General Monitors FL3112 User manual

Model FL3112
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 09/09
General Monitors reserves the right to change
published specifications and designs without prior
notice.
Part No. MANFL3112-EU
Revision H/09-09

Model FL3112
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Warranty Statement
General Monitors warrants the Model FL3112 to be free from defects in workmanship
or material under normal use and service within two years from the date of shipment.
General Monitors will repair or replace without charge any 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 prepaid to General Monitors’ plant
or representative from which 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 without General Monitors’ approval or which have been subjected
to neglect, accident, improper installation or application, or on which the original
identification marks have been removed 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 use or
performance of the product.
Warnings
WARNING - Installation and Maintenance must be carried out by suitably skilled and
competent personnel only.

Model FL3112
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E C Declaration of Conformity in accordance with EC & ATEX Directives
We at General Monitors Ireland Ltd., Ballybrit Business Park, Galway, Republic of Ireland, hereby declare
that the equipment described below, both in its basic design and construction, and in the version or
versions marketed by us, conforms to the relevant safety and health related requirements of the
appropriate EC Directives, only as follows:
a) Conforms with the protection requirements of Council Directive 89/336/EEC, + Amd 92/31 EEC +
Amd 92/68 EEC relating to Electromagnetic Compatibility, by the application of:
A Technical Construction File No. GM 99010 and Competent Body Report No. 4473/1P7, Issue 1
And
b) Conforms with the protection requirements of IEC 1010-1: 1990 + Amd 1:1992 +Amd 2: 1995
relating to safety by the application of:
A Technical Construction File No. GM 99010 and Competent Body Certificate No. 85EA1460A/5726
issued by:
ERA Technology Ltd. Cleeve Road, Leatherhead Surrey KT22 7SA, England. Tel: +44 1372
367000
This declaration shall cease to be valid if modifications are made to the equipment without our approval.
PRODUCT: FL3112 (DFIR) Flame Detector
It is ensured through internal measures and our ISO9001: 1994 certifications, that series production units
conform at all times to the requirements of these current EC Directives and relevant standards.
General Monitors Ireland Ltd. in order to comply with ATEX, will provide this Instruction Manual in a
European Language required to operate the product upon request. Should this be necessary, General
Monitors Ireland Ltd. should be notified of this request to allow adequate time to process the request.
ATEX Certificate Markings.
DEMKO 00 ATEX 127595
0518 II 2 G
EExed IIC T5 EExed IIC T6
-40ºC to +75ºC -40º C to +65ºC
Responsible Person: Date: 01-02-03
Denis Connolly
General Manager European Operations
The signatory acts on behalf of company management, and with full power of attorney

Model FL3112
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Table of Contents
Page
Model FL3112 .................................................................................................... i
Warranty Statement .................................................................................................... i
Warnings .................................................................................................... i
E C Declaration of Conformity in accordance with EC & ATEX Directives............. ii
Table of Contents .................................................................................................. iii
1.0 Introduction ................................................................................................... 1
1.1 General Description ................................................................................... 1
1.2 Principle of Operation................................................................................. 2
2.0 Specifications ................................................................................................... 4
2.1 System Specifications................................................................................ 4
2.2 Mechanical Specifications.......................................................................... 5
2.3 Electrical Specifications............................................................................. 5
2.4 Environmental Specifications..................................................................... 6
2.5 Modbus RTU Protocol................................................................................ 6
3.0 Installation ................................................................................................... 7
3.1 Upon Receipt of Your Equipment............................................................... 7
3.2 Choosing Detector Locations.....................................................................7
3.3 Detector Installation ................................................................................... 8
3.4 Interconnecting cable Guidelines ............................................................... 8
3.5 Installation Instructions.............................................................................. 9
3.6 Terminal Connections .............................................................................. 12
3.7 User Selectable Options........................................................................... 15
3.8 Factory Default Settings........................................................................... 17
4.0 Maintenance ................................................................................................. 19
4.1 General Maintenance............................................................................... 19
4.2 Cleaning the Lens .................................................................................... 19
4.3 Sensitivity Check...................................................................................... 20
4.4 Storage .................................................................................................... 20
5.0 Trouble Shooting.............................................................................................. 21
5.1 Trouble Shooting Chart............................................................................ 21

