Spectrex SharpEye 40/40R User manual

Model 40/40R
Single IR
Flame Detector
User Guide
FM, CSA Approved:
Class I Div. 1 Groups B, C, D
Class II/III Div. 1 Groups E, F, G
ATEX and IECEx Approved
Ex II 2 GD, EExde IIB+ H2 T5 (75°C)
Document ref: TM 40/40R, Rev (1) September 2008
218 Little Falls Rd., Cedar Grove, NJ 07009, USA
Phone: [phone] Fax: [phone]
Web-Site: www.spectrex-inc.com; Email: [e-mail]

ii

iii
Legal Notice
The SharpEye Optical Flame Detector described in this document is the property of Spectrex,
Inc.
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 Spectrex, Inc.
While great efforts have been made to assure the accuracy and clarity of this document,
Spectrex, Inc. 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.
Spectrex, Inc. 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. Spectrex, Inc. 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
Warning: This manual should be read carefully by all individuals
who have or will have responsibility for using, maintaining or
servicing the product.
The Detector is 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, Inc. Product warranty.
Warranty
SPECTREX INC. Agrees to extend to Purchaser/Distributor a warranty on the SPECTREX
supplied components of the SharpEye products. SPECTREX warrants to Purchaser/Distributor
that the products are free from defects in materials and workmanship for a period of five (5)
years, commencing with the date of delivery to Purchaser/Distributor. SPECTREX expressly
excludes damage incurred in transit from the factory or other damage due to abuse, misuse,
improper installation, or lack of maintenance or “Act of God” which are above and beyond its
control. SPECTREX will, upon receipt of any defective product, transportation prepaid, repair or
replace it at its sole discretion if found to have been defective when shipped. Said repair or
replacement is SPECTREX‟S sole liability under this warranty and SPECTREX‟S liability shall be
limited to repair or replacement of the component found defective and shall not include any
liability for consequential or other damages. The customer is responsible for all freight charges
and taxes due on shipments both ways. This warranty is exclusive of all other warranties
express or implied.

iv
Release History
Rev
Date
Revision History
Prepared by
Approved by
0
July 15, 2008
First Release
Ian Buchanan
Eric Zinn
1
September 23, 2008
Second Release
Ian Buchanan
Eric Zinn

v
About this Guide
This guide describes the SharpEye Model 40/40R Single IR Flame Detector
and its features and provides instructions on how to install, operate and
maintain the detector.
This guide includes the following chapters and appendixes:
Chapter 1, Introduction, provides a general overview of the product,
principles of operation, and performance considerations.
Chapter 2, Installing the Detector, describes how to install the
detector including preparations before installation, wiring and mode
settings.
Chapter 3, Operating the Detector, describes how to power-up and
test the detector. The chapter also lists the safety precautions you
should take when operating the detector.
Chapter 4, Maintenance and Troubleshooting, describes basic
maintenance procedures, and troubleshooting and support procedures.
Appendix A, Technical Specifications: Lists the detector‟s technical
specifications.
Appendix B, Wiring Instructions, lists the wiring instructions for
connecting the detector and also provides examples of typical wiring
configurations.
Appendix C, RS-485 Communication Network, provides an overview
of the RS-485 communications network.
Appendix D, Accessories, describes the accessories available for the
detector.
Appendix E, SIL-2 Features, describes the special conditions to
comply with the requirements of EN 61508 for SIL 2 according to TUV.

vi Abbreviations and Acronyms
Abbreviations and Acronyms
Abbreviation
Meaning
ATEX
Atmosphere Explosives
AWG
American Wire Gauge
BIT
Built In Test
EMC
Electromagnetic Compatibility
EOL
End of Line
FOV
Field of View
HART
Highway Addressable Remote Transducer-
communication protocol
IAD
Immune at Any Distance
IECEx
International Electrotechnical Commission Explosion
IPA
Isopropyl Alcohol
IR
Infrared
JP4
Jet Fuel
Latching
Refers to relays remaining in the ON state even after
the ON condition has been removed
LED
Light Emitting Diode
LPG
Liquefied Petroleum Gas
mA
MilliAmps (0.001 amps)
MODBUS
Master-slave messaging structure
N.C.
Normally Closed
N.O.
Normally Open
N/A
Not Applicable
NFPA
National Fire Protection Association
NPT
National Pipe Thread
SIL
Safety Integrity Level
UNC
Unified Coarse Thread
VAC
Volts Alternating Current

