Micropack FDS303 User manual

FDS303
MULTI SPECTRUM IR
FLAME DETECTOR
SAFETY & TECHNICAL MANUAL
Ref: 3303.0001
micropackfireandgas.com

2
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
HELP US TO HELP YOU
Every effort has been made to ensure the accuracy in the contents of our documents; however,
Micropack (Engineering) Ltd can assume no responsibility for any errors or omissions in our
documents or their consequences. This document has been processed through Micropack’s QA
procedures pertaining to ISO9001:2015 certification.
Micropack (Engineering) Ltd would greatly appreciate being informed of any errors or
omissions that may be found in our documents. To this end we include a form, given in
Appendix B, for you
to photocopy, complete and return to us so that we take the appropriate
action. Thank you.
CONTENTS
1
Introduction
4
1.1 Features 4
2
Safety Instructions
5
2.1
Specific conditions of use
5
2.2
Cautions
6
2.3
Important Safety Notices
6
2.4
EN 54-part 10 Limitation of use
7
3
Installation
8
3.1
Detector Enclosure
8
3.2
Mounting & Orientation
9
3.3
Wiring Procedure
11
3.3.1
0-20mA Output
12
3.3.2
Relay Output
13
3.3.3
Internal Inter-connections
14
3.4
Installation Checklist
15
3.4.1
Mechanical
15
3.4.2
Electrical
16
4
System Design Guidelines
17
4.1
Power Supply
17
4.2
Cable Selection
17
4.2.1 DC Power 17

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
5
Application Guidelines
19
5.1
Positioning Requirements
19
5.2
Detection Coverage
20
5.3
Exposure to Flare Radiation
20
5.4
Optical Contamination
20
5.5
Enclosed Areas
20
5.6
Detector Sensitivity
20
5.7
Detector Alarm Delay
20
6
Maintenance and Commissioning
22
6.1
Procedure
22
6.2
Functional Testing
24
7
Fault Finding
25
7.1
Removal of the Electronics
25
7.2
Replacement of the Electronics
25
7.3
Diagnostics
25
7.4
LED Indication
26
7.5
Power Fault
27
8Technical Specification 28
8.1
Electrical Specification
28
8.2
Mechanical Specification
28
8.3
Environmental Specification
29
8.4
Certification and Approvals
29
8.5
Operating Specification
29
Appendix A
Acronyms, Terms & Abbreviations
30
Appendix B
Help us to help you 31
Appendix C
Field of View 32
Appendix D
FM Approval Performance Report
33
Appendix E
Offshore Certification 35
Appendix F
IEC 61508 Failure Rate Data 36

4
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
1
Introduction
This Safety and Technical Manual applies to FDS303 Hardware Version 1.0 and above.
The MICROPACK FDS303 is a flame detector that has unsurpassed false alarm
immunity for a Multi Spectrum IR flame detector.
The Micropack flame detection range are the safest and most advanced flame
detectors on the market today. Our worldwide installed base has proven that the
Micropack technology is robust, even in the harshest of environments.
FDS303 flame detectors identify flame using certified flame recognition software.
FM Approvals ensures that our flame recognition software is fit for purpose through
rigorous research and testing to a range of fires fuelled by different fuel types and
various potential false alarm stimuli.
The FDS303 has been designed for use in standalone operation.
1.1 Features
•The FDS303 has a 90ocone of vision with a range of 60 metres to a 0.1m2pan
fire of heptane.
•Three detection sensitivity settings allowing the user to select the sensitivity that
is most suitable for their application.
•Superior false alarm immunity to common sources of unwanted alarms such as
Hot Process and Hot Work.
•Advanced optical verification test assuring readiness to perform when needed.
•Outputs include both relay contacts and 0-20mA.
•Separate termination chamber for ease of installation
•Certified Flame Simulator verifies operation from distances of 3 to 8 metres.
•FDS303 can operate via a standard 3 or 4 wire termination
•Microprocessor controlled heated optics increases resistance to moisture and
ice.