Model FL3112
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6.0 Spares & Accessories...................................................................................... 22
6.1 Spare Parts.............................................................................................. 22
6.2 Test Lamps .............................................................................................. 22
7.0 Modbus Serial Communications..................................................................... 23
7.1 Baud Rate................................................................................................ 23
7.2 Data Format............................................................................................. 23
7.3 Modbus Read Status Protocol (Query/Response).................................... 23
7.4 Modbus Write Command Protocol (Query/Response).............................. 24
7.5 Exception Responses and Exception Codes............................................ 25
7.6 FL3112 Command Register Locations..................................................... 27
7.7 FL3112 Operational Mode Command Register Details............................ 29
Customer Satisfaction Questionnaire ...................................................................... 36

Model FL3112
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1.0 Introduction
1.1 General Description
Fire is a phenomenon of combustion. Combustion is the continuous chemical reaction of a
reducing agent (fuel) and an oxidizing agent (oxygen, etc.) with the evolution of thermal
energy (heat). Fire is usually manifested in heat (IR), smoke, light (visible), and flame (UV).
Flame is the gaseous region of a fire where vigorous combustion chain reactions take
place. These reactions emit radiation covering the Infrared, Ultraviolet and the Visible
Spectral Regions.
The General Monitors Model FL3112 is a Digital Frequency Infrared (DFIR) Flame
Detector. The Model FL3112 detects the Infrared spectral regions of flame to produce a
system which is highly immune to false alarms caused by lightning, arc-welding, hot
objects, and other sources of radiation. In addition, the FL3112 can see through most
smoky type fires such as diesel, rubber, etc.
The Model FL3112 features include:
•Compact unitized design.
•Continuous optical path monitoring.
•Wide field of view.
•High false alarm immunity.
•0-20mA, Relays, Field Loop and Modbus RTU RS-485 serial communications output
versions.

Model FL3112
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1.2 Principle of Operation
IR Flame Detector
The Model FL3112 is a discriminating Digital Frequency Infra-Red Detector which makes
use of infrared detectors of different IR wavelengths and characteristics. This combination
provides a flame detection system which is highly immune to false alarms.
Incorporated in the IR circuitry is a flicker discrimination circuit. This permits the detector to
ignore steady state IR sources such as hot objects. The inherent flickering of a flame
provides the necessary modulation to activate the IR circuit.
The Model FL3112 Flame Detector processes these IR signals with a microcomputer and,
depending on the version, produces the following outputs:
•0 to 20 milliampere signal.
•Immediate WARN relay contacts.
•Time delayed ALARM relay contacts.
•FAULT relay contacts.
•RS-485 MODBUS RTU serial communications ports.
(See Sections 2 & 3 for more information on detector outputs)

Model FL3112
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COPM Circuitry
A self-testing feature called Continuous Optical Path Monitoring (COPM) checks the optical
path, the detector(s), and the related electronic circuitry once every minute. If foreign
material impairs the optical path of the infrared detector for two consecutive checks, the
unit will indicate FAULT. The optical FAULT outputs are, depending on the version, a 2.0
mA signal or de-energizing of the FAULT relay. The FAULT status is available via the RS-
485 serial communications port. (see Section 3-4 Terminal Connections). After a COPM
FAULT, a COPM check is performed every ten seconds until the obstruction is removed.
Then the COPM check will resume checking once per minute.
WARNING – A dirty or partially blocked lens can significantly reduce the detector’s field of
view and detection distance.
NOTE: Since the optical path is checked once per minute and it requires two check failures
to produce a FAULT, it may take up to two minutes for the unit to detect an obstruction.
Alarm Test
The Model FL3112 Flame Detector has a built-in Alarm Test feature. This test may be
activated via the serial communications port (see Section 3-4 Terminal Connections).
The Flame Detector will immediately go into WARN and then into the time delayed
ALARM. After two to ten seconds the Flame Detector will activate the ALARM. A latching
WARN and/or ALARM will remain latched until reset.
Visual Indicators
Two light emitting diodes (LEDs) are visible through the window. LEDs are provided for a
visual indication that corresponds with the detectors’ outputs. The following blinking
sequence indicates the operating condition:
•Timeout (2 minutes when the unit is first powered) – Green and red LEDs blinking
alternately.
•Ready – Green LED that flashes off 1 second, every 5 seconds.
•WARNing – Slow blinking red LED.
•ALARM – Fast blinking red LED.
•COPM FAULT – Slow blinking green LED.
•Low Voltage FAULT – Fast blinking green LED.