vii
Table of Contents
Model 40/40R Single IR Flame Detector User Guide ........................................ i
Legal Notice....................................................................................................iii
Warranty........................................................................................................iii
Release History ...............................................................................................iv
About this Guide.............................................................................................. v
Abbreviations and Acronyms .............................................................................vi
1Introduction .............................................................................................. 1
1.1 Overview .............................................................................................. 1
1.2 Model and Types.................................................................................... 2
1.3 Features and Benefits ............................................................................. 4
1.4 Principles of Operation............................................................................ 4
1.4.1 Fire Detection Principles of Operation ................................................. 4
1.4.2 Heated Optics.................................................................................. 5
1.4.3 HART Protocol ................................................................................. 5
1.4.4 RS-485 Modbus ............................................................................... 5
1.4.5 Product Certification......................................................................... 6
1.5 Performance Considerations .................................................................... 7
1.5.1 Detection Sensitivity ........................................................................ 7
1.5.2 Cone of Vision ................................................................................. 8
1.5.3 False Alarm Prevention ..................................................................... 9
1.5.4 Visual Indicators .............................................................................10
1.5.5 Output Signals................................................................................11
1.5.6 Detector Status ..............................................................................12
1.5.7 Auxiliary Relay as End-of-Line Resistor ..............................................13
1.6 Internal Detector Tests ..........................................................................13
1.6.1 Continuous Feature Test ..................................................................13
1.6.2 Built-In-Test (BIT) ..........................................................................14
2Installing the Detector ............................................................................ 17
2.1 General Guidelines ................................................................................17
2.2 Unpacking the Product...........................................................................18
2.2.1 Checking the Product Type...............................................................18
2.3 Required Tools......................................................................................18
2.4 Certification Instructions ........................................................................20

viii Table of Contents
2.5 Installation Cables ................................................................................21
2.5.1 Conduit Installation.........................................................................21
2.6 Installing the Tilt Mount (Part No. 40/40-001) ..........................................22
2.6.1 Tilt Mount Specifications ..................................................................23
2.6.2 Tilt Mount Assembly ........................................................................23
2.7 Connecting the Detector ........................................................................25
2.7.1 Verifying the Detector Wiring ...........................................................26
2.8 Configuring your Detector ......................................................................27
2.8.1 Alarm Delay ...................................................................................28
2.8.2 Address Set-up...............................................................................28
2.8.3 Function Set-up ..............................................................................29
2.8.4 Heated Optics.................................................................................29
3Operating the Detector ............................................................................ 31
3.1 Powering Up.........................................................................................31
3.2 Safety Precautions ................................................................................32
3.2.1 Default Function Settings .................................................................32
3.3 Testing Procedures................................................................................34
3.3.1 Automatic BIT Test .........................................................................34
3.3.2 Manual BIT Test..............................................................................34
3.3.3 Testing with Fire Simulator Model 20/20-312 .....................................34
4Maintenance and Troubleshooting ........................................................... 37
4.1 Maintenance.........................................................................................37
4.1.1 General Procedures .........................................................................37
4.1.2 Periodic Procedures .........................................................................38
4.1.3 Keeping Maintenance Records ..........................................................38
4.2 Troubleshooting....................................................................................39
Appendices.................................................................................................... 41
ATechnical Specifications........................................................................... 43
A.1 Electrical Specifications..........................................................................43
A.2 Mechanical Specifications .......................................................................45
A.3 Dimensions ..........................................................................................45
A.4 Weight.................................................................................................46
A.5 Environmental Specifications ..................................................................46
BWiring Instructions.................................................................................. 49
B.1 General Instructions for Electrical Wiring..................................................49
B.2 Typical Wiring Configurations .................................................................51

Table of Contents ix
CRS-485 Communication Network ............................................................. 55
C.1 RS-485 Overview ..................................................................................55
DAccessories.............................................................................................. 57
D.1 Long Range Fire Simulator .....................................................................57
D.1.1 Unpacking......................................................................................58
D.1.2 Operating Instructions.....................................................................58
D.1.3 Range ...........................................................................................59
D.1.4 Charging the Battery .......................................................................59
D.1.5 Technical Specifications ...................................................................60
D.2 Tilt Mount P/N 40/40-001 ......................................................................60
D.3 Weather Protection –P/N 777163 ...........................................................61
D.4 Laser Detection Coverage Pointer –P/N 777166 .......................................62
D.5 Air Shield –P/N 777161.........................................................................62
ESIL-2 Features ......................................................................................... 63
E.1 40/40R Optical Flame Detector ...............................................................63
E.1.1 Safety Relevant Parameters .............................................................63
E.1.2 Guidelines for Configuring, Installing, Operating and Service ................63
Technical Support...........................................................................................66

