Patol 5000 Series User manual

Page 1 of 15D1125 - Issue 2 - 1 December 2009Series 5000 - Manual 5010 / 5020
Patol Limited
5000 Series
Infra-red Fire Detection System
Internal Lens Cleansing & Purge Air Configuration
5010 Sensor Head - 5020 Controller
SPECIFICATION
INSTALLATION - COMMISSIONING
OPERATION - MAINTENANCE
Document Ref : D1125
Issue Change Date Remarks
1 Original 25/05/05
2 Additions 01/12/09
Patol Limited
Rectory Road,
Padworth Common,
Berkshire. RG7 4JD
United Kingdom.
Tel : [phone]
Fax : [phone]
Email : [email protected]
Web : www.patol.co.uk

Patol Limited
INDEX
1. INTRODUCTION
1.1 General
1.2 Principles
2. EQUIPMENT DETAIL
2.1 Description
2.2 Type 5010 Sensor Head
2.3 Type 5020 Controller
2.4 General Specification - Sensor & Controller
2.5 Operational Programmability - DIL Switch
2.6 Connections
2.7 Series 5000 Blower Units
3. INSTALLATION
3.1 Sensor Head
3.2 Controller Cable
3.3 Purge Air Supply
4. COMMISSIONING
4.1 Cable Checks
4.2 Controller Set Up
4.3 Power Up Procedure
4.4 Sensor Head & Purge Air Supply
4.5 Hot Body Simulation Tests
5. OPERATION
5.1 Normal
5.2 Alarm Condition
5.3 Trip Condition
5.4 Reset
5.5 Fault Warning
5.6 Lamp Test
5.7 Head Test
6. MAINTENANCE
6.1 General
6.2 Purge Air
6.3 Fault Monitoring Functions
6.4 Infra-red Detection
Page 2 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

Patol Limited
1 INTRODUCTION
1.1 General
The Patol 5000 Series of equipment is specifically designed for the protection of
establishments and systems where a movement of materials with a potential fire hazard is
a routine occurrence.
The 5000 Series system employs enhanced Infra-red monitoring technology that enables
the detection of fire initiating materials, whilst they are being transported, and before they
have reached a flame condition.
The system has many applications within industries such as Power Generation, Coal
Mining, Process Plant, Road Transportation and Rail Networks and has been specifically
designed to both meet the rigors of these environments and to provide the reliability
required.
The equipment monitors for fire and fire potential of materials in transit. The system can
detect anomalies where combustion has not yet been reached, but where there is sufficient
energy for a fire initiation upon destination arrival.
A typical example is in the coal feed systems on power stations where coal on the ‘out field
stack’ may very well smoulder with little adverse effect for long periods of time. However, if
imported to the power station it may have devastating effects on conveyor systems, holding
hoppers, blending plants etc.
♦ Detection of hazards at temperatures below flame point including both embers and
buried hot spots.
♦ Air purged system for Dusty environments with air pressure monitoring.
♦ Eight high integrity detectors for maximum reliability
♦ Multi-facet lensing provides wide uniform coverage superior to some ember/spark
detectors.
♦ Coincidence- Double Knock - option for unit detectors as standard.
♦ Timed auto reset / coincidence analyser circuit.
♦ Tuned response - solar blind.
♦ Special configurations and application specific calibration options.
♦ Specifically designed for high EMC compliance
1.2 Principles
The principle of operation is that
temperature dependant black body
emissions occur for all materials.
These emissions range through the
infra red spectrum to visible light.
Both the wavelength and level of
peak energy emission are related to
temperature.
The Series 5000 detectors are
designed to detect the changes in
these emissions that occur when a
hot body enters the field of view of
the detector.
By the use of both optical filtering and electronic analysis of the various parameters the
system is blind to visible light from the sun or local luminaires, whilst being able to detect
relatively low temperature material moving through the field of view.
123456789
200 C
320 C
SOLAR
o
o
10
Typical Black Body Energy Emissions
5000 RESPONSE FILTER
WAVELENGTH (Micrometres) Fig. 1
Page 3 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