Model FL3112
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2.0 Specifications
2.1 System Specifications
Certification:
EExed – IIC T5 -40ºC TO +75ºC
EExed – IIC T6 -40ºC TO +65ºC
IP66/67
IR Detector center wavelength: (figure 1-B)
4.35 microns
Typical Response Time*:
< 3 sec. @ 50 ft.
Minimum Response Time:
< 500 ms.
Field of Vision*: (figure 3-A)
120°maximum
Sensitivity:
50 feet (15.2m); Maximum distance for a 1 square foot (.092m2) gasoline fire to be
reliably detected.
Maximum Cable Parameters:
4-20mA Output Signal
9000 feet (2750 m), maximum 50 Ohms loop, with maximum 250 Ohms input
impedance of readout unit.
Remote power supply
3000 feet (930 m), maximum 20 Ohms loop and 24 VDC minimum. (See Section 3-4
Terminal Connections)
Approvals:
ATEX & CE Mark
Warranty:
Two Years
* NOTE:
1. Response Times and Field of View data have been derived by testing the Model
FL3112 Flame Detector with a 1 square foot gasoline fire. One cup of unleaded
gasoline on top of a one inch layer of water was ignited for each test. These are
typical values and different results may occur depending on the variation of each
fire.
2. To meet the directional dependence requirements of EN 54-10 the horizontal
viewing angle must not exceed ±30°.

Model FL3112
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2.2 Mechanical Specifications
Enclosure material
Material: Bronze AB2 or Stainless Steel
Colour: Natural
Dimensions:
Diameter 3.3 in (8.4 cm)
Length 5.4 in (13.7 cm)
Weight 5 lbs (2.3 kg)
Cable Entries: 2 x M20 or 2 x PG13.5
2.3 Electrical Specifications
Supply voltage range: 20 to 36 VDC
Nominal supply voltage: 24VDC
Maximum supply current: 150mA
Maximum output signal
Load @ 24 VDC: 600 Ohms
Output signal range: 0 to 20mA
FAULT signal: 0 to 0.2mA
COPM fault signal: 2.0mA ±0.2 mA
Ready signal: 4.0 ±0.2 mA
WARN signal: 16.0 ±0.2 mA
ALARM signal: 20.0 ±0.2 mA
Relay Contact Ratings:
1A MAX @ 30VRMS/42.2 VPK,
Resistive.
RS-485 Serial Communications Port:
Modbus RTU Protocol
128 units MAX. (247 units with repeaters)
Baud Rate: 2400, 4800, 9600 or 19200
RFI/EMI Protection
Complies with EN50081-2, EN50082-2
Status Indicator:
Two LED’s indicate status, fault conditions.

Model FL3112
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2.4 Environmental Specifications
Operating temperature range: -40°C to 75°C
-40°F to 176°F
Storage temperature range: -40°C to 75°C
-40°F to 176°F
Humidity range: 0 to 100% RH
non-condensing
2.5 Modbus RTU Protocol
For detailed information on data format, read commands, write commands, register
details, register locations, refer to the Serial Communications section in this manual.