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
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2
Safety Instructions
For the correct and effective use of this equipment, to maintain safety and avoid
hazards it is essential that you read and understand these instructions fully and act
accordingly BEFORE installing, operating or maintaining the equipment.
PAY ATTENTION TO ALL SAFETY WARNINGS AND CAUTIONS
2.1 Specific conditions of use
This equipment is certified and intended for use in potentially hazardous areas. Install and use
the equipment in accordance with the latest regulations.
The end user shall close any unused
entries using suitably certified blanking elements to maintain the housing’s type
of protection.
For European (ATEX) installations IEC/EN60079-14 ‘Electrical Installations in Hazardous Areas’ and
ICE/EN60079-17 ‘Inspection and Maintenance in Hazardous Areas’ should be strictly observed.
The Multispectrum IR flame detector type FDS303 is to be installed in places where there is a low
risk of mechanical damage.
For installations in North America the National Electrical Code (NEC) should be strictly observed.
In other countries the appropriate local or national regulations should be observed.
The equipment must be properly earthed to protect against electrical shock and minimise
electrical interference.
Do not drill holes in any housing or enclosure as this will invalidate the explosion protection.
Ensure that the enclosure lid is fully tightened and locked into position before energising the
equipment.
Do not open the enclosure in the presence of an explosive atmosphere.
All permits and proper site procedure and practices must be followed and the equipment must
be isolated from the power supply before opening the enclosure in the field.
Operators must be properly trained and aware of what actions to take in the event of a fire being
detected.
Cable to be used for installation is to be selected with a temperature rating of greater than 25
degrees Celsius above the maximum ambient temperature. The metric cable entries are fitted
with an internal stop. This will result in threads of the cable gland being visible. Do not over
tighten.

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
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2.2 Cautions
Use only approved parts and accessories with this equipment.
Do not attempt to replace the window as the Sapphire and the front cover are individually
matched pairs to meet the stringent requirement of the Hazardous area certification.
The threaded portions of the detector are flame paths. These threads and the flame paths
are not to be repaired.
To maintain safety standards, commissioning and regular maintenance should be performed
by a qualified person.
2.3 Important Safety Notices
Pay attention to the guidelines given throughout this document.
If in any doubt about the instructions listed within this manual, then please contact Micropack
(Engineering) Ltd. Micropack (Engineering) Ltd takes no responsibility for installation and/or use
of its equipment if this it is not in accordance with the appropriate issue and/or amendment of
the manual. Micropack (Engineering) Ltd reserve the right to change or revise the information
contained herein without notice and without obligation to notify any person or organisation of
such action.
Only those parameters and configurations highlighted with the FM diamond ( ) have been
tested and approved by Factory Mutual.
Warning
Do not open the detector assembly in a hazardous area. The detector
contains limited
serviceable components and should only be opened by trained
personnel.
Caution
The wiring procedures in this manual are intended to ensure functionality of the device under
normal conditions. Due to the many variations in wiring codes and regulations, total compliance
to these ordinances cannot be guaranteed. Be certain that all wiring complies with the all local
ordinances. If in doubt, consult the authority having jurisdiction before wiring the system.
Installation must be done by trained personnel.
Caution
To prevent unwanted actuation or alarm, extinguishing devices must be inhibited/isolated prior
to performance testing or maintenance.
Detector Orientation
Detectors should be mounted with the earth stud directly below the lens.

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
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Detector Positioning
Detectors should be positioned to provide the best unobstructed view of the area to be
protected.
The following factors should also be taken into consideration:
•Identify all high-risk fire ignition sources. Ensure that enough detectors are used to
adequately cover the hazardous area.
•Locate and position the detector so that the fire hazard(s) are within both the field of
view and detection range of the device.
•For best performance, the detector should be mounted on a rigid surface in a low
vibration area.
•Extremely dense fog or blizzard conditions could eventually block the vision of the
detector.
•For indoor applications, if dense smoke is expected to accumulate at the onset of a
fire, mount the detector on a side wall (approximately 1 to 2 metres) below the ceiling.
•The FDS303 has three sensitivity settings, which may be changed via a Micropack
application.
•The Detector carries out continuous internal hardware diagnostic testing to ensure
correct operation is relayed to the control system.
•The FDS303 is not designed to annunciate diagnostic failure of signal returns via
external wiring. Control systems and fire panels generally have fault monitoring for
such an eventuality.
2.4 EN 54-part 10 Limitation of use
The FDS303 is not approved for use in Oxygen-enriched atmospheres.
As the FDS303 responds to flame. It cannot be used in locations where flare stacks are within its
field of view or a reflected view is present without triggering alarms.
As the FDS303 responds to CO2Emissions of a flame the FDS303 cannot detect non-Hydrocarbon
fires, such as those using pure hydrogen, Silane and Sulphur as fuel.
The sensitivity of the FDS303 is reduced by obscurants such as smoke, fog and other
airborne particulates. The FDS303 may be blinded by extremely dense obscurants.
Arc welding should not take place within 10m of the FDS303 when using the highest
sensitivity setting.

