Spectrex SafEye Quasar 900 User manual

Quasar 900
Open Path Gas Detection System
User Guide
8200 Market Blvd, Chanhassen, MN 55317, USA
Phone: [phone] Fax: [phone]
Website: www.spectrex.net Email: [e-mail]

Legal Notice
The SPECTREX SafEye monitoring system described in this document is the property of Rosemount.
No part of the hardware, software or documentation may be reproduced, transmitted, transcribed, stored in a
retrieval system, or translated into any language or computer language, in any form or by any means, without
prior written permission of Rosemount.
While great efforts have been made to assure the accuracy and clarity of this document, Rosemount assumes no
liability resulting from any omissions in this document, or from misuse of the information obtained herein. The
information in this document has been carefully checked and is believed to be entirely reliable with all of the
necessary information included. Rosemount reserves the right to make changes to any products described herein
to improve reliability, function, or design, and reserves the right to revise this document and make changes from
time to time in content hereof with no obligation to notify any persons of revisions or changes. Rosemount does not
assume any liability arising out of the application or any use of any product or circuit described herein; neither
does it convey license under its patent rights or the rights of others.
TM888200 Rev. (Am), March 2018

TM888200 Rev. (Am), March 2018 v
Table of Contents
Table of Contents ............................................................................................ v
List of Figures ................................................................................................ ix
List of Tables.................................................................................................. ix
1About this Guide ...................................................................................... 10
1.1 Release History.....................................................................................11
1.2 Glossary and Abbreviations ....................................................................11
1.3 Notifications .........................................................................................12
2Product Overview .................................................................................... 15
3Technical Description .............................................................................. 17
3.1 Features ..............................................................................................17
3.2 Applications..........................................................................................18
3.3 Principles of Operation...........................................................................18
3.3.1 Definitions of Terms ........................................................................18
3.3.2 Spectral Fingerprint.........................................................................19
3.3.3 Optical Path ...................................................................................19
3.3.4 Microprocessor Based ......................................................................19
3.3.5 Gas Sensitivity ...............................................................................19
3.3.6 Gas Calibration ...............................................................................19
3.3.7 Flash Source ..................................................................................20
3.3.8 Heated Optics.................................................................................20
3.3.9 HART Protocol ................................................................................20
3.3.10 Modbus RS-485 ..............................................................................20
3.3.11 Tilt Mount ......................................................................................21
3.4 Product Certification ..............................................................................21
3.4.1 ATEX, IECEx...................................................................................21
3.4.2 FM/FMC .........................................................................................21
3.4.3 SIL-2.............................................................................................21
3.4.4 Functional Test ...............................................................................22
3.4.5 TR CU/EAC.....................................................................................22
3.4.6 Inmetro (UL) ..................................................................................22
3.5 Models and Types .................................................................................22
3.6 Description...........................................................................................24
3.6.1 Flash Source Unit............................................................................24

vi SafEye™ Open Path Gas Detection System Open Path Gas Detection System
3.6.2 Detector Unit..................................................................................25
4Operating Modes...................................................................................... 27
4.1 Operational Modes ................................................................................27
4.1.1 Normal Mode..................................................................................27
4.1.2 Maintenance Call Mode (3mA Output)................................................27
4.1.3 Fault Mode .....................................................................................27
4.1.4 Zero Calibration Mode (1mA Output) .................................................28
4.2 Visual Indicators ...................................................................................28
4.3 Output Signals......................................................................................29
4.3.1 0–20mA Current Output ..................................................................29
4.3.2 RS-485 Interface ............................................................................29
4.4 System Setup.......................................................................................30
4.4.1 Detection Function Programming ......................................................30
4.4.2 Detection Setup Function .................................................................30
4.4.3 Detector Default Setup ....................................................................31
5Technical Specifications........................................................................... 33
5.1 General Specifications ...........................................................................33
5.2 Electrical Specifications..........................................................................34
5.2.1 Power Consumption ........................................................................34
5.2.2 Electrical Input Protection ................................................................34
5.2.3 Electrical Outputs............................................................................34
5.3 Mechanical Specifications .......................................................................35
5.4 Environmental Specifications ..................................................................35
5.4.1 High Temperature ...........................................................................36
5.4.2 Low Temperature............................................................................36
5.4.3 Humidity........................................................................................36
5.4.4 Salt and Fog...................................................................................36
5.4.5 Water and Dust ..............................................................................36
5.4.6 Shock and Vibration ........................................................................36
5.4.7 Electromagnetic Compatibility (EMC) .................................................37
6Installation Instructions.......................................................................... 39
6.1 Introduction .........................................................................................39
6.2 General Considerations ..........................................................................39
6.2.1 Personnel.......................................................................................39
6.2.2 Required Tools................................................................................39
6.2.3 Site Requirements ..........................................................................39

