Honeywell Searchline Excel Cross-Duct Release Note

Searchline Excel Cross-Duct
Infrared Gas Detector
Technical Handbook

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MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook
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certied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 Europe, 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
EN 60079-14:2008 & IEC 60079-14:2007. Refer to EN 60079-29-2:2007 & IEC 60079-29-
2:2007 in Europe 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ameproofenclosuresarefullytightened.Thesecuring
boltsusedaremadefromaspecialcertiedgradeofsteel.OnlyboltssuppliedbyHoneywell
Analyticsshouldbetted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ttedtoSearchlineExcelshouldnotbemodied.If,however,it
becomesnecessarytomakemodicationstheymustcomplywiththerelevantnationalCodes
of Practice.
15. The optical energy emitted by the Searchline Excel is less than 20mW/mm2.
16. Searchline Excel Cross-Duct should only be used to detect gas mixtures where methane is the
main constituent (>70%) and the balance is C2- C6hydrocarbons.
Safety

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MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook
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onlybeperformedbyqualiedpersonnel.
Important Notices
1. HoneywellAnalytics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HoneywellAnalytics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.HoneywellAnalyticsarenotawareofanysignicanteffectsofexplosiveatmospheres
uponthesematerials.ContactHoneywellAnalyticsoroneoftheiragentsforspecicqueries.
Special Conditions of Use
InordertocomplywiththeATEX/IECExCertication,thefollowingspecialconditionsofusemustbeadheredto:-
1. The integral supply cables must be mechanically protected and terminated in a suitable terminal or junction
facility.
2. Thecoverxingscrewsshallbestainlesssteelgrade12.9minimum,gradeA2-80orgradeA4-80(only
useHoneywellsuppliedscrews)
Everyefforthasbeenmadetoensuretheaccuracyofthisdocument,however,HoneywellAnalyticscanassume
no responsibility for any errors or omissions in this document or their consequences.
HoneywellAnalyticswouldgreatlyappreciatebeinginformedofanyerrorsoromissionsthatmaybefoundin
the content of this document.
For information not covered in this document, or if there is a requirement to send comments/corrections about
thisdocument,pleasecontactHoneywellAnalyticsusingthecontactdetailsgivenonthebackpage.
HoneywellAnalytics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 information
isrequiredthatdoesnotappearinthisdocument,contactthelocaldistributor/agentorHoneywellAnalytics.
Safety

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Section Page
1. Introduction 7
2. Overview 9
2.2 Transmitter and Receiver Unit 10
2.2.1 Transmitter 10
2.2.2 Receiver 10
2.2.3 Mounting Block 11
 2.3 HeatedReectorPanel 11
3. Installation and Operation 12
3.1 Introduction 12
3.2 Siting and Mounting 12
3.2.1 General 12
3.2.2 Location for Best Coverage 12
3.2.3 Location to Maximise Reliability and Availability 12
3.2.4 Beam Path 13
3.2.5 Orientation 13
3.2.6 Access for Cleaning 14
3.3 Electrical Connections 14
3.3.1 General 14
3.3.2 Transmitter and Receiver Connections via DVC100 (M) MK2 15
3.3.3 Transmitter and Receiver Connections via DX100 (M) 15
3.3.4 Transmitter and Receiver Connections 16
3.3.5 Remote Installations 17
3.4 Power Supply 17
3.4.1 General 17
3.4.1.1 Transmitter and Receiver Unit 17
   3.4.1.2HeatedReectorPanel 17
3.4.2 Power Supply Connections - Turbo heating Disabled 19
3.5 Installation Procedure 20
3.5.1 General 20
3.5.2 Mechanical Installation 20
3.5.2.1 Transmitter and Receiver Unit 20
3.5.2.2HeatedReectorPanel 21
Contents

