Telescope Aim (Figure 13, item 3) to be in vertical to the Installation surface.

3. Look at the Aim view and locate the ‘Aim Cross’ in the middle of Installation Surface Hole on the opposite s ide. Rotate the Vertical and Horizontal Nuts (Figure 12, items 10,14) to achieve best result. Provide stability of the plate by securing and releasing the opposite nuts or screws gently.

4. Repeat step 3 until best result is achieved.

5. Provide final Screws and Nuts securing (Figure 12, items 9,11).

6. Remove the Alignment set carefully by unscrewing The Nuts and Screws from the Hole (Figure 13, item 2).

7. Perform detector wiring according to section 5.6 Note that in case of Air Duct installation the Detector is mounted at the front side. Therefore, it

must be removed from its mounting before any cover opening.

8. Install the Detector/ Flash Source on the Alignment Plate (Figure 12, item

8).

9. Secure the Detector/ Flash Source with Nuts and Flat Washers (Figure 12, item 15).

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1 Telescope Plate 2 Detector / Flash Source Securing Screw Hole 3 Telescope Aim

Figure 13. Telescope Alignment Set

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.6 Detector Wiring (see appendix D if EExde version used)

This section does not attempt to cover all of the standard practices and codes of installation. It emphasizes specific points providing the basic concept for qualified wiring installation personnel.

Warning!

Do not separate or close the housing section from the cover while the power is at “on” position.

Caution!

It is very important that the Cover and Housing sections be exposed to the environment for the least amount of time due to the internal

circuitry. Proper planning of the wiring is required in order to reduce the amount of time the Cover and Housing sections are apart.

5.6.1 Conduit/Cable Installation

1. To avoid water condensation in the detector, it should be installed with the conduits/electrical entries facing downward.

2. When using the Swivel Mount or Duct Mount, use flexible conduits for the last portion connecting to the detector.

3. When pulling the cables through the conduits, ensure that they are not tangled or stressed. Extend the cables about 12 in. (30cm.) beyond the detector location to accommodate wiring after installation.

4. After the conductor cables have been pulled through the conduits, perform a continuity test.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.6.2 Harness Connection (Figure 14)

1. Remove the four Threaded Plugs (13) from detector front.

2. Release the four Socket-Head Screws (14) that secure the detector housing (1) to its back cover (2) using No. 5 Hex Key for M6 screw. Hold

the housing during the removal of the screws. Pull the detector housing from its cover. The cover remains attached to the detector swivel mount. The housing slides under the cover and remains attached to it by a securing cable (8). Do not let cover simply drop but rather support it until it hangs. The terminal board (12) inside the detector cover is now revealed.

3. Remove the protective plug (6) mounted on the detector conduit inlet. Pull the wires through the detector cover (2) and secure them firmly to the cover using the cable-tie (16) attached to it. Use a 3/4”-14NPT or M25 x

1.5P explosion -proof conduit/electrical entry connection to assemble the conduit/cable to the detector.

4. Connect the wires to the required terminals (12) according to the wiring diagram. See Appendix B.

5. Connect a Grounding Cable to the Ground Terminal (7) outside the detector cover (2). The detector must be well grounded to Earth Ground for proper operation.

6. Verify the wiring. Imp roper wiring may damage the detector.

7. Check the wires for secure mechanical connection and press them neatly against the Terminal Board (12) to prevent them from interfering while

closing the detector’s housing.

8. Dress all wires so they will not interfere w ith the closure of the unit.

9. Seal the conduit inlet and outlet.

10. Align the two connectors guide pins in the Housing section with the correct openings in the housing section.

11. Carefully slide the Housing section onto the floating holes in the Female D Connector.

12. Using the long handled Hex key, tighten the four M6 1.0PX50 screws (14).

13. Insert the four Threaded Plugs (13).

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1 Housing 9 SW1 2 Cover 10 SW3 3 Screw Hole 11 SW2 4 Female D Connector 12 Terminal Board 5 Male D Connector 13 Threaded Plug 6 Conduit Inlet Plug 14 Socket Head Screw (M6x1.0Px50) 7 Ground Terminal Screw 15 Screw Pan Head (No. 4-40UNC-2Ax3/8”) 8 Securing Cable 16 Cable Tie

Figure 14. Detector with Cover (removed)

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.6.3 Detector Terminal Wiring

The detector contains a terminal board consisting of two terminal blocks.