8
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
3
Installation
The FDS303 design has been developed to allow simple installation. The detector comprises two
key components, the detector enclosure and the detector internal assembly. The detector
assembly located in the front of the enclosure should not be removed except by trained
personnel. Unauthorised removal or disassembly of the detector assembly will invalidate the
warranty. Only the rear end cap can be removed for terminal access.
3.1 Detector Enclosure
The detector electronics are housed in an enclosure certified for use in hazardous areas. For the
exact certification and conditions of use see certification label on the device, or the example
drawing below:
The enclosure comprises the front window cover including the window Part Number
3303.8004, the rear enclosure cover Part Number 2301.6009, the enclosure body Part Number
2301.6007, certification rating label see above Part Number 3303.6006.01, and the mounting
bracket Part Number 2301.6012.

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
3.2 Mounting & Orientation
The mounting bracket allows the detector’s vertical orientation to be adjusted from 0 to 45° and
allows a horizontal rotation of +/-45° when mounted from above.
Figure 1: Detector Mounting Bracket

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
Figure 2: Ceiling Mount
Figure 3: Wall Mount
Firm, vibration free mountings are essential for trouble free operation of optical systems and
the
detector should be fixed to a rigid mounting. When mounting on a wall in this orientation
allow for the cable gland and cable as this may restrict the downward rotation of the detector.

11
FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
3.3 Wiring Procedure
The wiring terminals are in the rear section of the detector enclosure and are accessible by
removal of the end cap.
The front section of the enclosure should only be accessed by trained personnel.
The terminal schematic detailed below shows the view looking inside the detector following
removal of the end cap.
Figure 4: Terminal Schematic
The detector has two types of alarm output available simultaneously
•0-20mA (source non-isolated)
•Relay (Alarm & Fault)
Listed below are wiring options dependent on the functional requirements of the detector.

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
3.3.1 0-20mA Output
The following wiring connection diagram shows correct wiring of the detector when a 0-20mA
output is required.
Figure 5: 3 Wire Termination
Factory Fixed Values
Current Output
Event
0mA
Power/Detector Fault
1.5mA
Optical Fault
4mA
Healthy
18mA
Alarm
21mA
Over-range
Note:
The tolerance on the above outputs is +/- 0.3 mA dc current with a maximum loop
resistance of 500 ohms

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
3.3.2 Relay Output
The following wiring connection diagrams shows wiring the detector when a relay output is
required. Reversal of polarity across terminals 1 & 2 enables Micropack RS485 communication
on terminals 3 & 4. This communication protocol when used with Micropack applications allows
configuration changes to the detector.
Figure 6: Relay Configuration Termination
NOTE: EOL and Alarm resistors values are defined by the client and the
control system/fire panel which the detectors are being integrated into.

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2018
3.3.3 Internal Inter-connections
The following diagram shows the internal inter-connections of the alarm and fault relay contacts
and jumpers. Each field connection is listed on this diagram for clarity.
Figure 7: FDS303 Internal Inter-connections