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Section Page
3.5.3 Electrical Installation 22
3.6 Commissioning 22
3.6.1 General 22
3.6.2 Connecting the Interrogator 22
3.6.3 Power Up 24
3.6.4 Setting the Real-Time Clock 25
3.6.5 Initialising the Searchline Excel Cross-Duct Gas Detector 26
3.6.6 Functional check 28
3.6.7 Finish 28
3.7 System Controller Calibration 29
3.8 Installation Checks/ Tests 30
4. Maintenance 35
4.1 Inspection and Cleaning 35
 4.2 Re-zero  36
4.3 Functional Checking 36
4.3.1 Functional Checking with Gassing Cell (Short Range versions only) 36
4.3.2 Functional Checking with Test Filters 37
5. Problem Solving 38
6. Specications  42
6.1 System 42
7. Certication  43
7.1 General 43
7.2 Conduit Technical Characteristics (ATEX, IECEx version) 44
 7.3 CerticationLabelsATEX,IECEx 44
7.3.1 Transmitter 44
7.3.2 Receiver 45
  7.3.3HeatedReectorPanel 46
7.3.4 System Diagram 47
 7.4CerticationlabelsUL 48
7.4.1 Transmitter 48
Contents

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Section Page
7.4.2 Receiver 49
  7.4.3HeatedReectorPanel 50
7.4.4 System Diagram With DX100M Termination Unit 51
8. Warranty Summary 52
AppendixA-HandheldInterrogator 53
A.1 Introduction 53
A.2 Overview 53
A.3 Connection to System 54
A.4 Basic User Tasks 55
A.5 Menus 56
A.5.1 Main Menu 57
A.5.2 Display Menu 57
A.5.3 Calibrate Menu 58
A.5.4 Diagnose Menu 63
  A.5.5CongMenu 65
A.5.6 Chg Mode 67
A.5.7 Power Off 67
A.6 PROBLEM SOLVING 67
Appendix B - Glossary 68
B.1 Terminology 68
B.2 Open Path Detector Measurement Units 69
B.3 Abbreviations 69
Appendix C - Accessories & Spare Parts 70
C.1 System Units 70
C.2 General 70
Contents

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MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook
The Searchline Excel Cross-Duct Gas Detector is an open path infrared gas detector for methane.
It will detect hydrocarbon gas mixtures where methane is the main constituent (>70% of the composition with
the balance being C2- C6hydrocarbons).ForothergasmixturespleasecontactHoneywellAnalyticsforadvice.
Searchline Excel Cross-Duct is specically designed for use where the path length is between 0.5 and 5
metres for applications such as air intake ducts. It consists of a Transmitter and Receiver unit, and a separate
HeatedReectorPanel.
The detector operates on the principle of infrared (IR) absorption. If a cloud of methane 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 detector output signal is proportional to 0-100%LEL (Lower Explosive Limit) of gas.
Searchline Excel Cross-Duct is suitable for use in Zone 1 or 2 hazardous areas (International) and for
Class 1 Division 1 or 2 area applications (North America).
Note: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.
Thishandbookconsistsofthefollowingparts:
• Chapter 1 Introduction
• Chapter 2 Overview
A brief description of the system components
• Chapter 3 Installation and Operation
Important information regarding detector positioning, electrical
connections, power supply requirements, mechanical installation and
commissioning, including an installation check list
• Chapter 4 Maintenance
Regular maintenance requirements and instructions for functional
checks
• Chapter 5 Problem Solving
 • Chapter6 Specications
 • Chapter7 Certication
• Appendix A Handheld Interrogator
• Appendix B Glossary
• Appendix C Accessories & Spare Parts
1. Introduction

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Information notices
Thetypesofinformationnoticesusedthroughoutthishandbookareasfollows:
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
HoneywellAnalytics.
Associated Documents
DX100SeriesTerminationUnitsTechnicalHandbook PartNo:2104M0701
DVC100(M)MK2TerminationUnitQuickStartGuide PartNo:2104M0409
WARNING
Indicates hazardous or unsafe practice that could result in severe injury
or death to personnel.
1. Introduction

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2.1 Introduction
SearchlineExcelCross-DuctgasdetectorconsistsofaTransmitterandReceiverunit,andaHeatedReector
Panel.TheTransmitterandReceiverunitgeneratesanddetectstheinfraredbeam.TheHeatedReectorPanel
ismountedattheoppositesideoftheducttoreectthebeamfromtheTransmitterbacktotheReceiver.
Note: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.
TherearetworangesofSearchlineExcelCross-Ductgasdetector.Theseare:
Version Path Length (m) Path Length (ft) Certication
Short Range: 0.5 — 2.5m (20in — 8ft) ATEX, IECEx, UL
Long Range: 2.5 — 5m (8ft — 15ft) ATEX, IECEx
ThelongrangegasdetectorusesalargerReectorPanelthantheshortrangeversion.
2. Overview
Heated Reflector Panel
Mounting Plate
Mounting Block
Transmitter
Conduit
Receiver
Junction Box
(type DVC100 (M) MK2)