Power Supply:

The input power is supplied to terminal 1. The Return is connected to 2.

Note

Ensure that the detector unit receives a minimum of 18 Volts DC and does not exceed 32 Volts DC.

Fault Relay:

The Fault Relay is normally open. The SPST relay is at terminal 4 and 5. The contacts are normally energised closed when the detector is in normal operation.

Alarm Relay:

The Alarm Relay is SPDT Relay. Terminals 6 and 7 are Normally Open and the contacts are closed when the detector is in the Alarm status. Terminals 7 and 8 are Normally Closed and the contacts are open when the detector is in the Alarm status.

Accessory Relay:

The Accessory output is Normally Open SPST relay. Its contacts are at terminals 9 and 10. It can be defined per user requirements (See Appendix B.)

Note

To protect the dry contacts from voltage surges when connected to reactive loads (electric motors, sirens, etc.) connect an appropriate varistor over these contacts.

4-20mA Output:

Terminals 11 and 12 are used for 4-20mA current output as specified in section

3.7.1 (See Appendix B.)

RS-485 Output:

Terminal 13 and 14 are used for the communication network (See Appendix B.)

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

5.7 Flash Source Wiring

5.7.1 Power Supply

Input power is supplied to terminal 1. The return is connected to terminal 2 (see figure 15).

Note

Ensure that the Flash Source unit will receive a minimum of 18 Volts DC and does not exceed 32 Volts DC.

Pre-wiring requirements and wiring requirements are identical to the appropriate requirements for the detector, as described in appendix A.

5.7.2 Harness Connection (Figure 14 )

The instructions for this are identical to the detector. Refer to section 5.6.2

5.7.3 Terminal Wiring (Table 6)

The Flash Source contains a terminal board. Terminal Wiring Instructions are identical to the Detector Wiring instructions. The Flash Source consists of two wires only. The Positive supply power connected to terminal 1, and the common return connected to terminal 2.

Connect the Grounding Cable to the Ground Terminal (Figure 15, item 4) outside the Flash Source cover (Figure 15, item 2). The detector must be well grounded to Earth Ground for proper operation.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1 Housing 5 Grounding Wire 2 Cover 6 Securing Cable 3 Conduit /cable Inlet Plugs 7 Screw Hole 4 Ground Terminal Screw 8 DIPswitches

Figure 15. Flash Source - Open View

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

6. Operating Instructions

6.1 SafEye Operation

Once the system is positioned, it will monitor for possible specified gases, automatically sending signals to a standard control panel or a PC.

This chapter describes the alignment, calibration and operation.

Important!

Accurate Alignment is essential for proper operation of the SafEye system.

6.2 Alignment of Unit (Figures 16 through 17) Using Swivel Mount

(See 6.3 for Alignment using Tilt mounts) This section applies to open -path installation only. For duct mount applications

the alignment is performed according to section 5.5.5. Therefore, skip steps 1 through 10 when duct mount installation is performed.

The Telescope is used for full alignment. Alignment procedure should be performed in two stages: Crude alignment then fine adjustment.

The Telescope includes a Periscope that consists of a prism and an ocular located vertical to the Telescope assembly. This allows the user to observe the

opposite unit perpendicular to the alignment when access from the rear of the unit is difficult/impossible. In installations where rear access is possible, the Periscope is not necessary. I n this case it can be removed by releasing the Periscope Fastening Screw (item 5 at figure 17).

Important Notes

a. Prior to Telescope Installation, verify that the Telescope and Its

Sight Mounting are free from any dirt to ensure proper alignment according to factory calibration.

b. Do not Attempt to change any factory calibration of the

Telescope or its mounting. This may prevent optimal alignment.

3. Make sure that the Detector and the Flash Source are installed properly. Installation instructions are described in section 5 of this document.

