General Monitors FL3102 User manual

MODEL FL3102
Digital Frequency Infra-Red (DFIR)
Flame Detector
The information and technical data disclosed in this
document may be used and disseminated only for the
purposes and to the extent specifically authorized in
writing by General Monitors.
Instruction Manual 07-08
General Monitors reserves the right to change
published specifications and designs without prior
notice.
MANFL3102
Part No. MANFL3102
Revision D/07-08

Model FL3102
i
Warranty
General Monitors warrants the Model FL3102 to be free from defects in
workmanship or material under normal use and service within two (2) years from
the date of shipment.
General Monitors will repair or replace without charge any such equipment found
to be defective during the warranty period. Full determination of the nature of,
and responsibility for defective or damaged equipment will be made by General
Monitors’ personnel.
Defective or damaged equipment must be shipped to General Monitors’ plant or
representative from which the original shipment was made. In all cases this
warranty is limited to the cost of the equipment supplied by General Monitors.
The customer will assume all liability for the misuse of this equipment by its
employees or other personnel.
All warranties are contingent upon proper use in the application for which the
product was intended and do not cover products which have been modified or
repaired with out General Monitors’ approval or which have been subjected to
neglect, accident, improper installation or application, or on which the original
identification marks have been re moved or altered.
Except for the express warranty stated above, General Monitors disclaims all
warranties with regard to the products sold, including all implied warranties of
merchantability and fitness and the express warranties stated herein are in lieu of
all obligations or liabilities on the part of General Monitors for damages including,
but not limited to, consequential damages arising out of/or in connection with the
performance of the product.
Warnings
WARNING - Through engineering design, testing, manufacturing techniques, and
rigid quality control, General Monitors supplies the finest flame detection systems
available. The user must recognize his responsibility for maintaining the flame
detection system in operational condition.
WARNING - The Model FL3102 DFIR Flame detector contains components,
which can be damaged by static electricity. Special care must be taken when
wiring the system, to ensure that only the connection points are touched.
SAFETY WARNING - Installation and Maintenance must be carried out by
suitably skilled and competent personnel only.
TOXIC, COMBUSTIBLE AND FLAMMABLE GASES & VAPORS ARE VERY
DANGEROUS. EXTREME CAUTION SHOULD BE USED WHEN THESE
HAZARDS ARE PRESENT.

Model FL3102
ii
System Integrity Verification
General Monitors mission is to benefit society by providing solutions through
industry leading safety products, services and systems that save lives and
protect capital resources from the dangers of hazardous flames, gases and
vapors.
The safety products you have purchased should be handled carefully and
installed, calibrated and maintained in accordance with the respective product
instruction manual. Remember these products are for your safety.
To ensure operation at optimum performance, General Monitors recommends
that certain maintenance items be performed.
Commissioning Safety Systems
Before power up, verify wiring, terminal connections and stability of mounting for
all integral safety equipment including, but not limited to:
•Power supplies
•Control modules
•Field detection devices
•Signaling / output devices
•Accessories connected to field and signaling devices
After the initial application of power (and any factory specified warm-up period) to
the safety system, verify that all signal outputs, to and from devices and modules,
are within the manufacturers’ specifications. Initial testing should be performed
per the manufacturers’ recommendations and instructions.
Proper system operation should be verified by performing a full, functional test of
all component devices of the safety system, ensuring that the proper levels of
alarming occur.
Fault/Malfunction circuit operation should be verified.
Periodic Testing of Field Devices
Periodic testing/calibrating should be performed per the manufacturers’
recommendations and instructions. Testing/Calibrating procedures should
include, but not be limited to:
•Verify integrity of all optical surfaces and devices
•For flame detectors, use the appropriate test lamp
When testing produces results outside of the manufacturers’ specifications,
replacement of the suspect device(s) should be performed as necessary.
Maintenance intervals should be independently established through a
documented procedure, including a Maintenance log maintained by plant
personnel or third party testing services.