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2.2 Transmitter and Receiver Unit
2.2.1 Transmitter
TheTransmitterproducesanintense,collimatedinfraredbeamfromaXenonarcashlamp.TheTransmitter
window is heated to minimise condensation and frosting. During particularly cold operating conditions, the
heating of the Transmitter window is increased to turbo levels. The turbo mode can be disabled if not required.
ElectricalconnectionstotheTransmitteraremadeviawireswhichrunthroughtheprotective,exibleconduit.
There are three Transmitter wires, red (+24V), black (0V) and green/yellow (GND).
Note: The infrared beam is invisible and eye safe.
2.2.2 Receiver
The Receiver collects infrared radiation from the Transmitter and performs measurements to enable methane
gas in the beam path to be detected.
The Receiver output signal is 4 - 20mA available as a source or sink option. The output is calibrated for a
range of 0 to 100% LEL methane.
Note: The detector uses the duct width in the calculation of gas reading – it is essential that this is
specied correctly during installation (See Appendix B.2 for the explanation of how open path gas
detectors measure gas concentration)
Output signal levels below 4mA are used to indicate Fault (0mA), Inhibit (2mA), Beam Blocked (2.5mA) and
Low Signal (3mA).
TheReceivercommunicateswiththeSHC1HandheldInterrogatorusinganRS485output.TheSHC1isused
to perform commissioning, functional testing and diagnostic procedures.
The Receiver window is heated to minimise condensation and frosting.
ElectricalconnectionstotheReceiveraremadeviawireswhichrunthroughtheprotectiveexibleconduit.
There are six Receiver wires, red (+24V), black (0V), white (4 - 20mA), orange (RS485 A), blue (RS485 B) and
green/yellow (GND).
2. Overview
Air Shield
Slot for test filter
Gas In/Out
Gassing Cell
Transmitter
Mounting Block
Beamsplitter
Receiver

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2.2.3 Mounting Block
The Transmitter and Receiver are factory aligned and xed to a mounting block. They should not be
disassembled. The mounting block has a top cover which can be removed to clean the Transmitter and
Receiverwindows.Insidethemountingblockthereisanangledwindow(thebeamsplitter)whichreectsthe
beam into the Receiver.
Themountingblockhastwofeaturesforfunctionalchecking-agascellandaslotforplastictestlters.
2.3HeatedReectorPanel
TheHeatedReectorPanelconsistsofaretro-reectorsealedinadouble-glazedunit,withanintegralheater
to minimise condensation and frosting.
TheReectorPanelshouldbemountedoppositetheTransmitterandReceiverunit,andperpendiculartothe
beam.
TheReectorrequiresanominal24Vpowersupply.
2. Overview