TM888200 Rev. (Am), March 2018 vii
6.2.4 The Source and Detector .................................................................40
6.2.5 Tips for Selecting a Gas Detector Location .........................................40
6.2.6 Wiring ...........................................................................................40
6.3 Preparations for Installation ...................................................................40
6.3.1 General .........................................................................................40
6.3.2 Equipment .....................................................................................41
6.3.3 Unpacking the Product.....................................................................41
6.4 Certification Instructions ........................................................................42
6.4.1 General Instructions........................................................................42
6.4.2 Special Conditions for Safe Use.........................................................43
6.5 Conduit/Cable Installation ......................................................................43
6.6 Detector/Source Mounting......................................................................44
6.6.1 Tilt Kit ...........................................................................................44
6.6.2 Detector/Source Installation.............................................................44
6.7 Detector Wiring ....................................................................................44
6.8 Detector Terminal Wiring .......................................................................48
6.9 Flash Source Wiring...............................................................................48
6.9.1 Wiring ...........................................................................................48
6.9.2 Terminal Wiring ..............................................................................49
7Operating Instructions ............................................................................ 51
7.1 SafEye Operation ..................................................................................51
7.2 Alignment of Unit ..................................................................................51
7.3 Powering up the System ........................................................................52
7.4 Safety Precautions ................................................................................53
7.5 Signal Verification .................................................................................53
7.5.1 Signal Values Limitation...................................................................53
7.6 Zero Calibration ....................................................................................54
7.7 Functional Check...................................................................................55
8Maintenance Instructions ........................................................................ 57
8.1 General Maintenance .............................................................................57
8.2 Periodic Maintenance .............................................................................57
8.2.1 Routine Optical Surface Cleaning ......................................................57
8.2.2 Signal Verification ...........................................................................58
8.2.3 Functional Check of Unit ..................................................................58

viii SafEye™ Open Path Gas Detection System Open Path Gas Detection System
9Troubleshooting ...................................................................................... 59
Appendix A: Wiring Configurations ........................................................... 61
A.1 RS-485 Communication Network.............................................................64
Appendix B: Accessories ........................................................................... 65
B.1 Tilt Mount ............................................................................................65
B.2 Pole Mount (U-Bolt 4-5 inch) ..................................................................65
B.3 Pole Mount (U-Bolt 2-3 inch) ..................................................................65
B.4 Wall Mount...........................................................................................65
B.5 Commissioning Kit ................................................................................65
B.6 HART Handheld Diagnostic Unit ..............................................................65
B.7 HART Handheld Harness Kit....................................................................66
B.8 USB/RS-485 Harness Converter Kit .........................................................66
B.9 Mini Laptop Kit ...........................................Error! Bookmark not defined.
B.10 Sunshade.............................................................................................66
Appendix C: SIL-2 Features ...................................................................... 67
C.1 Safety Relevant Parameters ...................................................................67
C.2 General Conditions for Safe Use..............................................................67
Technical Support ......................................................................................... 70