Model FL3102
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Periodic System Verification
The following system verifications should be performed at least annually:
Verify wiring, terminal connections and stability of mounting for all integral safety
equipment including, but not limited to:
•Power supplies
•Control modules
•Field detection devices
•Signaling / output devices
•Accessories connected to field and signaling devices
Proper system operation should be verified by performing a full, functional test of
all component devices of the detection system, ensuring that the proper levels of
alarming occur.
Fault/Malfunction circuit operation should be verified.
Maintenance intervals should be independently established through a
documented procedure, including a maintenance log maintained by plant
personnel or third party testing services.

Model FL3102
Quick Start Guide
i
1.0 Quick Start Guide
1.1 Upon Receipt of Equipment
All items shipped by General Monitors are packed in shock absorbing containers,
which provide a considerable degree of protection against physical damage.
When received, the contents should be carefully removed and checked against
the enclosed packing slip. All subsequent correspondence with General Monitors
must specify the equipment part number and serial number.
1.2 Choosing Detector Locations
Several variables are involved in selecting the locations to install detectors to
ensure proper flame detection. There are no hard and fast rules defining the
optimum location. There are some general suggestions that should be
considered in regard to particular conditions at the site where the unit(s) are
being installed:
1.2.1 Detector Field of View
Each Model FL3102 Flame Detector has a 120° maximum Cone of Vision. This
Cone has its vertex at the center of the detector (see Figure 1).
1.2.2 Optical Sensitivity Range
The distance at which the detector will respond to a flame is a function of the
intensity of that flame. The maximum distance is 50 feet (15.2m) for a gasoline
fire with a surface area of 1 square foot (0.92m2).
1.2.3 Environmental Factors
•Mounting should be as free from shock and vibration as possible and
convenient for visual inspection and cleaning.
•Detectors mounted in dirty atmospheric conditions will require more frequent
inspection, cleaning, and sensitivity checking.
•Observe the ambient temperature range for the specific model (see Section
8.1.4 Environmental Specifications). For outdoor installations or other areas
exposed to intense, direct solar radiation, the detector may reach
temperatures well above specifications. For this condition, a cover for shade
may be required to bring the detector temperature within specifications. As
with any cover or object near-by, make sure the field-of-view of the detector
is not obstructed.
•Avoid conditions of ice build up on the optical detector windows. Complete
icing-over of the IR detector window can result in fault conditions.

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Quick Start Guide
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1.3 Detector Installation
The Model FL3102 Detector is an explosion proof assembly rated for use in
Class I, Divisions 1 & 2, Group B, C & D, Class II, Group E, F & G, and
Class III areas. The detector(s) should be mounted pointing downward so that
dust/moisture will not accumulate on the IR windows. The detector(s) should be
mounted in locations, which will inhibit people or objects from obscuring the
detector’s Cone of Vision.
NOTE – Before installing these units, please read the warning statement on page
13 of this manual. These units must have a conduit seal installed.
Mounting hardware should be used as shown in Figures 2 and 3.
NOTE – The swivel (961-003) is rated for Class I, Div 1 & 2, Groups C & D. Use
mounting bracket for Group B areas.
The overall dimensions of the detectors and mounting hardware are shown in
Figure 4.

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Quick Start Guide
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Figure 1 FL3102 Field of View

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Quick Start Guide
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REAR VIEW
WALL MOUNTING
2.80[71.12]
2.80[71.12] 4.66[118.4]
REF HOLE :
4X Ø.26[6.6]
4X M6 WASHER
BRACKET ASSEMBLY
4X M6 X 14
30°
3.75[95.3] 5.00[127.0]
60°
30°
Figure 2 Swivel Elbow Drawing
(Class I, Div 1&2, Groups C&D)
Figure 3 Mounting Bracket Drawing
(Class I, Div 1&2, Groups B,C&D)

Model FL3102
Quick Start Guide
v
DATA+
DATA-
RESET
ALMTEST
DATA2+
0-20mA
DATA2-
+24VDC
COM
+24VDC
COM
CHAS GND 110
FLT 1 92
FLT 2 10 1
WARN C 5
WARN 2
FLT C
WARN 1
7
8
6
ALM 1
ALM 2
ALM C
3
4
2
6
4
3
5
8
7
9
FIELD TERMINATIONS
TB2 TB1
Figure 4 FL3102 Outline Drawing
WARNING – General Monitors requires that the conduit entry be sealed per the
Canadian Electrical Code Handbook (Part 1, Section 18-154). Conduit seals
prevent water from entering the units’ housing through the conduit entry. Water
entering the housing through the conduit entry will damage the electronics and
nullify the warranty.