4. Refer to Figure 16. Slightly release four Protective Sight Covers’ screws (Figure 16, item 6) from the Detector and the Flash Source. Do not remove

the screws from the Covers. Remove the Protective Sight Covers (Figure 16, item 7) from the Detector/Flash Source Assembly. Store the Cover in a clean place for reinstallation after alignment is completed.

5. Refer to Figure 17. Install the Telescope Assembly (1) on the Telescope Sight Mounting (2) of the Detector according to the drawing. Fasten the Telescope with Fastening Screw (3).

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1 Magnetic Mode Selector 5 Horizontal Adjustment Screw 2 Detector Housing 6 Sight Cover Screw 3 Detector Cover 7 Protective Sight Cover 4 Vertical Adjustment Screw 8 Adjustment Screw Securing Nut

Figure 16. Alignment and Mode Selection

Description

1 Telescope Assembly 6 Flash Source/Detector Housing 2 Sight Mounting 7 Socket Set Screws (3) 3 Telescope Fastening Screw 8 Vertical Adjustment Screw (2) 4 Periscope 9 Horizontal Adjustment Screw (2) 5 Periscope Fastening Screw 10 Adjustment Screw Securing Nut

Figure 17. SafEye Flash Source/ Detector Alignment

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

4. Detector Crude Alignment: Refer to Figure 17 for all the following instructions.

a. Use 3/16” Allen screwdriver to loosen up the 3 socket set screws (7). b. Tilt the Flash Source in the general direction of the Detector.

c. Rotate the Periscope (4) until its ocular is positioned in front of your

aiming eye for most convenient observation.

d. Observe through the Periscope (4) and locate the Detector in the

center of view of source unit.

e. Tighten three socket set screws (7) of the Detector’s Swivel Mount.

5. Release the Fastening Screw (3) and remove the Telescope from the Detector.

6. Flash Source Crude Alignment Repeat Steps 3 through 4 for the Flash Source.

7. Flash Source Fine Adjustment :

a. Release the Adjustment Screw Securing Nuts (10) from all Adjustment

Screws (8,9) to enable fine alignment.

b. Watch through the Periscope (4). The cross midpoint inside the

Telescope Lens should be aimed to the opposite unit (Flash Source) such that it is observed in the Periscope.

c. Rotate the Vertical Adjustment Screws (8) and the Horizontal

Adjustment Screws (9). This should be performed until the cross midpoint is combined with the center of the top of the Flash Source Telescope Sight Mounting (Figure 17, item 2).

d. Carefully secure the four Adjustment Screw Securing Nuts (10).

Release the Fastening Screw (3) and remove the Telescope (1) from the unit.

8. Detector Fine Adjustment Repeat Steps 3 and 7 for the Detector.

9. Repeat steps 3,7 and 8 if additional Adjustment is required.

10. Upon alignment completion perform the following:

a. Reinstall Protective Sight Covers on the Detector and the Flash

Source by screwing four Sight Cover screws (Figure 16, item 6).

b. Return the Telescope to its Original case.

11. Power on the system according to section 6.4

12. Perform zero calibration according to section 6.6

13. Perform Signal Intensity Check (SIC) according to section 7.2.2

14. Perform Functional Check (FC) according to section 6.7

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

6.3 Alignment of Unit (Figure 8, 9) Using Tilt Mount

Using the Telescope performs full alignment. Alignment procedure should be performed in two stages: Crude alignment then

fine adjustment. The Telescope includes a Periscope that consists of a prism and an ocu lar

located vertical to the Telescope assembly. This allows the user to observe the opposite unit perpendicular to the alignment when access from the rear of the unit is impossible. For installations where rear access is possible, the Periscope is not necessary. In this case it can be removed by releasing the Periscope Fastening Screw.

Important Notes

a. Prior to Telescope Installation, verify that the Telescope and its Sight

Mounting are free from any dirt to ensure proper alignment according to factory calibration.

b. Do not attempt to change any factory calibration at the Telescope or its

mounting. This may prevent optimal alignment.

Alignment procedure (refer to Figure 9):

1. Make sure that the Detector and the Flash Source are installed properly. Installation instructions are described in section 5 of this document.

