MSA General Monitors FL4000H User manual


Operating Manual
General Monitors® Model FL4000H
Multi-Spectral Infrared
  
OrderNo.:MANFL4000NH/S
PrintSpec:10000005389(EO)
CR:800000060233
MSAsafety.com
US

© MSA 2023. All rights reserved
WARNING!
Theseinstructionsmustbeprovidedtousersbeforeuseoftheproductandretainedforreadyreferencebytheuser.Readthismanualcarefullybefore
usingormaintainingthedevice.Thedevicewillperformasdesignedonlyifitisusedandmaintainedinaccordancewiththemanufacturer's
instructions.Otherwise,itcouldfailtoperformasdesigned,andpersonswhorelyonthisdevicecouldsustainseriousinjuryordeath.

ThewarrantiesmadebyMSAwithrespecttotheproductarevoidediftheproductisnotinstalledandusedinaccordancewiththeinstructionsinthis
manual.Pleaseprotectyourselfandyouremployeesbyfollowingtheinstructions.
PleasereadandobservetheWARNINGSandCAUTIONSinside.Foradditionalinformationrelativetouseorrepair,call1-800-MSA-2222during
regularworkinghours.
ForcountriesofRussianFederation,RepublicofKazakhstanandRepublicofBelarus,thegasdetectorwillbedeliveredwithapassportdocumentthat
includesvalidapprovalinformation.OntheCDwithmanualinstructionattachedtothegasdetectortheuserwillfindthedocuments"TypeDescription"
and"TestMethod"-appendixestoPatternApprovalCertificateofMeasuringinstrument,validinthecountriesofuse.
TheDeclarationofConformitycanbefoundunderthefollowinglink:https://MSAsafety.com/DoC.
MSAisaregisteredtrademarkofMSATechnology,LLCintheUS,EuropeandotherCountries.Forallothertrademarksvisit
https://us.msasafety.com/Trademarks.
GeneralMonitors
16782VonKarmanAvenue,Unit14
Irvine,CA92606
1-949-581-4464
ForyourlocalMSAcontacts,pleasegotoourwebsitewww.MSAsafety.com

US Model FL4000H 3
Contents
1 QuickStartGuide 5
1.1 MountingandWiringtheDetector 5
1.2 ApplyingPowertotheDetector 6
1.3 Testing 6
1.4 AboutthisManual 6
2 BeforeInstallation 6
2.1 SystemIntegrityVerification 6
2.2 CommissioningSafetySystems 7
2.3 ConditionsofUse 7
2.4 GlossaryofTerms 8
3 ProductOverview 9
3.1 GeneralDescription 9
3.2 FeaturesandBenefits 9
3.3 Applications 10
3.4 PrincipleofOperation 10
4 Installation 15
4.1 UnpackingtheEquipment 15
4.2 RequiredTools 15
4.3 DetectorLocationGuidelines 15
4.4 DetectorMountingandInstallation 17
4.5 FieldWiringProcedure 17
4.6 TerminalConnections 18
4.7 SwitchSelectableOptions 23
4.8 PoweringoftheFL4000H 24
4.9 PowerUpGroundingoftheTestandRelayResetLines 24
5 ModbusInterface 25
5.1 Introduction 25
5.2 CommunicationSlaveAddress 25
5.3 BaudRate 25
5.4 DataFormat 25
5.5 SupportedFunctionCodes 25
5.6 ModbusReadStatusProtocol(Query/Response) 25
5.7 ModbusWriteCommandProtocol(Query/Response) 26
5.8 ExceptionResponsesandExceptionCodes 27
5.9 CommandRegisterLocations 28
5.10 CommandRegisterDetails 31
6 Maintenance 41
6.1 GeneralMaintenance 41
6.2 CleaningtheSapphireWindow 41
6.3 SensitivityCheck 42
6.4 Storage 42
7 Troubleshooting 42
7.1 TroubleshootingChart 42
7.2 FinalAssembly 43
8 CustomerSupport 44
8.1 GeneralMonitors'Offices 44
8.2 OtherSourcesofHelp 44

4 Model FL4000H US
9 Appendix 45
9.1 Warranty 45
9.2 Specifications 45
9.3 RegulatoryInformation 47
9.4 ResponsetoFalseStimuli 47
9.5 SparePartsandAccessories 49
10 AppendixA 50