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
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3.4 Installation Checklist
Experience has shown that poor installation and commissioning practice may result in an
unreliable fire detection system that fails to meet the site performance targets. Before
installing the detector, it is important to consider where it is to be located and how it is to
be mounted. In order to maintain compliance with the EMC regulations it is essential the
electrical
installation be engineered correctly.
3.4.1 Mechanical
Notes When locating the detector consideration should be given to maintenance access to the
detector. The detector mounting should be secure and vibration free.
It is advisable to check the detection locations, prior to fabrication of the mounting
supports, as
changes are frequently made during construction at site which can affect
detector coverage.
The installation should allow space for subsequent detector removal, for maintenance or
repair,
to be easily achieved.
1 The detector should be fixed to a stable supporting structure using the mounting bracket
provided. The supporting structure must allow for horizontal adjustment of the detector
orientation. The support structure should be in place prior to detector installation.
Information
on mounting is available from Micropack (Engineering) Limited.
2
The threaded flame path of the enclosure cover and body must be protected from damage
during installation. Any such damage can destroy the validity of the enclosure.
3 The detector electronics shall be protected from mechanical damage and external sources
of EMI such as X-rays, RFI and electrostatic discharge. The detector should not face directly
towards
the sun.
4
Fit the mounting bracket to the support structure using 8mm bolts (not provided). The
detector (bracket) should be oriented to provide the desired coverage.
5 The detector enclosure body should be fitted to the mounting bracket. The bolts locate
into the bracket. Twist the enclosure to locate the bolts; these are then tightened using a
6mm Allen key.
6
Ensure the detector is orientated such that the earthing stud is directly beneath the lens.
7 Glanding should be carried out by trained personnel. The gland should be fitted in line
with installation standards for potentially explosive atmospheres that is 5 full threads
minimum with
the IP seal washer fitted at the bottom of the thread. This sealing
arrangement will result in a number of threads of the cable gland being visible. The gland
should be torqued between 15 to 20 N m (11 to 15 lb·ft).

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FDS303 Flame Detector
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3.4.2 Electrical
Notes It is advisable to check the detection locations, prior to fabrication of the mounting
supports, as
changes are frequently made during construction at site. Detector cabling
must be segregated from cables carrying high-speed data or high energy and/or high
frequency signals and other
forms electrical interference. The detector requires a clear
unobstructed view of the local hazard. In order to avoid local obstructions, such as pipe-
work and cable trays, a 2m helix should be allowed in the detector cabling. The detector
should only be fitted just prior to commissioning the detector. Experience shows that the
detector can be damaged due to cable testing
operations (Insulation Tests, etc.).
1
Isolate all associated power supplies. Ensure that they remain OFF until required for
commissioning.
2
The threaded flame path of the enclosure cover and body must be protected from
damage during installation. Any such damage can destroy the validity of the enclosure.
3
The electronics subassembly shall be protected from mechanical damage and external
sources of EMI such as X-rays, RFI and electrostatic discharge.
4
The enclosures external earth stud should be connected to a local earth point.
5
Remove the transit plug(s) from the enclosure body gland entries.
6
Fit approved cable glands.

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
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4
System Design Guidelines
The following guidelines are intended to assist with the electrical design and engineering of
systems where it is intended that flame detectors will be used.
4.1 Power Supply
The detector requires an absolute minimum supply voltage of 18Vdc, as measured at the
detector
terminals. The system power supply voltage and power distribution should be
arranged such
that on the longest cable run the detector(s) has a supply voltage of greater than
18Vdc.
4.2 Cable Selection
Cable to be used for installation is to be selected with a temperature rating of greater than 25
degrees Celsius above the maximum ambient temperature.
The metric cable entries are fitted with an internal stop. This internal stop has an IP washer
mounted directly above it. Ensure this is fitted to maintain the ingress protection. This will result
in threads of the cable gland being visible. Do not over tighten.
The installation and local regulations and standards determine the overall cable specification.
This section specifies suitable cable characteristics to ensure correct operation of the flame
detector.
4.2.1 DC Power
NOTE: Table 2 shows an absolute maximum for cable length; try not to approach this value.
DO NOT ground any cable shields at the detector housing.
Table 2: Maximum Cable Lengths (24Vdc supply)
Installation
based on 24V
nominal supply
Number of
Flame Detectors
Maximum Power
(W)
Maximum Cable
Length (m) with
1.5mm2
Conductors
(12Ω/km)
Maximum Cable
Length (m)with
2.5mm2
Conductors
(7.6Ω/km)
Detector 1 12W @ 24Vdc 500 Metres 780 Metres

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Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
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Table 3: AWG Conversions
Cross Sectional Area (mm2) American Wire Gauge (AWG)
Typical Conductor Resistance
per km (3280 ft.)
DC Ω/km @ 20°C (Approx.)
0.5 22 36
1.0 18 19
1.5 16 12
2.5 14 7.6