2. Install the Telescope Assembly (9) on the Telescope Site Mounting of the Source according to the drawing. Fasten the Telescope with Fastening Screw (10).

3. Crude Alignment - Source

a. Use 1/4” Allen screwdriver for all alignment screws. b. Loosen screws 5, 6. c. Approximately aim the Source horizontally toward the Detector. d. Tighten screw 5 e. Loosen screws 3, 4 f. Approximately aim the Source vertically toward the Detector g. Tighten screw 3

4. Repeat 3 for the Detector

5. Fine Alignment- Source

a. Aim the source at the Detector within horizontal axis using screws 7.

Aim the cross to the upper level of the telescope site of the detector.

b. Tighten screw 6. c. Aim within the vertical axis using screw 8.

d. Tighten screw 4 e. Make sure the telescope cross is pointing at the top of the telescope

site of the detector.

6. Repeat 5 for the Detector fine alignment.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

6.4 Powering on the system

Important!

Prior to any operation or maintenance follow the Safety Precautions given at section 6.5

1. M ake sure that the source and detector are connected to the power.

2. Make sure that the 4-20mA meter is connected to the detector.

3. Power up the system 18 -32VDC.

4. After 60 seconds, the left LED lights at green, the current meter will

indicate 4mA.

Note

If it is the first operation after installation, the LED may indicate any status. Zero calibration should be performed after powering the system (see section 6.5).

6.5 Safety Precautions

After powering-up, the detector requires minimal attention in order to function properly, but the following should be noted:

1. Caution! Avoid Looking directly into the flash radiation source. The UV

light pulses may cause damage to the eye’s retina when exposed from a short distance for a prolonged period of time.

2. Follow the inst ructions in the manual and refer to the drawings and

specifications issued by the manufacturer.

3. Do not open the detector housing, while power is supplied.

4. Do not touch internal parts other than the two functional switches.

Interference with internal circuits may impair detector performance and will invalidate manufacturers warranty.

5. Disconnect external devices, such as automatic extinguishing systems

before carrying out any maintenance task.

6.6 Zero Calibration

Precise alignment must be performed prior to the calibration procedure. Calibration should be performed in nice weather conditions with insignificant gas concentrations in the surrounding environment or indoors.

Note

To change modes, place the Magnetic Mode Selector (see Figure 16, item 1) on the detector for 2 seconds and wait for the LED indication.

After mode change allow a time lapse of 5 seconds before changing mode again. Standby mode is a temporary mode lasting about 20 seconds used to facilitate

Zero Calibration mode selection. If the mode selector is not placed during this 20 seconds period, the detector will be switched to Normal mode.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

1. Switch from Normal to Alignment mode. See Table 2 for LED status

indication.

2. Switch from Alignment to Standby mode. The LEDs will flash alternately

with a green color.

3. Switch from Standby to Calibration mode. The LEDs will turn off.

4. Wait up to 60 seconds until it switches to Normal mode (right LED green)

The detector reading is now set to normal. The 4-20mA output should indicate 4mA.

6.7 Functional Check of Unit

The SafEye system has been calibrated at the factory for the User's specific gas or vapor detection requirements. The following procedure validates the functional operation of the system. The Functional Check Filter is a convenient operational check used to confirm that response has not changed from previous readings. The filter is not used for calibration, which is unnecessary, nor does it equate to a particular quantity of gas.

Caution:

Automatic activation or any external device that should not be activated during the calibration check should be disconnected.

Notes:

1. This functional verification procedure is for a standard 4-20mA output.

2. Prior to starting the functional check, verify that the power to the units is on and that the current of the 420mA channel is stable. Record the reading.

1. Position the Functional Check filter in front of the SafEye Detector.

2. The functional check filter's window must be centered over the viewing window of the Detector.

3. Wait 20 seconds.

4. Read the 4-20mA current. Determine the difference between the reading taken with and without the Functional Check Filter. This difference is the 4-20mA current variance.