Model FL3102
Quick Start Guide
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1.4 Terminal Connections
All wire connections are made through the ¾ NPT openings in the Base
Assembly to the terminal block (See Figure 7). The Terminal Block is located on
the Base Assembly (See Figure 8) and accepts 12 AWG to 22 AWG stranded or
solid-core wire. Each wire should be stripped as shown in Figure 5.
Figure 5 Wire-Strip Length
To connect the wire to the Terminal Block, insert the conductor into the
connection space as shown in Figure 7 and tighten the corresponding screw
terminal.
Figure 6 Detector Housing and Base

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Quick Start Guide
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Figure 7 Terminal Block Operation
There are twenty possible terminal connections.
On this and the following pages is a description and specification for each
connection.
1.4.1 Alarm Relay
TB2, Term 2 = ALARM C
TB2, Term 3 = ALARM 1
TB2, Term 4 = ALARM 2
Description: The connections are to the SPDT ALARM relay. ALARM output is
time delayed for 2, 4, 8, or 10 seconds. This time delay can be set by RS-485 or
DIP-switch (see Section 3.5).
The ALARM output can be normally energized or normally de- energized,
latching or non- latching, and these options are also set via RS-485 or by
DIP-switch. (See Section 3.5 Switch Selectable Options)
Alarm Relay:
TB2, Term 2 = ALM C = Alarm Common
Normally de-energized
TB2, Term 3 = ALM 1 = Normally Closed
TB2, Term 4 = ALM 2 = Normally Open

Model FL3102
Quick Start Guide
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Normally energized
TB2, Term 3 = ALM 1 = Normally Open
TB2, Term 4 = ALM 2 = Normally Closed
The ALARM relay contact ratings are 8A @ 250VAC and 8A @ 30VDC.
CAUTION – For all relay connections see Figure 9.
Figure 8 Terminal Connections
1.4.2 Warning Relay
TB2, Term 5 = WARN C
TB2, Term 6 = WARN 1
TB2, Term 7 = WARN 2
Description: These connections are to the SPDT WARN relay. The WARN output
is immediate on the Model FL3102. The WARN output can be normally
energized or normally de-energized, latching or non-latching. These options are
also set via RS-485 or by a DIP-switch. (See Section 3.5, Switch Selectable
Options)
Warning Relay:
TB2, Term 5 = WARN C = Warning Common

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Quick Start Guide
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Normally de-energized
TB2, Term 6 = WARN 1 = Normally Closed
TB2, Term 7 = WARN 2 = Normally Open
Normally energized
TB2, Term 6 = WARN 1 = Normally Open
TB2, Term 7 = WARN 2 = Normally Closed
The WARN relay contact ratings are 8A @ 250VAC and 8A @ 30VDC.
CAUTION – For all relay connections see Figure 9.
Figure 9 Relay Contacts
1.4.3 Fault Relay
TB2, Term 8 = FLT C
TB2, Term 9 = FLT 1
TB2, Term 10 = FLT 2
Description: These connections are to the SPDT FAULT relay. The FAULT
output configuration is normally energized and non-latching. This is the standard
output configuration and it cannot be changed.
The FAULT circuit will be activated during the time-out function, a low power or
loss of power condition, and during a failed COPM check. During these
conditions, the FAULT relays will de-energize and the analog output signal will
drop to 0 mA (2mA for COPM Faults) for the duration of the FAULT.
Fault Relay:
TB2, Term 8 = FLT C = Fault Common
Normally energized
TB2, Term 9 = FLT 1 = Normally Open
TB2, Term 10 = FLT 2 = Normally Closed
The FAULT relay contact ratings are 8A @ 250VAC and 8A @ 30VDC.
CAUTION – For all relay connections see Figure 9.