Model FL3112
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3.0 Installation
WARNING - Installation and Maintenance must be carried out by suitably skilled and
competent personnel only.
3.1 Upon Receipt of Your Equipment
All items shipped by General Monitors are packed in shock absorbing containers which
affords 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.
3.2 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:
Detector Field of View
Each Model FL3112 Flame Detector has a 120°maximum Cone of Vision. (This Cone has
its vertex at the center of the detector, see figure 3-A).
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. Environmental Factors
2. Mounting should be as free from shock and vibration as possible and convenient
for visual inspection and cleaning.
3. Detectors mounted in dirty atmospheric conditions will require more frequent
inspection, cleaning, and sensitivity checking.
4. Observe the ambient temperature range for the specific model (see section 2-4
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.
5. Avoid conditions of ice build up on the optical detector windows. Complete icing
over of the IR detector window can result in fault conditions.

Model FL3112
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3.3 Detector Installation
The Model FL3112 Detector should be mounted pointing downward so that dust/moisture
will not accumulate on the IR window. The detector(s) should be mounted in locations
which will inhibit people or objects from obscuring the detector’s Cone of Vision.
Cable glands and stopping plugs should be installed with the o-rings supplied with the
FL3112. It is recommended to fit boots over cable glands to prevent water ingress at the
cable-to-gland junction.
Mounting hardware should be used as shown in figure 3-B. The overall dimensions of the
detector and mounting hardware is also shown.
3.4 Interconnecting cable Guidelines
•The FL3112 requires an interconnecting cable with an overall screen (shield) and
armour. Cables to BS5308 Part 2, Type 2 or equivalent are suitable.
•Interconnecting cables should be segregated from power and other “noisy” cables.
Avoid proximity to cables associated with radio transmitters, welders, switched mode
power supplies, inverters, battery chargers, ignition systems, generators, switch
gear, arc lights and other high frequency or high power switching process
equipment. In general, maintain a separation of at least 1m between instrument and
other cables. Greater separation is required where long parallel cable runs are
unavoidable. Avoid running instrument cable trenches close to lightning conductors
earthing pits.
•Complete all cable insulation tests before connecting the cable at either end.
•General Monitors do not recommend the use of cable shoes or crimps on any
junction box or housing wiring terminals. Poor crimping can cause bad connection
when unit experiences temperature variations. We therefore recommend good
practice is to just terminate cable.

Model FL3112
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3.5 Installation Instructions
3.5.1 FL3112 Cable Termination
•The FL3112 should be installed in accordance with the certification documents and
the relevant regulations of the country concerned.
•Ensure that approved Exe cable glands are used and installed according to the
manufacturer’s instructions.
•The cable armour must be terminated in the gland to ensure a positive electrical
connection.
•The cable screens (drain wires) must not be connected electrically to the electronic
circuitry of the FL3112.
•Connect Safety Earth to the chassis grounding screw available on the rear exterior
of the base assembly. This Safety Earth wire should have a wire gauge of at least
22 AWG (0.33mm2) and be no longer than 3 meters in length.
3.5.2 Cable Termination in Safe Area
•The cable armour must be connected to Safety Earth.
•The cable screens (drain wire) and power supply return (OV) must be connected to
Instrument Earth.
•The power supply or power distribution system employed should meet the
requirements of EN50081- 1/2 and EN60101-1.

Model FL3112
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Fi
g
ure 3-
A
FL3112 Field of View

Model FL3112
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Fi
g
ure 3-B Outline Drawin
g

Model FL3112
12
Figure 3-C Base Assembly with Terminal Block
3.6 Terminal Connections
The Terminal Block is located on the Base Assembly (See figure 3-C) and accepts 12
AWG (3.31 mm2) to 22 AWG (0.33 mm2) stranded or solid core wire. Each wire should be
stripped as shown in figure 3-D.
Figure 3-D Strip Length
Four of the six positions on the terminal block have functions which depend on the FL3112
version selected. The remaining two positions are reserved for the power connections.
Figure 3-C outlines the terminal block connections by version.
On this and the following pages is a description and specification for each of the signals
shown in figure 3-C.