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3.1 Introduction
Before designing or specifying an installation for Searchline Excel Cross-Duct, it is strongly recommended that
the installation design authority reads all of this chapter and considers how the information and recommendations
provided can be applied to their installation(s).
Ifyouhaveanyqueriesconcerningyourinstallationdesign,contactHoneywellAnalyticsoryourlocalagents.
HoneywellAnalyticsiscommittedtoensuringthatcustomersachievereliableoperationoftheirSearchline
Excel Cross-Duct Gas Detectors. For this reason, Searchline Excel Cross-Duct should only be installed by fully
trainedpersonnel(trainedbyHoneywellAnalyticsoraHoneywellAnalyticsauthorisedtrainer).
This training will provide the installer with a clear understanding of the Searchline Excel Cross-Duct product
and the associated accessories and tools. It will also provide familiarity with the installation, alignment and
commissioning procedures, plus installation assessment skills to identify potential problem areas.
Foreachinstallation,aninstallationchecksheetshouldbecompletedandreturnedtoHoneywellAnalyticsor
their agents. Details of this check sheet are given at the end of this chapter.
Note: THE INFRARED BEAM IS INVISIBLE AND EYE SAFE.
3.2 Siting and Mounting
3.2.1 General
When designing an installation for a Searchline Excel Cross-Duct gas detector it is important to give
consideration to where it is to be located, what potential sources of problems may be encountered in this
location and how the unit is to be mounted and supported.
Caution: TheTransmitter,ReceiverandReectorPanelunitshaveheatedwindowstominimise
condensationandfrosting.However,partialobscurationoftheReectorandinparticular
liquidwatercondensationontheReectorcancausenegativedrift,whichhasthe
effect of raising the alarm threshold. Wherever possible protect the Searchline Excel
Cross-Duct from dirt and condensation by mounting well inside the duct and ideally
downstreamoflters/dampers.
3.2.2 Location for Best Coverage
The placement of gas detectors should be determined following the advice of experts having specialist
knowledge of gas dispersion, experts having knowledge of the process plant system and equipment involved,
safety and engineering personnel. The agreement reached on the location of detectors should be recorded.
3. Installation and Operation
WARNING
The national Code of Practice regaurding selection, installation and
maintenance of electrical apparatus for use in potentially explosive
atmospheres must be complied with at all times.