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Quick Start Guide
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1.4.4 Alarm Reset Terminal
TB1, Term 3 = RESET
The RESET, when activated, returns a latched ALARM and/or WARN output,
that is no longer valid, to its original state. For this RESET function, place one
contact of a SPST normally open momentary switch to TB1 Terminal 3 and the
other contact to DC COM (the detector’s common). To activate, just press and
release the switch.
1.4.5 Alarm Test Terminal
TB1, Term 4 = ALARM TEST
By connecting one contact of a SPST normally open momentary switch to TB1
terminal 4 and the other contact to DC COM (the detector’s common) the user
can test the alarm outputs of the Flame Detector by activating this switch for one
to eight seconds depending on the alarm time delay setting. The Alarm Test will
activate the WARN and ALARM relay outputs as well as the appropriate analog
output. The Flame Detector will remain in this state until the switch is released.
The latching WARN and/or ALARM will have to be RESET manually. The Auto-
test feature cannot be daisy chained between two or more FL3102 Flame
Detectors.
1.4.6 Analog Output
TB1, Term 5 = 0 - 20mA (Analog Output)
The 0 to 20mA output is a current signal that corresponds to following:
FAULT signal: .0 to 0.2mA
COPM Fault signal: 2.0 + 0.2mA
Ready signal: 4.0 + 0.2mA
WARN signal: 16.0 + 0.2mA
ALARM signal: 20.0 + 0.2mA
The maximum analog output load is 600 ohms.
Cable Requirements:
For interfacing with 250 ohm input impedance devices, the following maximum
cable lengths apply (maximum 50 ohm loop):
AWG FEET METERS
14 9000 2750
16 5800 1770
18 3800 1160
20 2400 730
22 1700 520
Figure 10 Maximum Cable Lengths
for 250 Ohm Input

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Quick Start Guide
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1.4.7 Power
TB1, Term 7, 8 = +24VDC
TB1, Term 9, 10 = COM
These are the power connections. The supply voltage range is 20 to 36VDC at
the detector (low voltage is detected at 18.5 VDC). The following maximum cable
lengths apply for a +24VDC supply (maximum 20 ohm loop):
AWG FEET METERS
14 4500 1370
16 2340 715
18 1540 470
20 970 300
22 670 205
Figure 11 Maximum Cable Lengths
for +24VDC
1.4.8 RS-485 OUTPUT
TB1, Term 1 = DATA+
TB1, Term 2 = DATA
These are the connections for the RS-485 output. The RS-485 connection is
used to either query the unit’s status or to configure the unit. See Section
7 for detailed information on Modbus RTU protocol.
NOTE – If redundant RS-485 output is ordered, then the 0-20mA output is not
available and the wiring terminals are:
TB1, Term 5 = DATA2+
TB1, Term 6 = DATA2-
1.4.9 Chassis Ground
TB2, Term 1 = CHAS GND
This connection is available for use in wiring that requires a connection to
chassis ground. In general, all cable lengths specified are maximum values.
Good design practices dictate cable lengths conservatively shorter than the
maximum values given.

Model FL3102
Quick Start Guide
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PIN 1
21 4365
OPEN
87
PIN 1
321
ON
86 7
54
1.5 Switch Selectable Options
All settings on the Model FL3102 are done via a DIP-switch on the Power/Relay
board or via RS-485 (overrides switch settings). To set these options, remove the
detector head from the Base Assembly and locate the DIP-switch (see Figure
12). On the DIP-switch, ON/CLOSED means the switch is pushed in on the side
labeled ON or CLOSED (opposite the OPEN side). OFF/OPEN means the switch
is pushed in on the side with the number corresponding to the switch position or
the side labeled OPEN. (Refer to the tables in Figure 13 for the switch
assignments.) The settings for the WARN and ALARM outputs have been
covered in section 3.4. The time delay specifies the amount of time a WARN
condition persists before an ALARM condition will occur.
Figure 12 Dip Switch Location
OPTION OFF /
OPEN ON / CLOSED
100% Sens – 1 sqft @ 50 ft 1&2
75% Sens – 1 sqft @ 35 ft 2 1
50% Sens – 1 sqft @ 25 ft 1 2
2 Second ALARM Time Delay 3 4
4 Second ALARM Time Delay 3&4
8 Second ALARM Time Delay 4 3
10 Second ALARM Time Delay 3&4
ALARM non-latching 5
ALARM latching 5
WARN non-latching 6
WARN latching 6
ALARM normally energized 7
ALARM normally de-energized 7
WARN normally energized 8
WARN normally de-energized 8
Figure 13 Dip Switch Options