5. Record the 4-20mA current variance in a Maintenance Logbook. If the variance is more than a 30% change when compared to the previous check (see delivery form), repeat the alignment.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

7. Maintenance Instructions

7.1 General Maintenance

The SafEye system requires only simple periodic maintenance to provide satisfactory service and achieve maximum performance. The Detector and

Source units can be maintained with the use of common tools and equipment. Record the periodic test results in a Maintenance Logbook with a copy of the delivery form inside.

Note

The maintenance can be performed through RS-485, for more details refer to TM792050.

7.2 Periodic Maintenance

Recommended cleaning of optical surfaces to be performed periodically.

Note:

The frequency of cleaning operations is ultimately dependent upon the existing environmental conditions and the applications used .

1 Proper maintenance will allow the SafEye system to retain maximum

performance and reliability.

2 The optical surfaces of the Source and Detector viewing windows should be

kept as clean as possible as it is an active device.

3 Alignment procedures must be performed each time that the Source or the

Detector unit has been opened or moved for any reason.

4 The Signal Verification Check corroborates the current signals from the Flash

Source compared to that of previous alignments. It is recommended to perform this check every 6- 12 months. The signal should be checked

according to threshold levels (see. 7.2.2). 5 The functional check should be performed every 6 months (see 6.7) 6 Zero calibration (see 6.6) must be done every time the Detector or Source is

realigned or windows cleaned.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

7.2.1 Routine Optical Surface Cleaning

The SafEye system, being an optical device, must be kept as clean as possible. The optical surfaces concerned are the Source and Detector viewing windows. To clean the optical window, proceed as follows:

1. Turn off the power to the SafEye detector and source.

2. Where dust or dirt has accumulated on the optical surface, clean the surface with a small, soft -bristle brush.

3. The surfaces must then be washed thoroughly with water and a mild nonabrasive detergent.

4. Thoroughly rinse the glass surface with clean water; ensuring no residue is left behind.

5. Dry the glass with a clean dry soft cloth.

6. Enter in the Maintenance Logbook: Date, name of person and company who performed the maintenance service.

7. Turn on power to the SafEye detector and source.

8. Perform signal verification (section 7.2.2).

9. Perform zero calibration (see section 6.6).

10. Perform functional check (see section 6.7)

7.2.2 Signal Verification

The Signal Intensity Check determines if there is a misalignment or if the Flash Source signal is wearing over a period of time. Clean the optical surfaces prior to performing this check (see 7.2.1). This procedure should be performed in clear weather.

1. Enter Alignment Mode by placing the m ode selector on the side of the detector for 2 seconds.

2. Within the first 20 seconds the Detector indicates 3 different indication levels. See Table 1

3. Wait 20 seconds and count the number of LED flashes with the color, and adjust the value (see Table 19).

4. Record the new results in the maintenance log book.

5. Determine the absolute variance compared with the previous alignment reading in the maintenance logbook.

6. If the variance is more than 30%, perform alignment (see section 6) and zero calibration (see section 6.6). Call a technician for service if the SIC is less than 66 with both LED’s flash in red color.

Table 19. LED Signal Adjustment

Color (left-right) Number to be

added

Red-Red 0

Orange-Orange 62

Green -Orange 124

Green -Green 186

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Example:

At a hypothetical installation the LEDs are Green -Orange with 3 green flashes (left LED) and 6 orange flashes (right LED).

The number is 36 + 124 = 160 The next periodic maintenance reading has Orange-Orange LEDs with 8 orange

blinks (left LED) and 8 orange flashes (right LED). The number is 88 + 62 = 150 The variance is 160-150 = 10 Units The percentage of variance will be (10/160)*100 = 6.25% less then previous

alignment.

7.2.3 Function Check of Unit

The SafEye system has been calibrated at the factory per t he user’s specific gas or vapor detection requirements. This procedure validates the functional operation. The functional check must be done periodically. Refer to 6.7 for instructions.

Caution:

Automatic activation or any external device that should not be activated during the calibration check should be disconnected.

7.2.4 Maintenance Records

Record every maintenance operation performed on the Source and/or Detector in a Maintenance Log-book. The logs should include but not be restricted to the

following:

• The information identifying the measurement units.

• The date of installation and contractor.

• Entries for every maintenance operation performed to include at least the

description of the operation, date and personnel ID.

• Signal intensity records with SIC results.

• Calibration check (CC) results.

If the unit(s) is (are) sent to the authorized Supplier, a copy of the Maintenance Records must accompany the unit concerned.

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

8. Troubleshooting

Problem Cause Solution

LEDs are off and Fault is indicated at 0 mA level Both LEDs are on at yellow and fault is indicated at 0mA level Both LEDs are flashing at yellow and fault is indicated at 0mA lev el One LED is on at yellow and 4-20mA indication level is 2mA

Power is not supplied to the Detector Fault 2 Bring the detector unit for

Low voltage is supplied to the detector

Dirt has accumulated on the detector's window or on the Flash Source's window One unit at least has been moved or tilted Power is not supplied to the Flash Source The optical open path beam is blocked One unit at least has been moved or tilted Electrical problem at the Flash Source

Supply power to the Detector

service. Check the voltage level

supplied to the detector Clean the optical

windows (See Section

7.2.1). Perform Realignment

(See section 6) Supply power to the Flash Source Remove the obstruction

Perform Realignment (See section 6)

Perform SIC in order to measure signal intensity

Bring the Flash Source to a technician for service if it is not flashing

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Appendix A - Wire Selection Tables

General Instructions For Electrical Wiring

1. mA output or relay wiring - refer to Table 20 to determine the required wire gauge for general wiring Calculate the permitted voltage fall with respect to loads current, wire gauge and length of wires.

2. Power supply wires - refer to Table 21 to select wire gauge. DO NOT connect any circuit or load to Detectors’ supply inputs.

Table 20. Maximum DC resistance at 68°F for copper wire

AWG # mm2 Ohm per 100 ft. Ohm/100

meter 26 0.12 - 0.15 4.32 14.15 24 0.16 - 0.24 3.42 11.22 22 0.30 - 0.38 1.71 5.60 20 0.51 - 0.61 1.07 3.50 18 0.81 - 0.96 0.67 2.20 16 1.22 - 1.43 0.43 1.40 14 1.94 - 2.28 0.27 0.88 12 3.09 - 3.40 0.17 0.55 10 4.56 - 6.64 0.11 0.35

1. Select "Number of Detectors" connected in one circuit.

2. Select "wiring length" per your installation requirements.

3. Refer to "power supply range" for voltage extreme applied.

Table 21. Wiring length in feet (meter) No. of Detectors

24 18 16 14 - - 22-32 20 18 16 14 - - 22-32 16 20 18 16 14 - 22-32 12 20 18 16 14 - 20-32

8 20 18 16 14 - 20-32

4 and less 20 18 16 16 14 20-32

Feet 164 328 492 656 820

(Meters) (50) (100) (150) (200) (250)

Max. Length from Power Supply to Last

Recommended Wire Diameter Power Supply

Range (VDC)

Detector

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Appendix B: Wiring Option configurations

Figure 18. Detector’s Wiring Diagram

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Figure 19. 4-20mA Source Output

Figure 20. Typical 4 Wire Controller

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

RS-485 Communication Network

By using the RS- 485 network capability of the SafEye Detector and additional software, it is possible to connect up to 32 Detectors in an addressable system

with four (4) wires only (2 for power and 2 for communication). Using repeaters, the number of Detectors can be much larger (32 Detectors for each repeater) up to 64 on the same four (4) wires. When using the RS-485 network, it is possible

to read each Detector status (FAULT, WARNING, and ALARM). For more details, consult the factory.

Figure 21. RS-485 Networking

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Appendix C: Outline Drawing

Figure 22. Detector Outline Drawing With Swivel Mount

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Figure 23. Source Outline Drawing (65 dia Lens Type) With Swivel Mount

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Figure 24. Source Outline Drawing (80 dia Lens Type) With Swivel Mount

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Figure 25. Source Outline Drawing (Reflector Type) With Swivel Mount

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Figure 26. Detector and Tilt Mount Outline Drawing

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Figure 27. Source and Tilt Mount Outline Drawing

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Appendix D - Mounting the “EExde approved” version

The EExde approved version provides an additional EExe terminal box attached below the EExd detector and therefore allows easier access in hazardous areas (see fig. 28). The unit is prewired to the terminals in the additional EExe terminal section ready for field wiring connections

1. Detector/Source Mounting

The detector should be mounted by one of the following options: a. Swivel mount refers to paragraph 5.4.1. b. Tilt mount refers to paragraph 5.4.3. c. Duct mount refers to paragraph 5.5.