Patol Limited
2. EQUIPMENT DETAIL
2.1 Description
The 5000 Series system described here comprises three primary elements :-
Sensor unit - Type 5010
Control Unit - Type 5020
Air Supply / Blower Unit
The Sensor Unit is located above the materials transit path (e.g. conveyor) by means of the
adjustable mounting bracket and aligned such that the monitored hazard passes through
the sensor’s field of view. The height and angle of the sensor determine the width of the
monitored path.
The Type 5010 Sensor outer case is equipped with an air hose spigot for connection of an
air supply. This is required such that a positive air pressure is maintained within the sensor
unit.
There is a continuous air flow from the optical lens aperture which stops dust settling on the
lens. Also, by maintaining a positive pressure within the enclosure, ingress of explosive gas
or dust is prevented. The arrangement can permit the unit to be employed in a Hazardous
Area depending on applicable local regulations.
The air purging is essential in dusty environments such as coal conveyors, and is
recommended in even relatively clean applications. A series 5000 air purge blower is
employed when an ‘on site’ air supply is not available. (See section 2.7)
Within the unit is a pressure switch to monitor the purge air and signal a loss of pressure as
an Air Fault to the controller.
The Type 5020 Control Unit provides various indications and controls related to infra-red
detection alarms and fault monitoring.
The unit is mounted such as to provide ready access for operational and maintenance
purpose and connects to the sensor by means of a ten core screened signal cable.
Fig. 2
MONITORED MATERIALS
SENSOR
AIR
AIR PURGE UNIT CONTROLLER
110 / 230 Vac 24 Vdc
SHUT-DOWN
ALARM
TYPICAL SYSTEM
AIR HOSE
SIGNAL CABLE
HeightAngle
AIR FILTER
Page 4 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

2.2 Type 5010 Sensor Head
An octal detector sensing module is located within an aluminium alloy housing which is
mounted by means of an adjustable bracket permitting alignment in both vertical and
horizontal planes. The housing is equipped with a purge spigot for coupling to a 45mm I/D
air hose and internal screw terminals for connection to the controller cable.
The sensing module fits to the housing by means of a connector and thus may be readily
de-mounted (upon removal of the housing cover) without disturbance to cable connections.
The injected air exits via the IR lens aperture thus preventing ingress / settlement of dust.
2.3 Type 5020 Controller
The control module is easily de-mountable from the housing and connects to the sensor by
means of a ten core screened cable. These terminations, together with supply and output
contact connections are via two part screw terminals thus enabling installation of the
housing and site cables prior to fittment of the module.The housing has a high level of
ingress protection (IP67).
The unit incorporates a user programmable DIL switch to set the options which include
detector sensitivity setting, auto/manual reset sequence selection, and one-shot/
coincidence voting for the alarm and trip/shutdown outputs.
The sensor air pressure and signal cable connections are fault monitored/fail safe. The unit
incorporates an aux. fault input & common fault output contact.
Patol Limited
1234 ALARM TRIP SENAIR
DETECTORS FIRE FAULT
RESET TEST
PatolLimited 5000 Series
AUX 24V
ON
LAMPHEAD
TEST
75 mm (6.9 inches)
GREY
POLYCARBONATE
GLASS FILLED
CLEAR
POLYCARBONATE
COVER
DIL SWITCH
INDICATORS
PUSH-BUTTONS
TWO PART SCREW
TERMINALS
2.5 sq mm (14AWG)
REMOVABLE
PCB MODULE
MOUNTING HOLES
157x 157 mm (6.18x 6.18 inches)
4.5 mm (0.17 inch) DIA
175mm
(6.9 inches)
175mm (6.9inches)
Fig. 4
AIR HOSE
HOSE CLIP
SPIGOT
SIGNAL CABLE
CABLE GLAND
170
340
ADJUSTMENT
126
95
78
Fig. 3
170 mm (6.7 inches)
340 mm (13.4 inches)
126 mm (4.96 inches)
78 mm
(3.1 inches)
95 mm
(3.74 inches)
Page 5 of 15Series 5000 - Manual 5010 / 5020
75 mm (3.0 inches)
D1125 - Issue 2 - 1 December 2009