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3.2.3 Location to Maximise Reliability and Availability
Foroptimumperformance,takecaretoavoidareaswheretheunitsmaybeadverselyaffectedbythefollowing:
Vibration - Angular vibration of the structure to which Excel units are attached should be kept to less than
±0.5°. Where possible, avoid locations where high levels of vibration will be directly induced into the mounting
structure.Ifcloseproximitytosignicantsourcesofvibrationisunavoidable,takestepstoreducecoupling
of this vibration and maximise the rigidity of the mounting structure.
Mounting Rigidity – The duct wall thickness should be suitable to maintain rigidity of the Searchline Excel
Cross-Duct mounting to within ±0.5°.
Intense Heat-Exceliscertiedandspeciedforoperationinenvironmentsupto+65°C.Ifsourcesofintense
heat(arestacks,intensesunlight,etc.)arepresent,asunshade(PartNo:2104B2323)orsimilarshieldshould
bettedtotheunittoprotectitfromexcessiveheating.
Sources of Heavy Contamination - Avoid locations where high levels of contaminants will persistently be
blown onto the unit windows. Potential sources of heavy contamination include generator/turbine exhausts,
arestacks, drilling equipment, process vents/chimneys etc. If sources of heavy contamination cannot be
avoided,considerttingextrashieldingand/orprovidinggoodaccessformoreroutinecleaning.
Snow and Ice in Ambients Below -20°C - The heated optics on Excel units will melt snow or ice on the
windows in ambient temperatures down to approximately -20°C. Below this temperature, snow or ice blown
onto the window will not be melted until the ambient temperature rises. If long-term, outdoor operation in
very cold climates is intended, it is recommended that extra shielding/covers are employed to prevent snow/
ice from being blown onto the windows and building up.
Accidental Impact-Locationswherethereisasignicantlikelihoodofequipment,personnelormovingobjects
accidentally knocking Excel units out of alignment should where possible be avoided. If such locations cannot
be avoided, measures including improved mechanical protection and warning notices should be considered.
Since the Transmitter and Receiver protrude from the duct wall, adequate precautions should be taken to
protect personnel.
Intense Electromagnetic Fields - Searchline Excel Cross-Duct complies with EN50270 and as such is well
protectedfrominterferencebyelectromagneticelds.However,locationsincloseproximitytoradio/radar
transmitters,heavyelectricalplantandhighvoltagepowercablesmayexperienceeldstrengthsinexcessof
thosespeciedinthestandard.Wherepossible,suchlocationsshouldbeavoidedorunitsshouldbeinstalled
asfaraspossiblefromthesourceoftheelectromagneticeld.Measuresincludingadditionalscreening,ltering
andtransientsuppressionmayalsobeofbenetinsuchlocations.
To ensure optimum performance, do not cover the Excel with insulation, and allow free air movement around
the unit.
3.2.4 Beam Path
The path of the infrared beam inside the duct is unlikely to be affected by obstructions, however, consideration
shouldbegiventoavoid:
• Steam vents
• Splash and spray
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3.2.5 Orientation
TheSearchlineExcelCross-Ductunitsshouldbemountedonvertical,atsurfacessuchthattheopticalaxis
ishorizontal.Ensurethesurfaceisrigidandstable.Fitadditionalsupportspriortoinstallationifnecessary
(see note on Vibration, above).
TheHeatedReectorPanelshouldbemounteddirectlyopposite,andperpendiculartotheopticalaxisofthe
Transmitter and Receiver unit. If the duct walls are not exactly vertical or parallel, the position of the cut out
for the retro panel must be adjusted to compensate.
It is not advisable to install the Cross-Duct Excel on the top or bottom of the duct. In this orientation the
ReectorPanelortheTransmitterandReceiverunitwillbevulnerabletothebuildupofcontamination.
3.2.6 Access for Cleaning
SearchlineExcelCross-DuctTransmitterandReceiverunitandHeatedReectorPanelwillneedtobecleaned
regularly.InthecaseoftheReectorPanelitmayneedtoberemovedfromtheducttocleanthewindow.It
isadvisabletoprovideanaccesspointintheduct,adjacenttothereectorpanel,toallowittobecleaned.
3.3 Electrical Connections
3.3.1 General
Searchline Excel Cross-Duct complies with the EN50270. In order to maintain compliance with these standards
it is essential that the electrical installation of Excel is engineered correctly.
Electrical installation standards vary for different countries, companies and applications and it is the responsibility
of the installation design authority to determine the applicable standards and ensure compliance with them.
WhendesigningelectricalinstallationsforExcel,HoneywellAnalyticsrecommendthattheinstallationdesign
authorityconsidersthefollowing:
a. The unit cases should not, if possible, be connected to electrically noisy (dirty) metalwork or conductors.
Preferably, the case (internally connected to the green/yellow GND wire) should be connected to a low
noise instrument (clean) earth. See also para e. below. In order to facilitate electrical isolation of the
SearchlineExcelfromanoisyearthanisolationkitissupplied.Thiskitshouldbettedasstandardunless
local regulations forbid this.
b. Theentirelengthoftheeldcablingconnectedtoeachunitshouldbefullyshielded.Thisshouldbeconnected
to a low noise (clean) earth.
c. The low noise instrument (clean) earth system should only be connected to safety earth (usually dirty)
at a single point on the entire site/installation. This connection should be made in such a manner that it
does not introduce noise onto the low noise instrument earth. Star earthing arrangements minimise earth
current crosstalk.
d. Theshieldsoftheeldcablingshouldnotbeconnectedsuchthatearthloopsareproduced,orinamanner
that will result in the shields carrying large currents from heavy plant or equipment.
e. Ideally,theeldcableshieldshouldbeconnectedtotheunitsgreen/yellowGNDwire,providingasingle,
continuous earth shield. This connection must not be allowed to complete an earth loop.
f. The earth bonding arrangement must ensure that the maximum peak voltage between the unit case earth
andanyeldcableconductorislessthan350V.Voltagesinexcessofthiscancausepermanentdamage
totheunitsRFIprotectionlters.
g. The use of a single, screened cable for each gas detector ensures maximum screening and minimum
crosstalk. Cabling arrangements which use a single cable for connecting a number of eld devices
compromise screening, increase the potential for crosstalk and prevent implementation of true star earthing.
3. Installation and Operation