TM888200 Rev. (Am), March 2018 ix
List of Figures
Figure 1: System P/N Definition of Quasar 900 23
Figure 2: P/N Definition of Quasar 900.................................................................24
Figure 3: Flash Source .......................................................................................25
Figure 4: Detector .............................................................................................26
Figure 5: Tilt Mount ...........................................................................................45
Figure 6: Detector and Tilt Mount Assembly..........................................................46
Figure 7: Detector with Cover Removed ...............................................................47
Figure 8: Source with Cover Removed .................................................................49
Figure 9: Magnetic Mode Selector........................................................................54
Figure 10: Detector Wiring Terminal ....................................................................61
Figure 11: Source Wiring Terminal ......................................................................62
Figure 12: 0–20mA Sink 4-Wire ..........................................................................63
Figure 13: 0–20mA Non-Isolated Sink 3-Wire .......................................................63
Figure 14: 0–20mA Source 3-Wire ......................................................................64
Figure 15: RS-485 Networking for Wiring Option 3 ................................................64
List of Tables
Table 1: Gas Concentrations Measurement Terms 18
Table 2: Model Numbers and Installation Distances ...............................................22
Table 3: Detector LED Indications .......................................................................28
Table 4: Source LED Indications..........................................................................29
Table 5: Standard (default) 0–20mA Current for the Gas Channel ...........................29
Table 6: Detector Default Setup ..........................................................................31
Table 7: Source Default Setup ............................................................................32
Table 8: Detection Distance Range ......................................................................33
Table 9: Detector and Source Maximum Power Consumption ..................................34
Table 10: Tools .................................................................................................39
Table 11: Tilt Mount Kit......................................................................................44
Table 12: Wiring Options....................................................................................48
Table 13: Flash Source Wiring Options .................................................................49
Table 14: Maintenance Channel Limitation Values .................................................53
Table 15: Troubleshooting ..................................................................................59

About this Guide
10 SafEye™ Open Path Gas Detection System User Guide
1About this Guide
This manual describes the Quasar 900 Open-Path Gas Detection System and its
features and provides instructions how to install, operate, and maintain the
detector.
Note:
This user guide should be carefully read by all individuals who have or
will have responsibility for using, maintaining or servicing the product.
This guide includes the following chapters and appendices:
•Chapter 1, About this Guide, details the layout of the guide, includes the
release history, a glossary and abbreviations, and explains how notifications
are used in the guide.
•Chapter 2, Product Overview, provides a general introduction and overview
of the product and the guide, with a brief description of its content.
•Chapter 3, Technical Description, describes the detector’s theory of
operation.
•Chapter 4, Operating Modes, describes the detector’s operation modes,
user interface and indications.
•Chapter 5, Technical Specifications, describes the detector’s electrical,
mechanical and environmental specifications.
•Chapter 6, Installation Instructions, describes how to install the detector,
including wiring and mode settings.
•Chapter 7, Operating Instructions, describes the operating instructions
and power-up procedures.
•Chapter 8, Maintenance Instructions, describes the maintenance and
support procedures.
•Chapter 9, Troubleshooting, describes the solutions to problems that may
arise with the detector.
•Appendix A, Wiring Configurations, provides wiring diagrams for
installation.
•Appendix B, Accessories, provides a list of accessories available for the
Quasar 900 Open-Path Gas Detection System.
•Appendix C, SIL-2 Features, details the special conditions for compliance
with the requirements of EN 61508 for SIL-2.