1 Quick Start Guide
US Model FL4000H 5
1 QuickStartGuide
1.1 MountingandWiringtheDetector
Payspecialattentiontotheconduitsealentry(CanadianElectricalCodeHandbookPart1,Section18-154).
Mountthedetectorbyusingtheswivelmountormountingbrackethardware.
Figure 1 FL4000H Housing
1. Loosenthecaptivescrews(A)locatedontheopticalhousingassembly.
2. Pulltheopticalhousingassemblyfromthebasehousingassemblytoseparate,
gentlyrockfromsidetosideifnecessarytoloosentheconnector’sgrip.
3. Wiretheunittothesite-wiringfollowingtheconnectiondiagram(Figure5).
4. Reassembletheunitusingsteps1thru2inreverse.
CAUTION!
Donotunscrewthefieldwiringcircuitboardfromthebasehousinginordertowiretheunit.
Failuretofollowthiscautioncanresultinminorormoderateinjury.
Figure 2 Mounting Instruction Figure 3 Wall Mounting Assembly

6 Model FL4000H US
2 Before Installation
Figure 4 Bracket Assembly Figure 5 Field Terminations
1.2 ApplyingPowertotheDetector
Twolightemittingdiodes(LED’s)arevisiblethroughthewindow.Immediatelyuponpoweringupthedetector,bothLED’s
willstartblinkingalternatelyfor15seconds.Theunitwillthenenterthe“Ready”mode.Duringthe“Ready"mode,thegreen
LEDwillflashoff0.5secondsevery5seconds.
1.3 Testing
TesttheintegrityofyoursystembyusingaTestLamp.Theoriginalconfiguration(i.e.sensitivityandrelayoptions)canbe
changedbyreferringto4.7SwitchSelectableOptionsandthenchangingthedipswitchsettingslocatedonthebottomof
thepowerboard(SW1).
Theinstrumentisnowreadytooperate.
ConsulttheTestLampmanualformoreinformationontheinstrument’smanyfeatures.Ifyouhaveanyproblemsinthe
set-uportestingofthedetector,see7Troubleshooting,orcallthefactorydirect.
1.4 AboutthisManual
Thismanualprovidesinstructionsforinstalling,operating,andmaintainingtheGeneralMonitors(GM)FL4000HFlame
Detector.Theintendedaudienceincludesinstallationpersonnel,fieldservicetechnicians,Modbusprogrammers,and
othertechnicalstaffinvolvedininstallingandusinganFL4000H.
ModbusRegisterFormats
HexadecimalnumbersareusedinModbusregistersandareindicatedbytheadditionofeither“0x”infrontofanumberor
“h”afterthenumber(example:0x000Eor000Eh,respectively).
2 BeforeInstallation
2.1 SystemIntegrityVerification
GeneralMonitors’missionistobenefitsocietybyprovidingsafetysolutionsthroughindustryleadingproducts,services,
andsystemsthatsavelivesandprotectcapitalresourcesfromthedangersofhazardousflames,gases,andvapors.
GeneralMonitors’safetyproductsshouldbehandledcarefullyandinstalled,calibrated,andmaintainedinaccordancewith
theindividualproductinstructionmanuals.Toensureoperationatoptimumperformance,GeneralMonitorsrecommends
thatprescribedmaintenanceproceduresbefollowed.