Patol Limited
2.4 General Specification (Sensor and Controller)
2.4.1 Electrical:- Supply Voltage : 20 - 30 Vdc
Stand-by Current : 35 mA
Maximum Current : 70 mA (Full Alarm)
Terminals : 2.5 mm² (14 AWG)
2.4.2 Purge Air Supply:- Pressure : 5 mBar (2”WG)
Delivery : 5.0 litres / sec (11 cubic feet per min)
Input Fitting : 45mm (1 3/4”) dia hose spigot
2.4.3 Sensor Head:- Weight : 1.15 kg (2.5 lbs) - Excluding mounting arm
Weight : 1.45 kg (3.2 lbs) - Including mounting arm
2.4.4 Controller:- Weight : 0.9 kg (2 lbs)
Rating : IP67
2.4.5 Temperature :- -20°C to +70°C
2.4.6 Indications:- Detection Channels : Red LEDs - 5mm - 4 off
Alarm : Red LED - 8mm
Trip : Red LED - 8mm
Air Fault : Yellow LED - 5mm
Sensor Fault : Yellow LED - 5mm
Auxiliary Fault: Yellow LED - 5mm
Supply On - Green LED - 5mm
2.4.7 Outputs:- Alarm Contact : 1 pole C/O - 500mA @ 30Vdc / 120Vac
Trip Contact : 1 pole C/O - 500mA @ 30Vdc / 120Vac
Fault Contact : 1 pole C/O - 500mA @ 30Vdc / 120Vac
2.4.8 Controls:- Sensor Head Test Push-button
Reset Push-button
Lamp Test Push-button
2.4.9 Program DIL Switch :-8 Pole - Also refer to section 2.5
Sensitivity - 4 level
Latching / Auto Reset
Alarm - One Shot / Voting
Trip - One Shot / Voting
Auto Reset Timer - 4 settings
2.4.10 Inputs:- Auxiliary Fault (PSU / Charger etc.)
Remote Reset
2.4.11 Detectors:- 8 off - Using interlaced lensing - Configured as 4 pairs.
Sensitivity : 10 to 40 µW adjustable in four steps.
Spectral Filter : 5 to 14 µm
Transit speed : 1 to 6 m/s
Response : 80 - 1000 ºC (170 - 1800 ºF) - Refer Fig.5
Figure 5 indicates the
correlation between the
temperature and size of ‘hot
spot’ anomalies for a typical
installation to produce one or
more detector channel
activations at various trigger
level settings.
Exact response is dependant
on the emissivity factor of the
monitored material, sensor
orientation and target speed. 0100 200 300 400 500 600 700 800 900 1000
1
2
3
4
Temperature Degrees C
250mm Dia.
490 sq cm 100mm Dia. 78 sq cm 50mm Dia. 19.6 sq cm
29mm Dia.
6.45 sq cm
1 sq inch
25mm Dia.
4.9 sq cm
GLOWING / VISIBLE
Fig. 5
Page 6 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

Patol Limited
2.5 Operational Programmability - DIL Switch
The system is fitted with eight IR detectors that are arranged in pairs within a four channel
configuration. The DIL switch located at the top of the controller PCB permits the selection
of system parameters related to the triggering of these channels.
2.5.1 Alarm & Trip Outputs
The controller is equiped with two logic functions.
One function operates when any channel registers a detection (1 out of 4).
The other function operates on a voting principle which is activated when two
coincident channel detections occur (2 out of 4).
Two primary outputs are available - ALARM & TRIP
Each of these having both a discrete LED indicator & output relay contact
Poles 1 & 2 of the DIL switch permit selection of the following options:-
2.5.2 Latching / Auto Reset Selection.
Both ALARM & TRIP outputs may be set for either Latching or Auto Reset operation.
Poles 3 & 4 of the DIL switch permit selection of the following options:-
The time of delay before the Auto Reset occurs (when appropriate) may be set.
When the option for latching only on coincident (2 out of 4) detection is selected then
the Auto Reset delay is in effect the Scan Period within which a second channel must
occur after first detection. Poles 5 & 6 of the DIL switch set the delay / Scan period.
2.5.1 Detector Sensitivity
The detection sensitivity may be set by means of switch poles 7 & 8.
POLE 1 POLE 2 LED & RELAY OPERATION
OFF OFF ALARM & TRIP functions both operated on any sensor head detector activation.
( 1 out of 4)
ON OFF ALARM & TRIP functions both operated on coincident head detector activation.
( 2 out of 4)
OFF ON ALARM & TRIP functions both operated on any sensor head detector activation.
( 1 out of 4) as per Off Off
ON ON ALARM operated on any detector activation (1 out of 4)
TRIP operated on coincident (voted) activation (2 out of 4)
POLE 3 POLE 4 LATCHING OPERATION
OFF OFF ALARM & TRIP functions both auto-reset (see scan / reset delay following)
ON OFF 1 out of 4 functions auto-reset after scan / reset delay
2 out of 4 functions latch if within scan period
OFF ON All detections will Latch On
ON ON All detections will Latch On
POLE 5 POLE 6 SCAN - AUTO RESET TIME DELAY
OFF OFF Scan / Delay 0.5s (Shortest)
OFF ON Scan / Delay 1s
ON OFF Scan / Delay 1.5s
ON ON Scan / Delay 2s (Longest)
POLE 7 POLE 8 DETECTOR SENSITIVITY
OFF OFF Level 1 (Most Sensitive)
OFF ON Level 2
ON OFF Level 3
ON ON Level 4 (Least Sensitive)
Page 7 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

Patol Limited
2.6 Connections
2.6.1 General
A ten core shielded / screened cable is required for connections between the
Controller and Sensor Head. The remainder of the terminals located in the
controller provide various supply, output, and signal functions.
2.6.2 Sensor Head Cable - Terminals 1 to 11
The Sensor is connected to the Controller by means of a ten core shielded/
screened cable. This cable may be provided by Patol Ltd., as part of a “system
package”, and may be of a five pair form. The screen (earth) of the cable should
be tailed and connected as show in the above figure.
Earth continuity at Controller & Sensor Head terminals (#1) must be maintained,
and a system / site earth implemented at the Controller terminal #31 as is most
appropriate. This is in effect an instrumentation earth - not a safety earth.
Safety earth arrangements to the Sensor must be made as appropriate to local /
national standards.
2.6.3 Auxiliary Fault Signal - Terminals 12 &13
The controller incorporates an auxiliary FAULT input circuit. This may be
employed, for example, to integrate a failure / warning signal from an associated
local 24 Vdc power supply / battery charger. The circuit connection is both open &
short circuit fault monitored. The above diagram shows how both opening and
closing reporting contacts should be configured. If the circuit is not utilised then
the terminals should have a 10k resistor connected to blank off the indication /
warning.
2.6.4 Relay Contacts - Terminals 14 to 24
The controller provides three sets of repeat signal contacts. The above diagram
shows the contacts in their DE-ENERGISED condition. Alarm & Trip contacts are
normally de-energised; the fault contact is normally energised. The operation of
Alarm & Trip contacts may be programmed by means of the DIL switch.
2.6.5 Remote Reset Signal - Terminals 25 & 26
This input may be utilised for the connection of a local external push-button, or
for signalling from remote equipment.
2.6.6 Supply Connections - Terminals 27 to 31
Two terminals are provided for each supply pole.
It should be noted that the recommended EARTH connections are related to RFI
considerations and must not be taken as being compliant with any site SAFETY
EARTH requirements.
1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031
12345678910
11 10K
10K
TRIP ALARM FAULT
AUX. FAULT
I/P CONTACT
REMOTE
EXTERNAL /
RESET
PUSH BUTTON
+_
24 Vdc
SUPPLY
+_
SENSOR HEAD
+_4312
Detectors
AIR TEST
Sen Norm De-En Norm De-En Norm En
CONTROLLER
Fig. 6
shield / screen
Page 8 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

2.7 Series 5000 Blower Units
Where a suitable “on site” air supply is not readily available Patol 5000 Series air purge
units may be employed.
These devices are single and multistage centrifugal blowers that can be provided in a
variety of configurations that accommodate differing application requirements such as air
delivery volume / pressure, supply voltage and mounting arrangements.
Some units have an integral air filter. These filters, when fitted, are not intended to cope
with high dust environments (such as within coal conveyor housings) and the inlet should
be piped/ducted to a relatively clean air area.
The units are provided with a 2m flexible supply cable for connection at an adjacent
junction box.
Type 5040 and 5044 multistage blowers are shown below. For type 5051 single stage units
and other varieties within the range refer to separate datasheets.
As standard each blower is provided with a length of 45mm I/D hose for coupling inlet and
outlet to rigid ducting adaptors.
Patol Limited
Fig. 7 Type 5040
A B C D
264 (10.4”) 200 (7.87”) 167 (6.57”) 147 (5.79”)
Type 5044
Dimensional differences from Fig.7
A
B
C
D
OUTLET /
DISCHARGE
INLET
FILTER
Page 9 of 15Series 5000 - Manual 5010 / 5020
Type 5040 2 stage unit employed on most
applications.
Supply :- Available in 115/230 Vac 50/60 Hz
options.
Weight :- 5 kg
Delivery :- 5 l/s at 11 mBar - 10 l/s at 7.5 mBar
Size :- See drawings - Fig.7
Type 5044 4 stage unit employed with long duct
lengths.
Supply :- Options as above
Weight :- 7 kg
Delivery :- 5 l/s at 23.5 mBar - 10 l/s at 19 mBar
Size :- See table below
D1125 - Issue 2 - 1 December 2009

Patol Limited
3. INSTALLATION
3.1 Sensor Head
The angle and height of mounting determine the monitored width.
The example shown on the chart is for
a sensor mounted 0.8m above the
transit path at an angle of 30°. This
provides a maximum monitored width
of 1.3m which would be suitable for
most coal conveyors. The minimum
recommended angle is 30°. Should the
most practical mounting height (e.g.
1m) produce a wider view field than the
conveyor this is perfectly acceptable,
so long as the “overlap” on each side is
not so large that external hot targets,
such as vehicles on an adjacent
roadway, are within the units view.
3.2 Controller Cable
The Type 5010 Sensors are fitted with a 20mm gland as standard, which is suitable for the
flexible screened / shielded cable provided.
If the Controller is being mounted at a location “remote” from the Sensor, armored cable or
conduit may be employed, however this should terminate at an adjacent junction box. The
flexible controller cable should connect the Sensor to this JB in order to permit adjustments
to Sensor alignment. Any interposing cable must maintain the screen / shield connection.
On sites defined as “Hazardous Areas” it may be a requirement that all cables are installed
in conduit. In this case it is recommended that a short length of approved flexible conduit is
fitted between the Sensor Head and an adjacent junction box. The Sensor gland should be
replaced with an appropriate flexible conduit coupler which must be sealed with a suitable
conduit sealant, such as silicone rubber, in order to maintain the Purge Air pressure within
the enclosure.
Cable terminations at both Sensor and Controller are made at plug-in screw terminal
connectors with reference to Fig.6 in section 2.6.
This activity at the Sensor Head may be assisted by removal of the inner sensor module.
When re-fitting the Sensor lid it is essential that the air switch “pressure” tube is inserted
into the air inlet spigot such that the tube end lies in the input hose.
Refer to section 4.4 for further detail on air switch tube and sensor module removal.
Monitored Width
Angle
Height
Plane Of Conveyor
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5
Sensor Mountin
g
Hei
g
ht - m
1.3
30°
45°
55°
X°
Fig. 8
Fig. 9
Page 10 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

Patol Limited
3.3 Purge Air Supply
The Sensor unit is equipped with a spigot for connection to a flexible hose. The air supply
must be capable of delivering at least 5.0 ltrs/sec at this connection and maintain a
minimum pressure of 4.0 mBar (1.6” water gauge) in order to operate the sensor’s pressure
monitoring switch.
If an “on site” air supply is not available a Series 5000 Air Purge Unit should be employed.
These units are equipped with an easily removable and washable air filter, however these
filters are intended to preserve blower life in normal conditions. The blower should either be
installed outside the dirty/dusty area or the unit inlet piped to a clean air environment.
Intermediate rigid ducting is most readily achieved by the use of standard µPVC pipes and
fittings. 2 m of hose is provided with each purge unit for couplings at sensor & blower.
In coal handling plant applications twin conveyors may be required to be monitored.
A single blower may purge both sensors by employing a “T” branch in the air ducting.
In some applications the Air Purge Blower unit (APB) may need to be remote from the
Sensor. This may be due to the Sensor being situated at some distance from a “clean air”
environment; as in the reclaim tunnels of power station coal handling plants. Similarly, the
APB may need to be located in a “Safe Area” on sites with a “Hazardous” classification.
There are limits to the distance that any APB can deliver the required air to the Sensor
which are principally dependant on the APB specification and duct bore size. Other factors
such as the ducting inner wall surface characteristic and the air temperature/pressure also
have an effect.
5000 Series Air Purge units (APBs) are centrifugal blowers available in a variety of
multistage configurations. The standard unit is a two stage unit Type 5040, the second
most prevalent is the four stage Type 5044.
Whilst coupling hoses, reduction fittings and bends also have an effect, the following table
indicates typical limitations for smooth bore PVC ducting with the worst case air parameters
of minus 20°C at sea level pressure. (Warmer Air enables greater distance)
The table takes to account 2m flexible hose connections at Sensors, and 1m at the Blower.
CLEAN AIRPURGE AIR BLOWER UNITSENSOR AIR FLOW
DUCT LENGTH
Sensor
Qty Imp. Duct / Pipe Metric Duct / Pipe APB to Sensor Duct
O/D I/D O/D I/D 5040 2stg. 5044 4stg.
1 1-5/16 “ 1-1/4” 40mm 32mm 20m 60m
1-7/8” 1-1/2” 50mm 40mm 50m 140m
2-3/8” 2” 63mm 50mm 180m 520m
2
1-5/16 “ 1-1/4” 40mm 32mm 3m 12m
1-7/8” 1-1/2” 50mm 40mm 7m 28m
2-3/8” 2” 63mm 50mm 25m 100m
1 45mm 40m 110mFlexible Hose (Non-smooth)
5051 1stg.
n/a
10m
35m
n/a
n/a
n/a
7m
AIR INPUT
T Branch
SENSOR
SENSOR
BLOWER
UNIT
Fig. 10
Fig. 11
Page 11 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

4. COMMISSIONING
4.1 Cable Checks
The installation wiring should be checked for correct connection, continuity and insulation.
These checks should include:-
Sensor to Controller cable including screen / shield.
Controller supply cable.
Controller output cables. (alarm, trip, fault relay contact signals)
Controller input signal cables (aux. fault / remote reset)
Blower supply cable. (If appropriate)
4.2 Controller Set Up
The Controller program DIL switch must be set for the required operation.
In most applications the selected operation will be for both ALARM & TRIP to occur on
single channel detection. These outputs latching until manually reset.
It is recommended that initially, detection is set to the most sensitive level.
During maintenance / testing it may be of advantage to temporarily select the Auto Reset
mode. The associated reset / scan delay should be set for 1s.
The DIL switch setting for this configuration is:-
4.3 Power Up Procedure
4.3.1 Check that the air supply is connected and operational. If a 5000 Series blower is
employed this must be powered.
4.3.2 Check at the Sensor Head that purge air is blowing from the lens aperture.
Note : The purge air is monitored by a pressure switch located within the sensor
casing. If the air delivery is insufficient to operate the switch then the “Air Fault”
LED will be illuminated at stage 4.3.4 following. Reference should be made to
section 4.4.
4.3.3 Apply the controller electrical supply and check to be within limit - 20 to 30 Vdc.
4.3.4 Check that the Supply LED is illuminated and all other LEDs are Off.
4.3.5 Operate the Lamp Test push-button and check that all LEDs illuminate.
4.3.6 Momentarily remove the Purge Air Supply and check that the Air Fault LED is
illuminated and that the Fault output signal operates. (For duration of Air Supply
interruption).
4.3.7 Momentarily simulate an Auxiliary Fault input (if appropriate) and check that the
Aux Fault LED is illuminated and that the Fault output signal operates. (For
duration of the simulation).
4.3.8 Momentarily remove the electrical supply and check that the Supply LED is Off
and that the Fault output signal operates. (For duration of supply interruption).
4.3.9 Operate the Head Test push-button and check all Detector, Alarm & Trip LEDs
are illuminated and that Alarm & Trip output signals are operated.
4.3.10 Operate the Reset push button and check that the controller indications and
output signals return to normal. Repeat 4.3.9 and check remote reset operation if
appropriate.
Patol Limited
POLE 8 POLE 7 POLE 6 POLE 5 POLE 4 POLE 3 POLE 2 POLE 1
OFF OFF ON OFF ON ON OFF OFF
Page 12 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