About this Guide
TM888200 Rev. (Am), March 2018 11
1.1 Release History
Rev
Date
Revision History
Prepared by
Approved by
6
February
2013
First Release
Ian Buchanan
Eric Zinn
7
June 2013
Second release
Ian Buchanan
Eric Zinn
8
August 2013
Third Release
Ian Buchanan
Eric Zinn
9
January 2014
Fourth Release
Ian Buchanan
Eric Zinn
10
August 2014
Fifth Release
Ian Buchanan
Eric Zinn
11
January 2015
Sixth Release
Ian Buchanan
Eric Zinn
12
January 2017
Seventh Release
Jay Cooley
Ian Buchanan
13
February
2017
Eighth Release
Jay Cooley
Ian Buchanan
Am
March 2018
Ninth Release
Michal Heller
Udi Tzuri
1.2 Glossary and Abbreviations
Abbreviation/Term
Meaning
Analog Video
Video values are represented by a scaled signal
ATEX
Atmosphere Explosives
AWG
American Wire Gauge
BIT
Built-In-Test
CMOS
Complementary Metal-Oxide Semiconductor image
sensor
Digital Video
Each component is represented by a number
representing a discrete quantization
DSP
Digital Signal Processing
EMC
Electromagnetic Compatibility
EMI
Electromagnetic Interference
EOL
End of Line
FOV
Field of View
HART
Highway Addressable Remote Transducer –
communications protocol
IAD
Immune at Any Distance
IECEx
International Electro-Technical Commission
Explosion
IP
Internet Protocol
IPA
Isopropyl Alcohol
IR
Infrared
IR3
Refers to the 3 IR sensors in the VID

About this Guide
12 SafEye™ Open Path Gas Detection System User Guide
Abbreviation/Term
Meaning
JP5
Jet Fuel
LED
Light Emitting Diode
MODBUS
Serial communications protocol using Master-Slave
messaging
N/A
Not Applicable
N.C.
Normally Closed
NFPA
National Fire Protection Association
N.O.
Normally Open
NPT
National Pipe Thread
NTSC
National Television System Committee (a color encoding
system)
PAL
Phase Alternation by Line (a color encoding
system)
P/N
Part Number
RFI
Radio Frequency Interference
RTSP
Real Time Streaming Protocol
SIL
Safety Integrity Level
UNC
Unified Coarse Thread
VAC
Volts Alternating Current
1.3 Notifications
This section explains and exemplifies the usage of warnings, cautions, and notes
throughout this guide:
Warning:
This indicates a potentially hazardous situation that could result in
serious injury and/or major damage to the equipment.
Caution:
This indicates a situation that could result in minor injury and/or
damage to the equipment.

About this Guide
TM888200 Rev. (Am), March 2018 13
Note:
This provides supplementary information, emphasizes a point or
procedure, or gives a tip to facilitate operation.

Product Overview
TM888200 Rev. (Am), March 2018 15
2Product Overview
The SafEye Quasar 900 IR Open-Path Gas Detector employs an advanced Xenon
Flash Source and integrated electronics package, both of which are encased in
improved stainless steel housings, which provide high quality and performance,
fast response, and line-of-sight gas monitoring. The complete SafEye system is
backed by a 3-year warranty, and the Xenon Flash source bulb has a 10-year
warranty.
The Quasar 900 detects ambient combustible gases over a path length of up to
660ft/200m, even in harsh environments where dust, fog, rain, snow, or
vibration can cause a high reduction of signal. The SafEye Quasar 900 can
maintain operation in up to 90% signal obscuration and ±0.5 degree of
misalignment.
The Quasar 900 is manufactured only from stainless steel, with a heated optical
window to improve performance in ice, snow, and condensation conditions. The
programmable functions are available through a RS-485 or HART port used with
host software supplied by SPECTREX, and a standard PC or IS handheld unit.
The Quasar source and detector unit enclosures are ATEX and IECEx approved
Exd flameproof with an integral segregated rear and an Exe terminal
compartment, which avoids exposure of the sensors and electronics to the
surrounding environment. The detector also has a plug interface for connection to
a handheld PC or HART unit, which meets intrinsically safe standards. Hence the
combined approval:
Ex II 2(2) G D
Ex db eb ib [ib Gb] IIB+H2 T4 Gb
Ex tb IIIC T135°C Db
Ta=–55°C to +65°C
This manual provides a full description of the detector and its features. It includes
instructions on the installation, operation, and maintenance of the detector.
•To use the WinHost software to change the required functions, and for a
description of its maintenance, please refer to Manual TM 888050.
To use the HART Protocol to change the required functions and for a description
of its maintenance, please refer to Manual TM 888030. To set functions, the
HART can be connected on the 0–20mA line or through the IS port.
Warning:
The source and detector are not field-repairable due to the meticulous
alignment and calibration of the sensors and the respective circuits.
Do not attempt to modify or repair the internal circuits or change their
settings, as this will impair the system's performance and void the
SPECTREX product warranty.

Technical Description
TM888200 Rev. (Am), March 2018 17
3Technical Description
3.1 Features
•Long-range gas detection of up to 660ft/200m
•Simultaneous detection of C1-C8 flammable gases
•High sensitivity and fast response to hydrocarbon gases
•Heated optics to improve performance in ice, condensation, and snow
conditions
•Continuous operation in extreme or harsh environmental conditions
•Solar blind and immune to industrial environments
•Withstands extreme vibrations
•Standard 0–20mA output
•“Maintenance Call Mode” (3mA)
•HART Protocol: Communication Protocol
•RS-485 Output Modbus compatible with PC Communication Network for a
maximum of 247 systems
•Simple 1-person installation, alignment, and calibration
•ATEX and IECEx approved per:
Ex II 2(2)G D
Ex db eb ib [ib Gb] IIB+H2 T4 Gb,
Ex tb IIIC T135°C Db
Ta=–55°C to +65°C
•FM/FMC approved per:
Class I Div. 1 Group B, C, and D;
Class II/III Div. 1 Group E, F, and G
•TR CU/EAC approved per:
1Ex db eb [ib Gb] IIB + H2 T4 Gb X
Ex tb IIIC T135°C Db X
–55°C ≤ Ta ≤ +65°C
•TUV approved per SIL-2 requirements
•Inmetro (UL) approved
•Functional tested by FM per EN60079-29-4 and approved per FM 6325
•Programmable configuration via the handheld unit

Technical Description
18 SafEye™ Open Path Gas Detection System User Guide
•Fast connection to IS-approved handheld diagnostic/calibration unit
•A 3-year warranty for the complete SafEye system
•A 10-year warranty for the Xenon Flash bulb
3.2 Applications
The Quasar 900 system can be used to monitor flammable gas concentration in
various applications, such as:
•Petrochemical, pharmaceutical, and other chemical storage and production
areas
•Flammable and toxic chemical storage sites, and hazardous waste disposal
areas
•Refineries, oil platforms, pipelines, refueling stations, and fuel storage
facilities
•Hazardous loading docks, transportation depots, and shipping warehouses
•Engine rooms
•Compressor and pumping stations
•Test cells
•LNG-LPG Systems
•Offshore Floating Production Storage and Shipping vessels (FPSO), and fixed
oil rigs
3.3 Principles of Operation
The Quasar system detects gases through dual-spectral range monitoring,
analyzing the absorption of radiation caused by gases in the atmosphere, and
comparing the ratio to background atmospheric absorption.
3.3.1 Definitions of Terms
The following list defines gas concentration measurement terms that are used in
this manual:
Table 1: Gas Concentrations Measurement Terms
Term
Description
LEL
Lower Explosive Limit: The minimum concentration of
a substance (gas/vapor) in air mixture that can be
ignited. This mixture is different for every gas/vapor,
measured in % of LEL.
LEL.m
Integral of Concentration in LEL units (1 LEL = 100%
LEL) and the operation distance in meters (m).