x List of Figures
List of Figures
Figure 1: Field of View ........................................................................................ 8
Figure 2: Indication LED.....................................................................................10
Figure 3: Detector with Tilt Mount .......................................................................22
Figure 4: Tilt Mount Assembly.............................................................................23
Figure 5: Tilt Mount Assembly (dimensions in mm and inches)................................24
Figure 6: Detector with Cover Removed ...............................................................25
Figure 7: Wiring Terminals .................................................................................51
Figure 8: Typical Wiring for 4-Wire Controllers (Using Option 1 or 2 Wiring) .............52
Figure 9: 0-20mA Wiring (Sink) 4-Wire Connection ...............................................53
Figure 10: 0-20mA Wiring (Source) 3-Wire Connection ..........................................53
Figure 11: RS-485 Networking............................................................................55
Figure 12: SharpEye Long Range Fire Simulator 20/20-312....................................57
Figure 13: 40/40R Detector Target Point ..............................................................58
Figure 14: Tilt Mount .........................................................................................60
Figure 15: Weather Protection ............................................................................61
Figure 16: Laser Detection Coverage Pointer ........................................................62
Figure 17: Air Shield..........................................................................................62

List of Tables xi
List of Tables
Table 1: Wiring Options ...................................................................................... 3
Table 2: Fuel Sensitivity Ranges........................................................................... 8
Table 3: Immunity to False Alarm Sources ............................................................ 9
Table 4: LED Indications ....................................................................................10
Table 5: Available Output Types..........................................................................11
Table 6: Detector Status ....................................................................................12
Table 7: Output Signals versus Detector State ......................................................12
Table 8: Results of a Successful BIT ....................................................................15
Table 9: Results of an Unsuccessful BIT ...............................................................15
Table 10: Results of a Successful Manual BIT........................................................16
Table 11: Results of an Unsuccessful Manual BIT ..................................................16
Table 12: Tools .................................................................................................18
Table 13: USA Version .......................................................................................23
Table 14: European Version................................................................................23
Table 15: Model 40/40R Wiring Options ...............................................................26
Table 16: Functions ...........................................................................................29
Table 17: Default Function Values .......................................................................32
Table 18: Results of Successful Fire Simulator Test ...............................................35
Table 19: Troubleshooting Table .........................................................................39
Table 20: Contact Ratings ..................................................................................44
Table 21: 20 mA Current Output .........................................................................44
Table 22: Maximum DC resistance at 68°F (20ºC) for copper wire...........................49
Table 23: Wiring Length in Feet (Meter) ...............................................................50
Table 24: Wiring Connections .............................................................................52

xii List of Tables

Overview 1
1Introduction
➣In this chapter…
Overview
page 1
Model and Types
page 2
Features and Benefits
page 4
Principles of Operation
page 4
Performance Considerations
page 6
Internal Detector Tests
page 13
1.1 Overview
The 40/40R Single IR Flame Detector detects hydrocarbon-based fuel and
gas fires using advanced flame tools.
All 40/40 Series Detectors include a heated optical window for improved
performance in icing, snow and condensation conditions.
Detection performance can be easily adapted to all environments,
applications and requirements, by changing the detector‟s configuration
parameters. Adjusting these parameters, as well and performing other
maintenance and monitoring tasks, is possible by means of RS485-based
Modbus communication or HART communication (in models with 0-20mA
output).
The detector enclosure is ATEX certified EExd flameproof with an integral,
segregated, rear, EExe terminal compartment (avoiding exposure of the
sensors and electronics to surrounding environment), hence the combined
approval EExde IIB + H2 T5 (75°C) or T4 (85°C).
The SharpEye 40/40R Detectors are designed to operate as a stand-alone
unit directly connected to an alarm system or an automatic fire
extinguishing system. The detector can also be a part of a more complex
system, where many detectors and other devices are integrated through a
common control unit.