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FDS303 Safety and Technical Manual
Rev: 1.7 ECN: 4535Ref: 3303.0001
FDS303 Flame Detector
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5
Application Guidelines
In considering the application of the detector it is important to know of any conditions that may
prevent the detector from responding. The detector provides reliable response to Hydrocarbon
flames within its field of view, and insensitivity to common false alarm sources. Solid obstructions
or a direct view of intense light sources may result in a reduction in the coverage and/or a
reduction
in the detector sensitivity. Scaffolding or tarpaulins in the detector’s field of view may
reduce coverage. Contamination of the detector window may result in a reduction in sensitivity.
The detector has a 90° conical field of view. The location and orientation of the detector in
relation to the protected area determines the actual footprint.
Achieving the desired coverage
depends on congestion within the protected space, the location
of the detector(s) and the
distance of the detector from the hazard. It may be necessary to install
more than one detector
within an area to achieve adequate coverage.
The detector sensitivity, expressed as fire size at a distance, is determined by the radiant heat
output of the fire. This is a function of the fuel source, how it is released and distance from the
detector to the fire.
In common with other forms of flame detection the detector’s sensitivity is reduced and
potentially blinded by dense obscurants such as smoke, fog and other airborne particulates.
The detector is insensitive to arc welding; however, this should not be conducted within 10m of
the
detector.
5.1 Positioning Requirements
The following guidelines have been based on operational feedback, reflecting commonly
experienced problems which can be traced to a failure to observe the following:
•Ensure the mounting position is free from vibration or movement.
•Prevent accidental knocking or forcing out of alignment.
•Isolate as far as possible from local electrical interference sources.
•Ensure sufficient detection to achieve adequate coverage for all likely hazards.
•Minimise exposure to contamination of the detector face plate.
•Ensure ease of maintenance access to detector (i.e. direct ladder or scaffold
access).
•Do not allow the FDS303 to have direct view of hot surfaces.
•Ensure that the FDS303 has no direct view or reflected view of a friendly fire.
•The detector should be aimed downward by at least 10o to 20o.
All these issues are of crucial importance to a successful installation and they should be afforded
great attention during the detailed design, construction and commissioning phases of the work.

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5.2 Detection Coverage
Detector locations can be chosen from computer models or from site surveys. The detectors
should be aligned to view the intended hazard considering any obstruction and
congestion.
Software analysis of the actual detector coverage may be required to ensure adequate coverage
of the hazards. This analysis can also be used to optimise the number of detectors and the loop
configuration. The cones of vision are detailed in Appendix C.
5.3 Exposure to Flare Radiation
Flame detectors are frequently used where hydrocarbon fire hazards are expected; these are
quite often processing plants where a flare stack is in use nearby. The detector shall not have a
direct view of the flare or a reflected view of the flare.
5.4 Optical Contamination
There are many sources of contamination such as oil, water (deluge water, rain and sea-spray),
snow, ice, and internal misting. Excessive contamination of the detector faceplate may result in
an increased maintenance requirement and potentially reduce the detector’s sensitivity. Where
detectors are mounted at low level, care should be taken to avoid contamination (such as water
and oil) from equipment above the detector. Care should be taken in sighting the detector to
minimise the likelihood of such contamination. The detector is designed such that an optical
fault
is indicated after a confirmation period of 15 minutes, when half of the detection range
remains. This is indicated by the fault output and is evident by the yellow colour of the LED on
the face of the detector. The optical fault condition
indicates that the detector requires cleaning
or service. The optical fault indication is self-clearing.
5.5 Enclosed Areas
In enclosed areas, if dense smoke is expected to accumulate at the onset of the fire, the detector
should be mounted 1 to 2 metres below the ceiling level.
5.6 Detector Sensitivity
The detector’s response to a fire is a function of the fuel source and how it is released, fire size
and distance, orientation to the detector and local ambient conditions. The typical figures are
based on in-house tests except where marked with the FM logo these tests were conducted and
certified by Factory Mutual. As with all tests the results must be interpreted according to the
individual application considering all possible variables.
The detector sensitivity to different fuel sources is dependent on the Radiant Heat Output of the
flame, the detectors typical response is shown below (see table 4). The detector will only detect
Hydrocarbon fires.
5.7 Detector Alarm Delay
The detector can be factory configured with an alarm delay of up to 30 seconds. If this option is
selected, however, it invalidates the SIL 2 and FM certification shown within this manual.