1.1 Installation All the installation instructions are the same as defined in Paragraph 5.4.1, 5.4.3 and 5.5. a. On swivel mount option there are two options of detector/source install on the

swivel mount. You can use the thread on the de cover marked either Triangle Symbol or

a Square Symbol (Figure 28). b. On tilt mount option you must use the Triangle Symbol. c. On duct mount the detector is installed from the front of the detector.

2. WIRING (REFER TO FIG. 28.)

1 Disconnect power. 2 Release the four (4) slotted-head screws (item 3) that secure the chamber

cover (Item 2). The chamber is now revealed.

3 Remove the protective plug mounted on the detector conduit inlet, pull the

wires through the detector chamber (Item 7). Use M25x1.5 explosion-proof conduit connection to asse mble the conduit to the detector.

4 Connect the wires to the required terminals (Item 4) according to the wiring

diagram. See paragraph 2.1 and figures no. 29 and no. 30.

5 Connect the grounding wire to the ground screw outside the detector cover

(Item 5).

The detector must be well grounded to Earth Ground for proper operation.

6 Verify the wiring. Improper wiring may damage the detector. 7 Check the wires for secure mechanical connection and press them neatly

against the terminal to prevent them from interfering while closing the cover (Item 2).

8 Place and secure the cover chamber (Item 2) using four (4) slotted-head

screws (Item 3).

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

Description

1. Modified Back Cover 5. Ground Terminal

2. EExe Chamber Cover 6. Mounting Thread

3. Slotted Screw 7. EExe Chamber

4. Terminal Block 8. Conduit Inlet

Figure 28: Flame Detector Assembly - Wiring Diagram

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

2.1 Terminal Wiring

Each detector and source unit has a separate EExe terminal box directly attached/assembled to it and prewired to the terminal strip in the EExe box (Item

4). There are two possible wiring options – please follow the wiring scheme below which is appropriate to that ordered:

The terminal block is labeled 1 to 6 (See Fig. No.28) The following describes the function of each electrical terminal of the detector:

RS-485 & 4-20mA Version

Option A (See Fig. No. 29)

Power Supply

(Terminal Numbers 1, 2):

Input power - Terminal No. 1. RETURN - Terminal No. 2.

RS-485 as specified in appendix C. (Terminal Numbers 3, 4):

Terminal No. 3 - positive (+) lead. Terminal No. 4 - negative ( -) lead.

4- 20mA Output (Terminal Numbers 5,

6): as specified in paragraph 5.e

Terminal No. 5 - output Terminal. Terminal No. 6 - input Terminal. (see appendix B for more details)

Alarm & Fault Relays Version

Option B (See Fig. No. 30)

Power Supply

(Terminal Numbers 1, 2):

Input power - Terminal No. 1. RETURN - Terminal No. 2.

Alarm Relay (Terminal Numbers 3, 4): The Alarm output is a NO. SPST contact at Terminal Numbers 3 and 4. The contacts are closed at Alarm Mode. Fault Relay (Terminal Numbers 5, 6): The Fault output is N.C. SPST contact at Terminal Numbers 5 and 6. The contacts are open at Fault condition.

Figure 29: OPTION A

Detector Assembly - Wiring Diagram

Figure 30: OPTION B

Detector Assembly - Wiring Diagram

Spectrex Inc. - SafEyeTM 200 Gas Detector Manual – TM 792100, Rev. D, May 2004

For additional details or assistance, please contact

218 Little Falls Road

Cedar Grove, NJ 07009, USA

Tel: +1 (973) 239 -8398

Fax: +1 (973) 239-7614

Email: spectrex@spectrex-inc.com

Web- site: www.spectrex-inc.com

Your Local Authorized Distributor:

Spectrex Series 200 User Manual

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