SharpEyeTM Single IR Flame Detector User Guide
2 Model and Types
1.2 Model and Types
The 40/40R is provided in various configurations depending on:
Wiring options
Temperature ranges
Type of cable entries
Housing type
Required approval
The configuration detail is included in the product part number on the
product label and takes the form: 40/40R XXXXX, where XXXXX defines the
model according to the above requirements.
To modify the default or pre-ordered configuration and perform
maintenance tasks, please refer to the HART Protocol TM777030, the
RS-485 Manual TM 777050 or TM777060.
The Part Numbers are defined as:
40/40R X XX X X
Ex Approval
Wiring
Configuration
Temperature
Electrical
Entries
Housing
F –FM / CSA
C - ATEX / IECEx
1 - 75°C
2 - 85°C
1 - M25
2 - ¾" NPT
See Table 1
S - Stainless Steel
A - Aluminum
Table 1 describes the wiring options in detail.

TM 40/40R, Rev. (1) September 2008
Model and Types 3
Table 1: Wiring Options
Wiring
Option
Connections Provided
1
Power
Manual
BIT
Fault
Relay
N.C.
Alarm
Relay
N.O.
4-20mA
Sink
RS-485
2
Power
Manual
BIT
Fault
Relay
N.C.
Alarm
Relay
N.O.,
N.C.
4-20mA
Source
RS-485
3
Power
Manual
BIT
Fault
Relay
N.O.
Alarm
Relay
N.O.,
N.C.
4-20mA
Source
RS-485
4
Power
Manual
BIT
Fault
Relay
N.C.
Alarm
Relay
N.O.
Auxiliary
N.O.
RS-485
5
Power
Manual
BIT
Fault
Relay
N.O.
Alarm
Relay
N.O.
Auxiliary
N.O.
RS-485
Note: Wiring Option 1 is Default. The mA „Sink‟ output can be altered to
„Source‟ type with a link between Terminals 1 and 8. No other wiring options
can be changed on site.
For example, product number 40/40R-321SC has the following options:
Wiring Option: 3 (Power, Manual BIT, RS-485, 0-20mA (Source) with
HART Protocol, Fault Relay (N.O.), Alarm Relay (N.O, N.C.))
Temperature Range: 2 (85°C)
Cable Entry: 1 (M25)
Housing: S (Stainless Steel)
Approval: C (ATEX, IECEx)
Note: Check your specific part numbers against the information in Checking
the Product Type on page 18.

SharpEyeTM Single IR Flame Detector User Guide
4 Features and Benefits
1.3 Features and Benefits
Single IR Channel: Between 4.4 - 4.6 microns.
Built In Test (BIT): Manual and Automatic (see Built-In-Test (BIT) on
page 14).
Heated Window: Prevents effects of icing, snow, condensation.
Electrical Interface:
Dry contact relays
Communication network RS-485
0-20mA output
HART Protocol: Communication protocol (see HART Protocol on page 5).
EExde: Integral junction box for easy wiring.
SIL-2: TÜV Approved.
Hazardous Area Certification: ATEX, IECEx,FM, CSA.
EN54-10 : Approved LPCB (BRE, UK).
1.4 Principles of Operation
This section describes the 40/40R principles of operation and includes:
Fire Detection Principles of Operation, page 4
Heated Optics, page 5
HART Protocol, page 5
RS-485 Modbus, page 5
Product Certification, page 6
1.4.1 Fire Detection Principles of Operation
The Single IR flame detector provides early warning of flaming fires
involving organic materials (hydrocarbon fuels and vapors). These fires emit
strong IR radiation in the 4.4-micron spectral band where the CO2(the main
combustion product of any organic substance) has a unique spectral peak.
This detector contains an advanced infrared sensor and optical filter that
provides maximum sensitivity to the CO2emission spectral band at 4.4
micron.
The detector is designed to withstand “harsh” environment conditions, for
example; extreme temperatures, high humidity and vibrations.

TM 40/40R, Rev. (1) September 2008
Principles of Operation 5
1.4.2 Heated Optics
The SharpEye 40/40 Flame Detector uses heated optics. The heater
increases the temperature of the optical surface by 5°F - 8°F (~3°C - 5°C)
above the ambient temperature to improve performance in icing,
condensation and snow conditions.
The heated optics can be set to one of the following:
Not operated
On continuously
Automatic (Auto), per temperature change (default): you can define the
start temperature below which the window is heated. (The default
temperature is 68°F (20°C).) This temperature can be defined between
32°F (0°C) to 122°F (50°C). The heating stops when the temperature is
27°F (15°C) above the start temperature.
For more information, see Configuring your Detector on page 27.
1.4.3 HART Protocol
The SharpEye 40/40 Flame Detector 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 process 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, you are able to perform:
Detector set-up
Detector troubleshooting
Detector health and status
For more details, refer to the HART Manual TM 777030.
1.4.4 RS-485 Modbus
For more advanced communications, the 40/40 detector has an RS 485
Modbus-compatible output that provides data communication from a
network (up to 247 detectors) to a host computer or universal controller for
central monitoring. This feature allows for reduced installation costs, easy
maintenance and local or remote diagnostic tools.