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Quick Start Guide
xiii
NOTE - The instrument is now ready to operate! Please consult the manual for
more information on the instrument’s many features.
NOTE - If you have any problems in the setup or testing of the detector, please
refer to the “Troubleshooting Section”, or call the factory direct.
Worldwide Service is available by calling:
Lake Forest, California Phone: [phone]
(24 hr. service) Fax: [phone]
Houston, Texas Phone: [phone]
Fax: [phone]
Ireland Phone: [phone]
Fax: [phone]
Singapore Phone: [phone]
Fax: [phone]
United Arab Emirates Phone: [phone]
Fax: [phone]
United Kingdom Phone: [phone]
Fax: [phone]

Model FL3102
1
Table of Contents
WARRANTY ......................................................................................... I
WARNINGS ......................................................................................... I
SYSTEM INTEGRITY VERIFICATION................................................................. II
1.0 QUICK START GUIDE.............................................................................. I
1.1 Upon Receipt of Equipment ..........................................................i
1.2 Choosing Detector Locations........................................................i
1.2.1 Detector Field of View......................................................i
1.2.2 Optical Sensitivity Range .................................................i
1.2.3 Environmental Factors .....................................................i
1.3 Detector Installation......................................................................ii
1.4 Terminal Connections .................................................................vi
1.4.1 Alarm Relay...................................................................vii
1.4.2 Warning Relay..............................................................viii
1.4.3 Fault Relay .....................................................................ix
1.4.4 Alarm Reset Terminal......................................................x
1.4.5 Alarm Test Terminal........................................................x
1.4.6 Analog Output..................................................................x
1.4.7 Power .............................................................................xi
1.4.8 RS-485 OUTPUT............................................................xi
1.4.9 Chassis Ground..............................................................xi
1.5 Switch Selectable Options..........................................................xii
TABLE OF CONTENTS........................................................................................ 1
TABLE OF FIGURES ........................................................................................ 5
2.0 INTRODUCTION...................................................................................... 7
2.1 General Description..................................................................... 7
2.2 Principle of Operation.................................................................. 8
2.2.1 IR Flame Detector .......................................................... 8
2.2.2 COPM Circuitry............................................................... 9
2.2.3 Alarm Test...................................................................... 9
2.2.4 Visual Indicators............................................................. 9

Model FL3102
2
3.0 INSTALLATION..................................................................................... 10
3.1 Upon Receipt of Equipment ...................................................... 10
3.2 Choosing Detector Locations.................................................... 10
3.2.1 Detector Field of View.................................................. 10
3.2.2 Optical Sensitivity Range ............................................. 10
3.2.3 Environmental Factors ................................................. 10
3.3 Detector Installation................................................................... 11
3.4 Terminal Connections ............................................................... 15
3.4.1 Alarm Relay.................................................................. 16
3.4.2 Warning Relay.............................................................. 17
3.4.3 Fault Relay ................................................................... 18
3.4.5 Alarm Test Terminal..................................................... 19
3.4.6 Analog Output............................................................... 19
3.4.7 Power ........................................................................... 20
3.4.8 RS-485 OUTPUT.......................................................... 20
3.4.9 Chassis Ground............................................................ 20
3.5 Switch Selectable Options......................................................... 21
4.0 MAINTENANCE..................................................................................... 22
4.1 General Maintenance................................................................ 22
4.2 Cleaning the Lenses.................................................................. 22
4.3 Sensitivity Check....................................................................... 23
4.4 Storage...................................................................................... 23
5.0 TROUBLESHOOTING........................................................................... 24
5.1 Trouble Shooting Chart............................................................. 24
5.2 Final Assemblies ....................................................................... 25
6.0 CUSTOMER SUPPORT......................................................................... 26
7.0 MODBUS COMMUNICATIONS............................................................. 27
7.1 Baud Rate.................................................................................. 27
7.2 Data Format............................................................................... 27
7.3 MODBUS Read Status Protocol (Query/Response)................. 28
7.3.1 MODBUS Read Query Message.................................. 28
7.3.2 MODBUS Read Response Message........................... 28
7.4 MODBUS Write Command Protocol (Query/Response)........... 29
7.4.1 MODBUS Write Query Message.................................. 29
7.4.2 MODBUS Write Response Message ........................... 29
7.4.3 Function Codes Supported........................................... 29
7.5 Exception Responses and Exception Codes............................ 30
7.5.1 Exception Responses................................................... 31
7.5.1.1 Function Code Field......................................... 31
7.5.1.2 Exception Code Field....................................... 31
7.6 Command Register Locations................................................... 32
7.6.1 Operational Mode Commands ..................................... 32
7.7 FL3102 Operational Mode Command Register Details............ 35
7.7.1 Analog .......................................................................... 35
7.7.2 Mode............................................................................. 35
7.7.3 Status/Error .................................................................. 35
7.7.4 Fire Type ...................................................................... 36
7.7.5 Model Type................................................................... 36