Technical Description
TM888200 Rev. (Am), March 2018 19
3.3.2 Spectral Fingerprint
Each hazardous material is detected at a specific wavelength selected according
to its specific spectral absorption or “fingerprint.” The detection process involves
2 separate filters: one transmitting radiation that is absorbed by a particular gas,
and one that is not sensitive to it.
3.3.3 Optical Path
The presence of hazardous airborne vapors, gases, or aerosols in a monitored
area is detected when the defined substance crosses/enters the optical path
between the radiation source unit and the detector.
Hazardous gases/vapors present in the atmosphere cause absorption of the
radiation pulse at specific wavelengths in the optical path between the radiating
source and the detector unit. This causes a change in the signal intensity
received by the detector, which is translated into an output related to the
detector’s measuring scale.
The system analyzes the defined open path at the spectral bands specific to the
materials being monitored. The Automatic Gain Control (AGC) unit compensates
for environmental disturbances such as fog and rain, through a constant
comparison with its dual spectral beam.
3.3.4 Microprocessor Based
The incoming signals are analyzed by the built-in microprocessor. A sophisticated
mathematical algorithm calculates the various functions of the detected signal
thresholds. Statistics, ratio algorithms, data communications, diagnostics, and
other functions are performed.
3.3.5 Gas Sensitivity
The SafEye Quasar 900 Model uses wavelengths around the 2.3µ spectral band to
measure air flammability potential between the source and detector. At this
wavelength, all hydrocarbon materials have an absorption peak. This enables the
detector to achieve regular sensitivity of 0–5 LEL.m.
The Quasar 900 detects hydrocarbon gases including methane, ethylene,
propane, ethane, butane, and others.
3.3.6 Gas Calibration
The Quasar 900 has 3 calibrations that can be changed by function setup:
•Gas 1 –100% methane
•Gas 2 –100% propane
•Gas 3 –100% ethylene
The full scale of methane and propane is 5 LEL.m, while the full scale of ethylene
is 8 LEL.m. Gas calibration is available to LEL values defined by NFPA 325 and
IEC 60079-20. Instruments certified to ATEX/IECEx, EAC, and Inmetro are
calibrated to LEL values defined by the IEC standard, while configurations
certified to FM/FMC are calibrated per the NFPA norm.
The full scale of methane and propane is 5 LEL.m.

Technical Description
20 SafEye™ Open Path Gas Detection System User Guide
3.3.7 Flash Source
The Xenon Flash Source was originally introduced in the first SafEye development
and was designed to overcome false alarms, which were experienced by early
generations of the open path system. The new SafEye Quasar 900 employs the
latest generation of flash bulbs to provide even more power and an extended
operation life of up to 10 years.
3.3.8 Heated Optics
SafEye Quasar includes heated optics for the detector and source. To improve
performance in conditions where there is ice, condensation, or snow, the heater
increases the temperature of the optical surface by 5–8°F / 3–5°C above the
ambient temperature. The heated optics are configured to automatically operate
when the change in temperature requires heating (default).
However, the heated optics can be defined as one of the following modes:
•Not operated (not an option on the source unit)
•On continuously
•Automatic, per temperature change (default)
See System Setup, page 30.
When operated “per temperature change,” the user can define the start
temperature below which the window will be heated (default is 41°F/5°C). This
temperature can be defined from 32°F/0°C –122°F/50°C. Heating stops when
the temperature is 27°F/15°C above the start temperature.
3.3.9 HART Protocol
The Quasar 900 uses the HART Protocol.
HART Communication is a bi-directional industrial field communication protocol
used to communicate between intelligent field instruments and host systems.
HART is the global standard for smart instrumentation, and the majority of smart
field devices installed in plants worldwide are HART-enabled.
HART technology is easy to use and very reliable.
Through the HART connection, the SafEye is able to perform:
•Detector setup
•Detector troubleshooting
•Detector health and status
For more details, refer to Manual TM888030.
HART communication can be connected on the 0–20mA line or through the IS
connection, with a standard handheld unit loaded with the host software and
attached by a special harness.
3.3.10 Modbus RS-485
For more advanced communications, the Quasar 900 has a RS-485 Modbus-
compatible output that provides data communication from a network (up to 247