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h. Any electrical interference induced onto the 4 - 20mA loop conductors by the installation must be kept
below the levels necessary to comply with the general requirements of EN 60079-29-2 and IEC 60079-
29-2. In practice, this means that peak noise currents induced on the current loop should be no greater
than ± 0.25mA
j. The 0V rail of the control card/control system is directly connected to one side of the 4 - 20mA current
sensing resistor. Electrical noise on this rail is therefore directly connected to the 4 - 20mA input. In order
to avoid additional noise being induced on the 0V rail, it should not be commoned with the safety earth/
ground, which frequently carries a high level of electrical noise.
k. All electrical equipment connected to the gas detector should comply with EN50270.
l. The24Vsupplyshouldbefreefromlargetransientsanductuations.
m. Theeldcablingconductorsshouldhavesufcientcrosssectionalareatoensurethattheminimumsupply
voltage applied to the gas detector is 18V.
n. Searchline Excel Cross-Duct Receivers should not be installed in close proximity to the antennae of high
powered radio, radar and satellite communication equipment.
3.3.2 Transmitter and Receiver Connections via DVC100 (M) MK2
3.3.3 Transmitter and Receiver Connections via DX100 (M)
3. Installation and Operation
Field Wiring
+24VDC IN (Terminal 1)
0V (Terminal 3)
4-20mA (Terminal 5)
Earth Terminal
MOD BUS DRAIN (Terminal 9)
MOD BUS A (Terminal 10)
MOD BUS B (Terminal 11)
Earth Terminal
+24V (Terminal 2)
0V (Terminal 4)
Cross-Duct
Transmitter Wiring
Cross-Duct
Receiver Wiring
R5485 (B) (Blue) (Terminal 8)
R5485 (A) (Orange) (Terminal 7)
4-20mA (White) (Terminal 6)
Earth (Green / Yellow) (Earth Terminal)
+ 24VDC (Red) (Terminal 2)
0V (Black) (Terminal 4)

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3.3.4 Transmitter and Receiver Connections
3. Installation and Operation
1 6
1
6
Cross-Duct Reciever
Connections
Control Cabinet
Connections
Cross-Duct
Transmitter
Connections
Modbus A
Blue (B)
Orange (A)
Red (+24VDC)
White (4-20mA)
Black (0V)
Green/Yellow (Earth)
Modbus B
+24VDC - in
4-20mA - out
0VDC - in
Red (+24VDC) Black (0V)
Green/Yellow
(Earth)
Safety/
protec-
tive
ground
Screen Modbus Drain
DX100 (M) Junction Box
Cable Shield
Instrument
(clean) Earth
The earth bonding arrangement must
ensure that the maximum peak voltage
between the unit case earth and any
eld cable conductor is less than 350V.
Voltages in excess of this can cause
permanent damage to the unit’s RFI
protection lters.
A
B
Ex d or Ex e Junction Box
SHC Protection Device
Flying
Lead
(Tempo-
rary Con-
nection)
SHC1
Transmitter
Connections
Controller
Connections
Receiver
Connections
Black 0V
4-20mA
GND
0V
+24V
BRN 4-20mA
BLU
Red +24V
Green/ GND
2-wire
crimp ferrules
Earth Terminal
GRN/YEL GND
WHITE 4-20mA
ORANGE A
BLUE B
RED +24V
BLACK 0V
Earth
Cable Shield

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3.3.5 Remote Installations
Forremoteordifcult-to-accessinstallations,theDVC100(M)/DX100(M)canbepositionedinaconvenient
location by using an intervening junction box (e.g. PL6I2/AKRON/Killark) attached to the Transmitter and
Receiver unit’s mounting plate.
A maximum cable length of 1km between the unit and the DVC100 (M)/ DX100 (M) is permissible (RS485
compliant).
3.4 Power Supply
3.4.1 General
The Searchline Excel Cross-Duct gas detector is designed to be operated from a nominal 24V DC supply. The
supply voltage at the terminals must be within the range 18 to 32V for the Transmitter and Receiver unit, and
withintherange18to28VfortheHeatedReectorPanel.
3.4.1.1 Transmitter and Receiver Unit
TheTransmitterandReceiverunitmaximumpowerconsumptionandcablelengthsareasfollows:
Unit Type Maximum Power
Consumption (W)
Maximum Cable Length
(m) with 1.5mm2
Conductors (12 ohms/km)
Maximum Cable Length
(m) with 2.5mm2
Conductors (7.6 ohms/km)
Transmitter and Receiver 13 340 540
Notes:
1. Control room supply voltage assumed to be +24V.
2. Standard conguration of the Transmitter is with turbo heating enabled.
Terminal sizes: DVC 100 (M) 0.5mm2- 4mm2 (20AWG - 12AWG)
DX100 (M) 0.5mm2- 4mm2 (20AWG - 12AWG)
HA Junction Box 00780-A-0100 0.5mm2- 6mm2 (20AWG - 10AWG)
3.4.1.2HeatedReectorPanel
TheHeated ReectorPanelrequires18-28Vdcsupply voltage.Becauseit isa resistiveheater,the power
consumptiondependsonthesupplyvoltage.Powerconsumptioncanbecalculatedasfollows:-
Power = V2where V is the supply voltage and R is the resistance of the heater
Toensuresufcientheatingoverawiderangeofsupplyvoltage,twoconnectionoptionsareavailable,which
use different heater resistances depending on the supply voltage available (>20V or 18-20V).
3. Installation and Operation
R