Model FL3112
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POWER INPUTS
+B and 0V
These are the power connections. The supply voltage range is 20 to 36 VDC 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 mm2FEET METRES
14 AWG 2.08 4500 1370
16 AWG 1.31 2340 715
18 AWG 0.82 1540 470
20 AWG 0.52 970 300
22 AWG 0.33 670 205
ANALOGUE OUTPUT
4 – 20mA
The 4 to 20mA output is a current signal that corresponds to the following specification:
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
Output Load Max.: 600 ohms
For interfacing with 250 ohm input impedance devices, the following maximum cable
lengths apply (maximum 50 ohm loop):
AWG mm2FEET METRES
14 AWG 2.08 9000 2750
16 AWG 1.31 5800 1770
18 AWG 0.82 3800 1160
20 AWG 0.52 2400 730
22 AWG 0.33 1700 520
COMMUNICATIONS OUTPUTS
DATA 1A
DATA 1B
DATA 2A
DATA 2B
These are the connections for the RS-485 serial communications ports 1 & 2. 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.
RELAY OUTPUT (Figure 3-E)
A1 ALM
Description: This connection is the WARN relay contact. The WARN output is immediate
on the Model FL3112. The WARN output can be normally energized or normally de-
energized, latching or non-latching.
WARN relay contact rating is 1A @ 30VRMS/42.2VPK Resistive.

Model FL3112
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A2 ALM
Description: This connection is the ALARM relay contact. The ALARM output is time
delayed for 10, 2, 4 or 8 seconds. The ALARM output can be normally energized or
normally de-energized, latching or non-latching.
ALARM relay contact rating is 1A @ 30VRMS/42.2VPK Resistive.
FAULT
Description: This connection is the FAULT relay contact. 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 relay will de-energize and the analogue output signal will drop to 0
mA (2mA for COPM Faults) for the duration of the FAULT.
FAULT relay contact rating is 1A @ 30VRMS/42.2VPK Resistive.
COMM
Description: This is the common connection of the WARN, ALARM and FAULT relay
contacts.
Figure 3-E Relay Outputs
FIELD LOOP OUTPUTS (Figure 3 – F)
LP+ and LP-
Description: These are the field loop connections to a fire card such as General Monitors’
IN042.
The FAULT relay, when energized, inserts a 5600ohms, 2Watt End-Of-Line resistor
across these connections.
The ALARM relay, when energized, inserts a 560ohms, 2Watt resistor across the End-
Of-Line resistor. The WARN relay has no effect.
For a description of relay functionality refer to the section RELAY OUTPUTS above.
Figure 3-F Field Loop Outputs

Model FL3112
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RESET
All versions of the FL3112 may be reset by interrupting the power supply for a minimum of
two seconds. Versions with serial communications can also be reset by using the Remote
Reset command. Refer to section 7 for details.
SAFETY EARTH
This connects the FL3112 enclosure to Safety Earth. An alternative connection is available
on the rear exterior of the base assembly. The Safety Earth wire should have a wire gauge
of at least 22 AWG (0.33mm2) and be no longer than 3 meters in length.
WARNING: Under no condition should the retaining strap screws be used for
Safety Earth purposes
3.7 User Selectable Options
All user selectable option settings on the Model FL3112 are held in EEPROM. It is
recommended the option settings be specified when ordering the FL3112.
Versions with serial communications capabilities can be (re)programmed via the
communications port(s). Refer to section 7 for details. Other versions can be
(re)programmed with the Program Card accessory if necessary.
PROGRAM CARD ACCESSORY
The Program Card is a small module with a DIP switch which can be read by the FL3112
microprocessor.
DIP switch positions 5 to 8 select the options being programmed, such as Sensitivity and
Alarm-time-delay, Relay or Return to Factory Default settings. DIP switch positions 1 to 4
determine the actual parameter settings. Refer to the following tables for details:
SENSITIVITY and ALARM-TIME-DELAY Options
Sensitivity (%)
A
larm-time-delay (sec)
DIP 100 75 50 10 2 4 8
1 OFF OFF ON ON
2 OFF ON OFF ON
3 OFF OFF ON
4 OFF ON OFF
5 OFF OFF OFF OFF OFF OFF OFF
6 OFF OFF OFF OFF OFF OFF OFF
7 ON ON ON ON ON ON ON
8 ON ON ON ON ON ON ON