4.4 Sensor Head & Purge Air Supply
The purge air is monitored by a pressure switch located within the sensor casing.
The switch is factory set to operate at approximately 3.74 mBar (1.5 inch water gauge).
The operation of the switch is dependant on the differential pressure between the air input
point to the Sensor and the external atmosphere.
Should an “Air Fault” be prevailing at stage 4.3.4, even though it is apparent that purge air
is present, the switch’s monitoring tubes should be checked for correct positioning.
Similarily, the switch setting may be “marginal” for the air flow/pressure being achieved on
the installation, in which case an adjustment can be made.
Checks & Adjustments
4.4.1 Remove the sensor lid to access the pressure switch and inner sensor module.
4.4.2 Check that both the “pressure” & “vacuum” tubes are fitted to the switch.
4.4.3 Check that the “vacuum” tube exits via the hole in the lower case face and is not
blocked.
4.4.4 When re-fitting the sensor lid the “pressure” tube must sit in the inlet spigot / hose.
4.4.5 Adjustment of the pressure switch may be undertaken by loosening the two
mounting screws and sliding the switch upward. A setting screw is located on the
lower face of the switch. The operation of the switch may be monitored with a
multimeter at the switch terminal.
4.4.6 Access to both switch and terminals may be improved by un-plugging the inner
sensor module after removal of the two retaining screws.
4.5 Hot Body Simulation Tests
A heat simulation test should be conducted. This testing may be facilitated by temporarily
setting the system to auto reset mode by placing DIL switch poles 3 & 4 Off.
In either Auto Reset or Latching mode the “window” of the Sensor Head will momentarily
illuminate Red when any IR Detector triggers.
The test is conducted by moving a “hot” (IR emitting) target into the view field of the Sensor
Head and observing / checking the consequential Alarm/Trip operation.
It is preferable that the “test target” is of sufficient size and temperature that the simulation
can be conducted at the plane of the monitored path (conveyor) such that the view field of
the Sensor can be validated. However, a smaller and cooler “test target” may be employed
so as to at least confirm basic operation of the sensor. It will be necessary with a “target” of
this nature to introduce it to the view field nearer to the Senor than the “monitored plane”.
If the location of the Sensor is classified as a “Hazardous Area” it will be necessary to make
special arrangements for this testing as the electrical / hot nature of the test simulation may
breach normal site regulations. It may even be that the test is precluded.
Refer to section 6.4 for information on “test targets”.
111
Patol Limited
PRESSURE TUBE
PRESSURE
SWITCH
&
MOUNTING
SCREWS
VACUUM TUBE
PRESSURE
SWITCH
PRESSURE
SWITCH
TERMINALS
INNER
SENSOR
MODULE
MODULE
RETAINING
SCREWS
CONTROLLER
CABLE
TERMINALS
Fig. 12
Page 13 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