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ShortRangeHeatedReectorPanel(Partnumbers2104B0715,2104B0717)
Terminal Identication Wire Colour Customer Connection
(>20V)
Customer Connection
(<20V)
Heater Resistance
(R)
1 White 0V 0V
2 Black or Brown >20Vdc 100Ω
3Blue 18-20Vdc 68Ω
6 Green Earth Earth
LongRangeHeatedReectorPanel(Partnumber2104B0716)
Terminal Identication Wire Colour Customer
Connection (>20V)
Customer
Connection (<20V) Heater Resistance (R)
1 White 0V 0V
2 Black or Brown >20Vdc 33Ω
3Blue 18-20Vdc 23Ω
6 Green Earth Earth
Important:IftheTransmitterandReceiverunitsharesapowersupplycablewiththeHeatedReector
Panel, a check must be made to verify that a minimum voltage of 18V is available at the
TransmitterandReceiverwhentheReectorPanelisoperating.
3. Installation and Operation
Terminal 6
Terminal 3
Terminal 2
Terminal 1
Conduit
External Earth (GND) Insulating Adaptor Field Wiring
Earth (GND) Terminal

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MAN0889_Issue 3_03/13 Searchline Excel Cross-Duct Technical Handbook
3.4.2 Power Supply Connections - Turbo heating Disabled
When connected as shown in section 3.3 Transmitter and Receiver Connections the Transmitter has turbo
heating mode enabled.
This means that during conditions of low ambient temperature, additional heating power is applied to the unit’s
window to minimise condensation, frosting and snow buildup.
If the application/installation does not require turbo heating, power consumption can be reduced by disabling
this mode.
The turbo heating is disabled by reversing the power supply connections to the Transmitter as shown in the
following diagram. All other connections remain the same.
Notes:
1. Only Transmitters have turbo mode heating which can be disabled. The Receiver uses proportional
heating, which cannot be disabled.
2. Even with turbo mode heating disabled the Transmitter window still receives standard levels of
heating.
3. Do not reverse the Receiver power supply connections. This will not damage the unit, but the unit
will not work.
3. Installation and Operation
Junction BoxTransmitter Connections
Reverse these connections to
disable turbo-heating Cable Shield
Control Cabinet Connections
Black 0V +24V DC Supply Tx +24V
Tx 0V
Instrument
(Clean) Earth
0V DC Supply
Red +24V
Green/
GND
Yellow

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3.5 Installation Procedure
3.5.1 General
Installing the Searchline Excel Cross-Duct is done in two stages. First the duct is prepared, and the Excel
componentsmechanicallyxedinplace.Secondly,theelectricalwiringisconnected.TheTransmitterand
Receiver assembly must be fully assembled and mounted to the duct structure before making the electrical
connections.
3.5.2 Mechanical Installation
Verify that the equipment to be installed is correct for the type of installation required (i.e. short or long range.)
3.5.2.1 Transmitter and Receiver Unit
Identifytheholesinthemountingplateusingthefollowingdrawingandtable:
3. Installation and Operation
155mm
100mm
Identity Quantity Size Used for
A 4 M6 tapped Mounting block mounting
B 8 6.5mm Mounting plate to support
bar mounting
C 2 14mm Clearance for support bar
xing nuts
D 1 10mm Drain for mounting block
E 1 25mm Cross-Duct optical
measurement path
F 1 M6 tapped
DVC100 (M) junction
box mounting
(used in conjunction with
bottom two F1 holes)
F1 4 M6 tapped DVC100 (M) MK2 junction
box mounting
G 4 M6 tapped BARTEC junction box
mounting
H 2 M10
tapped
DX100 (M) junction box
mounting
NOTE: If unused, the top two
F1, top two G and the F holes
should be blanked off to avoid
leakage from the duct. Use
the 5 off M6 x 8 screws, single
coil washers and plain washers
supplied.