2 Before Installation
US Model FL4000H 7
2.2 CommissioningSafetySystems
Beforepowerup,verifywiring,terminalconnections,andstabilityofthemountingsforallessentialsafetyequipment
including,butnotlimitedto:
• Powersupplies
• Controlmodules
• Fielddetectiondevices
• Signaling/outputdevices
• Accessoriesconnectedtofieldandsignalingdevices
Aftertheinitialpowerupandanyfactoryspecifiedwarm-upperiodofthesafetysystem,verifythatallsignaloutputs,toand
fromthedevicesandmodules,arewithinthemanufacturer’sspecifications.Initialcalibration/calibrationchecking/testing
shouldbeperformedaccordingtothemanufacturer’srecommendationsandinstructions.
Propersystemoperationshouldbeverifiedbyperformingafull,functionaltestofallcomponentdevicesofthesafety
system,ensuringthattheproperalarmlevelsoccur.Fault/Malfunctioncircuitoperationsshouldbeverified.
2.3 ConditionsofUse
WARNING!
• Toxic,combustible,andflammablegasesandvaporsaredangerous.Extremecautionshouldbeusedwhenthese
hazardsarepresent.
• Keepcovertightwhilecircuitsarealive.
• Donotopenwhenanexplosiveatmosphereispresent.
Failuretofollowthesewarningscanresultinseriouspersonalinjuryordeath.
• AnEnd-Of-Line(EOL)resistorwithamaximumpowerdissipationofupto0.6Wmaybefittedinthecircuitinsidethe
enclosure;however,itmustbeinstalledbytheuser/installerinaccordancewiththerelevantinstructionsthatare
stipulatedinthemanufacturer'sproductmanual.
NOTE:Usefastenerswithyieldstress450MPa.
• TheFL4000HFlameDetectorflangedjoint,betweenthewindowcoverandmainbody,maybesitedtowithina
distancenolessthan9.62mmofanyadjacentsurface,oritssunshieldwhenfitted.
• Throughengineeringdesign,testing,manufacturingtechniques,andrigidqualitycontrol,GeneralMonitorssupplies
thefinestflamedetectionsystemsavailable.Theusermustrecognizehisresponsibilityformaintainingtheflame
detectionsysteminoperationalcondition.
• TheFL4000Hcontainscomponentsthatcanbedamagedbystaticelectricity.Inordertoavoidstaticelectricity,
specialcaremustbetakenwhenwiringthesystemtoensurethatonlytheconnectionpointsaretouched.
• TheFL4000HisratedExplosionProof(XP)foruseinhazardouslocations.
• ConduitsealsorsuitablyapprovedExdglandsmustbeusedtopreservetheexplosionproofsafetyoftheFL4000H
andhelppreventingressofwaterorgasfromtheconduitsystems.Aconduitsealmustbeinstalledwithin18inches
oftheenclosureperNECregulations.
• SiliconeRoomTemperatureVulcanization(RTV)isnotanapprovedmoisturebarrier.Ifused,damagetointernal
componentswillarise.
• DamagetotheFL4000Hhousingwhereanyinternalcomponentsorprotectivesealsarebroken,compromisesthe
safetyandusabilityofthedevice.AnFL4000Hwithadamagedoropenhousingshouldnotbeusedinahazardous
environment.Suchdamageincludesfracturesinthehousing,cracksinanyinternalcomponents,orcracksinthe
protectiveseals.

8 Model FL4000H US
2 Before Installation
2.4 GlossaryofTerms
Term/Abbreviation Definition
A Amps
AC AlternatingCurrent
ANN ArtificialNeuralNetwork
AWG AmericanWireGauge
BaudRate Thenumberofsignallevelchangespersecondinaline,regardlessoftheinformationcontentof
thosesignals
bps Bitpersecond
CableArmor Cablehavinginterlockedorcorrugatedarmorwhereitisessentialtoprovidepositivegrounding
ofcablearmor
CableScreen Meshsurroundingacable
COM DCGround
COPM ContinuousOpticalPathMonitoring
CR ControlRoom
CRC CycleRedundancyCheck
DC DirectCurrent
DCS DistributedControlSystem
De-Energized Todisconnectfromapowersource
DSP DigitalSignalProcessor
EEPROM ElectricallyErasableProgrammableRead-OnlyMemory
EMI ElectromagneticInterference
Energized Toapplyvoltageorenergy
FOV FieldofView
FS FullScale
GM GeneralMonitors
HART HighwayAddressableRemoteTransducer-communicationprotocol
Hex HexadecimalNumber
I/O Input/Output
InstrumentEarth Groundedusingagroundingstrap
Latching Referstorelaysremaininginthe“on”stateevenafterthe“on”conditionhasbeenremoved
LED LightEmittingDiode
LSB LightSignificantBit
mA Milli-Ampsrefersto1/1000ofanAmp
Master Controlsoneormoredevicesorprocesses
Modbus Master-slavemessagingstructure
N/A NotApplicable
NC NormallyClosed
NO NormallyOpen
Non-Latching Referstorelaysbeingresettotheinitialstateafter“on”conditionhasbeenremoved
NPT NationalPipeThread