Patol Limited
5. OPERATION
5.1 Normal
When the system is healthy only the green supply LED will be illuminated.
5.2 Alarm Condition
An Alarm condition will occur on abnormal Infra-red detection by the Sensor Head.
Normally this status will Latch On, however in special configurations the condition can be
set to momentary operation; auto resetting after a selected delay.
During the ALARM :-
• One or more Red DETECTOR indicators will be illuminated.
• The Red ALARM indicator will be illuminated.
• An ALARM output is signalled by means of a relay contact.
5.3 Trip condition
A Trip condition will occur on abnormal Infra-red detection by the Sensor Head.
Normally this status will be coincident with the ALARM condition and will Latch On.
In special configurations the condition can be set such as to require more detector triggers
than for ALARM. Similarly, the condition can be set to momentary operation; auto resetting
after a pre-selected delay.
During the TRIP :-
• One or more Red DETECTOR indicators will be illuminated.
• The Red TRIP indicator will be illuminated.
• A TRIP output is signalled by means of a relay contact.
5.4 Reset
Latched Alarm and Trip conditions may be normalized by :-
• Operation of the Controller’s integral Reset push-button.
• Operation of the remote reset push-button / signal (if implemented)
5.5 Fault Warning
The equipment continuously monitors for various fault conditions and is equipped with
indicators to identify the failure.
• Yellow AIR FAULT indicator illuminated - Sensor Head “purge air” failed.
• Yellow SEN FAULT indicator illuminated - Sensor Head disconnected.
• Yellow AUX FAULT indicator illuminated - Auxiliary equipment fault input signal.
• Green 24 V ON indicator extinguished - Electrical supply failed.
On any of the above conditions a FAULT output is signalled by means of a relay contact.
The indications and output will automatically normalize on rectification of the fault.
5.6 Lamp Test
Operation of the Controller’s integral Lamp Test push-button illuminates all indicators.
Output relay signals are not initiated on this test.
5.7 Head Test
Operation of the Controller’s integral Head Test push-button signals the Sensor Head and
simulates a detection condition on all circuits. The system will respond as if a true Alarm /
Trip condition has occurred, including operation of Alarm & Trip relay contact outputs.
Page 14 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009

Patol Limited
6. MAINTENANCE
6.1 General
It is recommended that a System Log Book / File is raised at the Commissioning Stage and
that the system configuration and initial settings recorded. These should include:-
• Operation configuration and Sensitivity - DIL switch set-up.
• Supply voltage.
Subsequently all system events should be recorded in the log.
These should include all maintenance activity, changes to settings, Fault warnings and
Alarm/Trip occurrences. (including cause and actions taken ).
An operational regime should be developed that includes both frequent inspection of the
Sensor Head for undue accumulation of dust, and to confirm air (blower) operation. The
regime should encompass use of the Lamp & Head Test controls to check basic operation.
In addition, the system should be subjected to a periodic service as defined in the
following.
6.2 Purge Air Filter
The blower filter should be removed and washed using a warm water soap solution.
The use of solvent cleaners is not recommended.
6.3 Fault Monitoring Functions
Tests should be conducted to confirm the correct operation of the fault monitoring circuits :-
6.3.1 Purge Air Pressure - Check as per 4.3.6
6.3.2 Auxiliary Fault - Check as per 4.3.7
6.3.3 Supply Failure - Check as per 4.3.8
6.4 Infra-red Detection
A heat simulation test should be conducted by moving a “hot” (IR emitting) target into the
view field of the Sensor Head and checking the consequential Alarm/Trip operation.
The controller may be temporarily set for auto reset mode by means of the DIL switch.
The “window” of the Sensor Head will momentarily illuminate Red on any Detector trigger.
It is preferable that the “test target” is of sufficient size and temperature to enable
simulation at the plane of the monitored path (conveyor) in order to validate the view field of
the Sensor . Smaller and/or cooler “test targets” may be used closer to the Sensor so as to
at least confirm basic operation of the Sensor.
Fig.5 in Section 2.4 indicates the relationship between the surface area and temperature
required for triggering at the various trip settings.
If the location of the Sensor is classified as a “Hazardous Area” it may be necessary to
make special arrangements for this testing as the electrical / hot nature of the test
simulation will breach normal regulations. It may even be that the test is precluded.
Potential “test targets” are :-
Type 5501 Infra-red Radiator - Test and Commissioning Platen - Patol product.
100W Lamp Bulb - (The Sensor responds to the glass temperature - not the visible light).
Domestic Flat Iron (smoothing iron).
Electrical or Catalytic soldering iron.
Note : Infra-red LED Torches are NOT suitable for testing 5000 Series equipment.
Patol Limited Rectory Road, Padworth Common, Berkshire, United Kingdom.
Tel: [phone] Fax: [phone]
Page 15 of 15Series 5000 - Manual 5010 / 5020 D1125 - Issue 2 - 1 December 2009