Model FL3102
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7.7.6 Software Revision ........................................................ 36
7.7.7 COPM Fault.................................................................. 36
7.7.8 EEPROM Override....................................................... 36
7.7.9 Options......................................................................... 37
7.7.10 Comm 1 Address.......................................................... 38
7.7.11 Comm 1 Baud Rate...................................................... 38
7.7.12 Comm 1 Data Format................................................... 39
7.7.13 Fire Window COPM Fault Total (Photodiode).............. 39
7.7.14 Fire Sensor COPM Fault Total..................................... 40
7.7.15 Sun COPM Fault Total ................................................. 40
7.7.16 Remote Reset............................................................... 40
7.7.17 Remote Alarm Test ...................................................... 40
7.7.18 Clear COPM Faults ...................................................... 40
7.7.19 Comm 1 or 2 Total Receive Errors............................... 41
7.7.20 Comm 1 or 2 Bus Activity Rate %................................ 41
7.7.21 Comm 1 & 2 Function Code Errors.............................. 41
7.7.22 Comm 1 & 2 Starting Address Errors........................... 41
7.7.23 Comm 1 Only Total Receive Errors ............................. 41
7.7.24 Comm 1 & 2 RXD CRC Lo Errors................................ 41
7.7.25 Comm 1 & 2 RXD CRC Hi Errors................................. 41
7.7.26 Comm 1 Only Overrun Errors....................................... 41
7.7.27 Comm 1 Only Noise Flag Errors .................................. 42
7.7.28 Comm 1 & 2 Framing Errors ........................................ 42
7.7.29 Comm 1 or 2 Message Interval.................................... 42
7.7.30 Comm 2 Only Total Receive Errors ............................. 42
7.7.31 Comm 1 Only SCI Errors.............................................. 42
7.7.32 Clear Comm 1 & 2 Errors............................................. 42
7.7.33 Comm 2 Address.......................................................... 43
7.7.34 Comm 2 Baud Rate...................................................... 43
7.7.35 Comm 2 Data Format................................................... 44
8.0 APPENDIX ...................................................................................... 45
8.1 Specifications ............................................................................ 45
8.1.1 System Specifications .................................................. 45
8.1.1.1 Detector Location............................................. 45
8.1.1.2 IR Detector center wavelength (Figure 15)...... 45
8.1.1.3 Typical Response Time* .................................. 45
8.1.1.4 Minimum Response Time................................. 45
8.1.1.5 Field of Vision* (Figure 16)............................... 45
8.1.1.6 Sensitivity ......................................................... 45
8.1.1.7 Maximum Cable Parameters............................ 45
8.1.1.8 Warranty........................................................... 46
8.1.2 Mechanical Specifications............................................ 46
8.1.3 Electrical Specifications................................................ 46
8.1.3.1 Supply voltage range (see NOTE)................... 46
8.1.3.2 Relay Contact Ratings...................................... 46
8.1.3.3 RS-485 Output ................................................. 46
8.1.3.4 Baud Rate ........................................................ 46
8.1.3.5 RFI/EMI Protection........................................... 46
8.1.3.6 Status Indicator ................................................ 46
8.1.4 Environmental Specifications....................................... 47
8.1.4.1 Operating temperature range........................... 47
8.1.4.2 Storage temperature range.............................. 47