SharpEyeTM Single IR Flame Detector User Guide
6 Principles of Operation
1.4.5 Product Certification
The 40/40R Flame Detectors have the following certifications:
ATEX, IECEx, page 6
FM, CSA, page 6
SIL-2 Approved, page 6
EN54-10, page 6
1.4.5.1 ATEX, IECEx
The 40/40R Optical Flame Detector is certified to:
ATEX Ex II 2 GD per SIRA 07ATEX 1149 and IECEx SIR. 07.0085.
EExde IIB + H2:
T5 Ambient Temp. -55°C to +75°C.
T4 Ambient Temp. -55°C to +85°C.
This product is suitable to use in hazardous zones 1 and 2 with IIB + H2gas
group vapors present.
1.4.5.2 FM, CSA
The 40/40R Optical Flame Detector is certified to FM and CSA Explosion
Proof per:
Class I, Division 1, Groups B, C and D, T5 Ta = 85°C.
Dust Ignition Proof –Class II/III Division 1, Groups E, F and G.
Ingress Protection –IP67, IP66, NEMA 250 Type 6P.
For more details see Report Project ID3029553.
1.4.5.3 SIL-2 Approved (TÜV)
The 40/40R Optical Flame Detector is certified to SIL-2 requirement per IEC
61508.4, Chapter 3.5.12.
The alert condition according to SIL-2 can be implemented by:
Alert signal via 0-20mA current loop.
or
Alert signal via alarm relay and fault relay.
For more details and guidelines for configuring, installing, operating and
service –see SIL-2 Features on page 63 and TÜV Report No.
968/EZ348.00/009.
1.4.5.4 EN54-10
The 40/40R Optical Flame Detector is certified to EN54-10 and CPD.
The detector has been tested and approved per EN54-10 by LPCB
(BRE, UK).

TM 40/40R, Rev. (1) September 2008
Performance Considerations 7
This test includes functional test, environmental test, EMI/EMC test and
software check.
For more details see EN54-10 Report No. TE243256.
1.5 Performance Considerations
This section describes performance aspects of the 40/40R and includes:
Detection Sensitivity, page 7
Cone of Vision, page 8
False Alarm Prevention, page 9
Visual Indicators, page 10
Output Signals, page 11
Detector Status, page 12
Auxiliary Relay as End-of-Line Resistor, page 13
1.5.1 Detection Sensitivity
Detection sensitivity is the maximum distance at which the detector reliably
detects a specific size of fire and typical type of fuel (standard fire).
1.5.1.1 Standard Fire
Defined as a 1ft2/ 0.1m2n-heptane pan fire, with maximum wind speed of
6.5 ft/sec (2 m/sec).
1.5.1.2 Sensitivity Ranges
The detector has two response levels:
WARNING (Pre-alarm)
ALARM
The detection distance, for the WARNING level, is approximately 10% higher
than the ALARM distance.
The detection distance for the alarm level is 50 ft (15m) from a standard
fire. For some typical ambient conditions, the Zeta parameter as defined in
NFPA 72 for the detector is 0.005 (1/meter).
Note: Zeta parameters may vary significantly with changes in temperature,
air pressure, humidity, visibility conditions, and so on.
1.5.1.3 Other Fuels
The detector reacts to other types of fire as follows:
The baseline fire refers to n-heptane 1ft2(0.1m2) pan fire, and is defined
as 100% sensitivity.
For fuel fires –standard pan fire size: 1 ft2(0.1 m2).
For gas flames - 20 inch (0.5m) high, 8 inch (0.2m) width plume fire.

SharpEyeTM Single IR Flame Detector User Guide
8 Performance Considerations
Maximum Response Time: 10 sec.
Table 2: Fuel Sensitivity Ranges
Type Of Fuel
Max. Distance ft (m)
Gasoline
50 (15)
N-Heptane
50 (15)
JP4
37 (11)
Kerosene
37 (11)
Diesel Fuel
37 (11)
Alcohol 95%
25 (7.5)
IPA
25 (7.5)
Methanol
25 (7.5)
Methane
16 (5)
LPG
16 (5)
Paper
20 (6)
Polypropylene
10 (3)
1.5.2 Cone of Vision
Horizontal: 90°
Vertical: 90°
Figure 1: Field of View