3 Product Overview
US Model FL4000H 9
Term/Abbreviation Definition
OVReturn Overvoltagereturn
OVDC PowerSupplyCommonGround
Oxidation CombiningwithOxygen
PCB PrintedCircuitBoard
PLC ProgrammableLogicController
ppm Partspermillion
RFI RadioFrequencyInterference
RMS Root-Mean-Square
ROM ReadOnlyMemory
RTV RoomTemperatureVulcanization
SafetyEarth Groundedtotheearth
Slave Oneormoredevicesorprocessescontrolledbyamastercontroller
SMT SurfaceMountTechnology
SPANValue Theprogrammedrangeofmeasurablepartspermillion
SPDT SinglePole,DoubleThrow
SPST SinglePole,SingleThrow
TB TerminalBlock
V Volts
VAC VoltsAlternatingCurrent
VDC VoltsDirectCurrent
XP ExplosionProof
3 ProductOverview
3.1 GeneralDescription
Figure 6 FL4000H Front View
TheGeneralMonitorsFL4000HisaMultiSpectralInfrared(MSIR)FlameDetector
(Figure6).TheFL4000Hemploysstate-of-theartinfrared(IR)detectorsanda
sophisticatedartificialneuralnetwork(ANN)basedsignalprocessingtoproducea
systemthatishighlyimmunetofalsealarmscausedbylightning,sunlightreflection,
arc-welding,hotobjects,andothersourcesofradiation.Inaddition,theFL4000Hcan
seethroughmostsmokytypefiressuchasdiesel,rubber,etc.
TheFL4000Hiscertifiedasexplosionproofforuseinhazardouslocations(9.3.2
ClassificationAreaandProtectionMethods).Itcanalsobeusedforgeneral-purpose,
nonhazardousapplications.
3.2 FeaturesandBenefits
HighFalseAlarmImmunity:ProvidesreliableflamedetectionperformancebyutilizingaproprietaryANNprocessing
algorithmtominimizefalsealarms.RefertoTable37formoredetailsonthebehavioroftheinstrumentinthepresenceof
falsestimuli.
WideFieldofView(FOV):Encompassesalargerareaofdetectionwithuniformsensingandnoblindspots.Modular
Design:Resultsinlowmaintenanceandreducedtotalcostofownership.
CompactUnitizedDesign:Enhanceseaseofinstallationandmaintenance.
ContinuousOpticalPathMonitoring(COPM):Regularlymonitorstheopticalpathtoensurethewindowisnotdirty.

10 Model FL4000H US
3 Product Overview
0-20mAAnalogOutput:Transmitsalarmandfaultindicationtoaremotedisplay,computer,orotherdevicesuchasan
alarm,dispensingdevice,ormastercontroller.
DualRedundantModbusRS-485UserInterface(StandardFL4000HConfiguration):Providesthecapabilityto
operatetheFL4000Hremotely,using2redundantchannels.Thisinterfaceallowstheusertoremotelychangethealarm
andwarningrelaysettings,clearselectedfaults,clearerrorcounters,changebaudrates,andchangeformatsforserial
communicationlines.
HARTProtocol2(OptionalHARTConfiguration):TheHARTequippedFL4000HsupportstheHARTcommunication
protocolversion6.Usingthisprotocol,userscantransmitdiagnostics,settings,andotherdevicestatusinformationthat
improvestheefficiencyofremotecommunication.
NOTE:FL4000HHARTshouldnotbeusedwithGeneralMonitorsTA402AandFL802Controllers.
3.3 Applications
TheFL4000Hprovidesflamedetectionforawiderangeofapplications,including,butnotlimitedtothefollowing:
Industries SampleApplications
OilandGas OnandOffshorePlatforms
GasPipelines CompressorBuildings
Airports/Military AirplaneHangars
GasTurbines TurbineEnclosures
ChemicalPlants ProcessBuildings
LoadingTerminals TruckingOn/OffLoadingAreas
Petrochemical ProcessAreas
Refineries TankFarmsandProcessAreas
Table 1 Sample Industry Applications
3.4 PrincipleofOperation
TheFL4000Hisadiscriminatingmulti-spectralinfrareddetector,whichmakesuseofinfraredsensorsfordifferentIR
wavelengthsandcharacteristics.Thiscombinationprovidesaflamedetectionsystem,whichishighlyimmunetofalse
alarms.
TheANNnetworkclassifiestheoutputsignalsfromthedetectoraseitherfireorno-fire.Theunitthenproducesthe
followingoutputsignals:
• 0to20mAsignal(3.5or1.25to20mAwithoptionalHARTprotocol)
• ImmediateWARNrelaycontacts
• TimedelayedALARMrelaycontacts
• FAULTrelaycontacts
• RS-485Modbusoutput
• RedundantRS-485Modbusoutput
NOTE:Referto4Installationand5ModbusInterfaceformoreinformationondetectoroutputs.
3.4.1 VisualIndicators
Twolightemittingdiodes(LEDs)arevisibleonthefrontdetectorwindow.TheseLEDsprovideavisualindicationthat
correspondswiththedetector’soutputs.TheLEDflashingsequencesinTable2indicatevariousoperatingconditions: