Honeywell Searchline Excel Open-Path Release Note

Searchline Excel Infrared Gas Detectors
Open Path and Cross-duct
Technical Handbook

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Ensure that you read and understand these instructions BEFORE operating the equipment. Please pay
particular attention to the Safety Warnings.
WARNINGS
1. The Searchline Excel gas detector is certified for and intended for use in potentially hazardous
areas. Install and use the Searchline Excel gas detector in accordance with the latest regulations.
2. For installations in the UK, the Code of Practice SELECTION, INSTALLATION AND
MAINTENANCE OF ELECTRICAL APPARATUS FOR USE IN POTENTIALLY EXPLOSIVE
ATMOSPHERES should be strictly observed. General recommendations are given in BS 5345:
Part 1:1989. Specific requirements for flameproof (Type ’d’), intrinsically safe (Type ’I’) and increased
safety (type ’e’) protection are given in BS 5345: Part 3: 1979, BS 5345: Part 4:1977 and BS
5345: Part 6:1978 respectively. Consideration should also be given to BS EN 60079-14. Refer to
BS 6959:1988 in the UK or the appropriate local or national regulations.
3. For installations in North America, the national Electrical Code (NFPA 70 - 1990) or later issues
should be strictly observed.
4. Elsewhere, the appropriate local or national regulations should be used.
5. The Searchline Excel gas detector must be properly earthed to protect against electrical shock
and minimise electrical interference. For electrical installation design considerations refer to
Section˚3.
6. Operators must be fully aware of the action to be taken if the gas concentration exceeds an alarm
level.
7. Dismantling or repair of equipment should be carried out in the safe area only.
8. Test gases may be toxic and/or combustible. Refer to Material Safety Sheets for appropriate
warnings.
9. Do not drill holes in any housing as this will invalidate the explosion protection.
10. In order to maintain electrical safety, the unit must not be operated in atmospheres with more
than 21% oxygen.
11. Ensure that the bolts which secure flameproof enclosures are fully tightened. The securing bolts
used are made from a special certified grade of steel. Only bolts supplied by Zellweger Analytics
should be fitted for this purpose.
12. Do not open the enclosure in the presence of an explosive atmosphere.
13. The transmitter unit contains high voltages when operational. These are discharged when the
unit is removed from its enclosure.
14. The conduit and cable glands fitted to Searchline Excel should not be modified. If, however, it
becomes necessary to make modifications they must comply with the relevant national Codes of
Practice.
SAFETY

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CAUTIONS
1. Use only approved parts and accessories with the Searchline Excel gas detector.
2. To maintain safety standards, commissioning and regular maintenance of the Searchline Excel
gas detector should be performed by qualified personnel.
IMPORTANT NOTICES
1. Zellweger Analytics Limited can take no responsibility for installation and/or use of its equipment
if this is not done in accordance with the appropriate issue and/or amendment of the manual.
2. The user of this manual should ensure that it is appropriate in all details to the exact equipment to
be installed and/or operated. If in doubt, the user should contact Zellweger Analytics Limited for
advice.
3. Effect of explosive atmosphere on materials.
Searchline Excel is made from materials which exhibit good resistance to corrosive and solvative
substances. The Exd enclosures are made from 316 stainless steel and the explosion protected
windows are made from toughened soda lime glass. Zellweger Analytics are not aware of any
significant effects of explosive atmospheres upon these materials. Contact Zellweger Analytics
or one of their agents for specific queries.
ZellwegerAnalytics Limited reserve the right to change or revise the information supplied in this document
without notice and without obligation to notify any person or organisation of such revision or change.
If further details are required that do not appear in this manual, contact Zellweger Analytics Limited or one
of their agents.
SAFETY

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Every effort has been made to ensure the accuracy in the contents of our documents, however, Zellweger
Analytics Limited can assume no responsibility for any errors or omissions in our documents or their
consequences. Zellweger Analytics Limited would greatly appreciate being informed of any errors or
omissions that may be found in our documents. To this end we include the following form for you to
photocopy, complete and return to us so that we may take the appropriate action.
HELP US TO HELP YOU
Marked up copies attached (as appropriate): Yes / No
Please inform me of the outcome of this change: Yes / No
For Marketing Communications, Zellweger Analytics Limited:
Actioned By: Date:
Response: Date:
To: Marketing Communications
Zellweger Analytics Limited
Hatch Pond House
4 Stinsford Road
Nuffield Estate
POOLE. Dorset
BH17 0RZ
United Kingdom
Tel.: [phone]
Fax.: [phone]
E-mail : [email protected]
From:
Address:
Tel.:
Fax.:
E-mail:
I suggest the following corrections/changes be made to: ..................

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CONTENTS
SAFETY 2
HELP US TO HELP YOU 4
1. INTRODUCTION 7
2. OVERVIEW 9
2.1 Introduction 9
2.2 Transmitter 10
2.3 Receiver 11
2.4 Adjustable Mountings 13
3. INSTALLATION AND OPERATION 14
3.1 Introduction 14
3.2 Siting and Mounting 15
3.3 Electrical connections 19
3.4 Power supply 24
3.5 Unpacking 25
3.6 Installation procedure 28
3.7 Alignment and commissioning 34
3.8 System Controller calibration 49
3.9 Installation Checks/Tests 50
4. CROSS-DUCT EXCEL 57
4.1 Introduction 57
4.2 Gas Detector Description 57
4.3 Installation and Operation 58
4.4 Installation Procedure 61
4.5 Electrical Installation 65
4.6 Initialising the Excel Gas Detector 68
4.7 Maintenance 70
4.8 Problem Solving 72
5. MAINTENANCE 73
5.1 Inspection and Cleaning 73
5.2 Functional Checking 73
5.3 Calibration Check using the Gassing Cell 74
5.4 Display Gas Reading 75
5.5 Alignment Telescope 76
5.6 Operational Maintenance (FM) 76

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CONTENTS
6. PROBLEM SOLVING 77
7. SPECIFICATIONS 82
7.1 System 82
7.2 Detectable gases 83
8. CERTIFICATION 84
8.1 General 84
8.2 CENELEC 85
8.3 UL 91
8.4 CSA/FM 96
APPENDIX A - HANDHELD INTERROGATOR 100
A.1 Introduction 100
A.2 Overview 100
A.3 Connection to System 101
A.4 Basic User Tasks 102
A.5 Menus 103
A.6 Problem Solving 116
APPENDIX B - GLOSSARY 117
B.1 Terminology 117
B.2 Measurement Units 117
B.3 Abbreviations 118
APPENDIX C - ACCESSORIES & SPARE PARTS 120
C.1 System Units 120
C.2 General 120

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Searchline Excel is a hydrocarbon gas detection system that is available in two versions:
•Searchline Excel Open-Path Gas Detector
•Searchline Excel Cross-Duct Gas Detector
Searchline Excel Open-Path Gas Detector (OPGD) consists of a Transmitter unit that sends an
infrared beam to a Receiver unit up to 200 metres away, and can be located where a flammable
hydrocarbon gas cloud is likely to occur.
The Cross-Duct version of Searchline Excel is used where the path length is less than 5 metres,
for applications such as air intake ducts. Most of the installation and operating instructions for
the Open-Path Excel apply to the Cross-Duct Excel, but see Chapter 4 for specific information
about the Cross-Duct version.
Both types of gas detector operate on the principle of infrared (IR) absorption. Gases absorb
light at specific wavelengths depending on their molecular composition. Hydrocarbon gases
absorb in the infrared region of the spectrum. If a cloud of hydrocarbon gas is present, part of
the infrared light is absorbed by the gas, causing a reduction in the signal received that is
proportional to the amount of gas in the beam.
The Searchline Excel Transmitter unit produces the infrared light, and the Receiver unit features
optical detectors and signal processing electronics. Each unit is housed in a robust stainless
steel housing. The Receiver produces a 4 - 20mA analogue output equivalent to 0 - 5 LEL.m
(Lower Explosive Limit metres) of gas.
NOTE: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.
Searchline Excel is designed for use in the most demanding environments/applications and
provides a sensitive, fast and reliable response. The sophisticated open-path technology provides
immunity to sunlight and minimises the effects of environmental factors such as rain, fog, ice,
snow and condensation.
The Transmitter and Receiver units incorporate heated optics designed to minimise the build
up of humidity, condensation, snow or ice on the glass windows, that could obscure the optics
in extreme conditions.
The system is microprocessor controlled with integral self-diagnostics and fault finding facilities.
Local communication between an operator/technician and the gas detector system is made via
an associated Handheld Interrogator that uses the Receiver s inbuilt RS485 serial link. The
interrogator provides the user with a menu-style interface to select and invoke commands for
commissioning and configuring the system, and for viewing the system state and measurements.
The interrogator is connected to the Receiver via one of Zellweger Analytics’ DVC100/DX100/
DX100 (M) types of Termination Unit, or via other types of junction box using the optional SHC
Protection Device. The DVC100 and DX100 are passive junction boxes whereas the DX100
(M) features an active digital interface that allows a remotely located control centre to monitor
the gas detector’s signal output and perform basic commands using the Modbus Remote Terminal
Unit (RTU) protocol over an RS485 link.
1. INTRODUCTION

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This handbook consists of the following parts:
•Chapter 1 Introduction
•Chapter 2 System Description
•Chapter 3 Installation And Operation
•Chapter 4 Cross-Duct Excel
•Chapter 5 Maintenance
•Chapter 6 Problem Solving
•Chapter 7 Specifications
•Chapter 8 Certification
•Appendix A Handheld Interrogator
•Appendix B Glossary
•Appendix C Accessories & Spare Parts
Information notices
The types of information notices used throughout this handbook are as follows:
WARNING
Indicates hazardous or unsafe practice that could result in severe injury
or death to personnel.
Caution: Indicates hazardous or unsafe practice which could result in minor injury to
personnel, or product or property damage.
Note: Provides useful/helpful/additional information.
If more information beyond the scope of this technical handbook is required please contact
Zellweger Analytics.
Associated Documents
Searchline Excel Open-Path Infrared Gas Detector
Basic Installation Guide Part No: 2104M0510
Searchline Excel Cross-Duct Infrared Gas Detector
Basic Installation Guide Part No: 2104M0511
DX100 Series Termination Units Technical Handbook Part No: 2104M0701
1. INTRODUCTION

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2.1 INTRODUCTION
Each type of Searchline Excel gas detector consists of two units, a Transmitter and a Receiver.
This separate Transmitter/Receiver configuration provides the most reliable basis for open
path gas detection.
There are no transceiver units or retro-panels available for the Searchline Excel, except for the
Cross-Duct version, which is only for use between 0.5 and 5 metres path length. For a description
of Cross-Duct Excel, see Chapter 4.
PL612
(or other junction box)
Flexible conduit
DVC100/DX100/DX100 (M)
(or other junction box)
Mounting bracket
Pivot block
Monitored
path
5-200m
Mounting plate
Transmitter
Receiver
2. OVERVIEW

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There are five ranges of Searchline Excel gas detector. These are:
Open-Path Short Range 5 — 40m (15ft — 130ft)
Medium Range 20 — 120m (65ft — 390ft)
Long Range 120 — 200m (390ft — 650ft)
Cross-Duct Short Range: 0.5 — 2.5m (20in — 8ft)
Long Range: 2.5 — 5m (8ft — 15ft)
See Chapter 4 for details of the Cross-Duct Excel.
When designing an installation for Searchline Excel it is important that the correct range of the
gas detector for each path to be monitored is selected and specified.
Note: In order to avoid the problems associated with gas detectors being used beyond their
specified ranges or when incorrectly aligned, an Instrument Assisted Alignment (IAA)
procedure for Searchline Excel checks for correct gas detector type, operating range
and signal levels before allowing the gas detector to activate.
The Transmitter and Receiver are each mounted upon robust, adjustable mounting brackets.
These brackets bolt to a mounting plate, which is designed to accommodate a variety of junction
boxes, accessories and mechanical mounting configurations. The small size and flexibility of
Searchline Excel and its mounting arrangements are intended to make correct installation design
as simple as possible. Installation details are given in Chapter 3.
2.2 TRANSMITTER
The Searchline Excel Transmitter produces an intense, collimated infrared beam which is produced by a
Xenon arc flashlamp.
The flashlamp s infrared output is collimated using mirrors which enables a more uniform beam
(no chromatic aberrations) to be produced and hence reduces alignment sensitivity. In order to
prevent annoying visible flashes, the visible emissions from the flashlamp are blocked by a
filter.
The Transmitter s flashlamp is pulsed at precisely 4Hz, each pulse lasting for approximately
one microsecond. The precise timing and extremely short duration of these pulses give the
Transmitter a very distinctive signature. This distinctive signature makes it easy for the Receiver
to distinguish Searchline Excel Transmitter pulses from both natural and artificial sources of
infrared radiation.
NOTE: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.
The medium and long range Transmitters contain a higher power flashlamp and larger optics
than the standard short range unit. The resulting infrared beam is many times brighter which
allows for a considerable increase in operating range.
2. OVERVIEW