SafEye Open Path Gas &
Flame Monitoring System
*
instruction manual
! WARNING
THIS MANUAL MUST BE CAREFULLY READ BY ALL INDIVIDUALS WHO HAVE OR WILL HAVE
THE RESPONSIBILITY FOR USING OR SERVICING THE PRODUCT. Like any piece of complex
equipment, the unit will perform as designed only if it is installed, used and serviced in
accordance with the manufacturer’s instructions. OTHERWISE IT COULD FAIL TO PERFORM
AS DESIGNED AND PERSONS WHO RELY ON THIS PRODUCT FOR THEIR SAFETY COULD
SUSTAIN SEVERE PERSONAL INJURY OR DEATH.
The warranties made by Mine Safety Appliances Company with respect to the
product are voided if the product is not used and serviced in accordance with
the instructions in this manual. Please protect yourself and others by following
them. We encourage our customers to write or call regarding this equipment
prior to use or for any additional information relative to use or repairs.
In the U.S., to contact your nearest stocking location, dial toll-free 1-800-MSA-INST.
To contact MSA International, dial 1-412-967-3228.
http://www.MSAnet.com
© MINE SAFETY APPLIANCES COMPANY 1996 - All Rights Reserved
* SafEye is a trademark of Spectrex
Distributed by
MSA INSTRUMENT DIVISION
P.O. Box 427, Pittsburgh, Pennsylvania 15230
(L) Rev 0
813285
Warnings and Cautions
1.
The units described in this manual must be installed,
operated, and maintained in strict accordance with its
labels, cautions, warnings, instructions, and within the
limitations stated.
2.
Do not paint any item of the SafEye Open Path Gas and
Flame Monitoring System. If painting is done in an
area where the unit is located, make sure paint is not
deposited or placed on the glass window of the unit.
Such paint deposits on the glass interfere or block the
light from the light source unit directed toward the
detection unit. This will prevent the detection of any
gas or flame between the two units.
3.
The only absolute method to assure proper overall
operation of the SafEye Open Path Gas and Flame
Monitoring System is to check it with the MSA
Calibration Cell (P/N 813275) and FlameGard Flame
Simulator (P/N 805405). Consequently, a check must
be included as part of the routine inspection of
the system.
4.
Both the detector and the light source unit is sealed. Do
not attempt to disassemble and/or modify or adjust
any of these units.
5.
Alteration of the SafEye Open Path Gas and Flame
Monitoring System, beyond the scope of this manual or
by anyone other than authorized service personnel,
could cause the product to fail to perform as designed,
and persons relying on this product for their safety
could sustain severe personal injury or death.
6.
Install, locate and operate the System in accordance to all
applicable codes including, but not limited to, the
National Fire Prevention Code and National Electric
Code. Only qualified personnel familiar with and
properly trained for gas detection equipment
maintenance should work on the units.
7.
Apply proper safeguards against unintentional
obstruction or blockage of either the detector or light
source unit. Ensure that water, dust, lint, snow or other
obstructions do not block the detector or light
source windows.
8.
Do not open the Detector or Light Source housing for
any reason while circuits are powered as an electrical
shock hazard exists with the unit opened.
9.
The Detector or Light Source units are not field
repairable. Do not attempt to make repairs or
adjustments as this will only cause the units to
function improperly.
10. The System is designed to detect gases, flames or
vapors in air. It cannot measure the concentration of
gases or vapors; nor can it detect flame in steam, fog,
snow, mist, sleet, dust or other adverse conditions that
obscure the path between the light source and
the detector.
11. Protect the system from extreme vibration. Do not
mount the sensing head in direct sunlight as this may
cause overheating of the units.
12. The SafEye Open Path Gas and Flame Monitoring
System will only detect hydrocarbon base gases and
flame. This unit does NOT detect non-hydrocarbon
base flammable gas, such as hydrogen and hydrogen
sulfide; nor does it detect any non-hydrocarbon base
flame, such as manganese or sodium. If unsure of the
suitability of these units to your situation, please
contact MSA.
FAILURE TO COMPLY WITH THE ABOVE WARNINGS CAN RESULT
IN SERIOUS PERSONAL INJURY OR DEATH.
MSA Instrument Warranty
1.
Warranty- Seller warrants that this product will be free from
mechanical defect or faulty workmanship for a period of
eighteen (18) months from date of shipment or one (1) year
from installation, whichever occurs first, provided it is
maintained and used in accordance with Seller’s instructions
and/or recommendations. This warranty does not apply to
expendable or consumable parts whose normal life expectancy
is less than one (1) year such as, but not limited to,
non-rechargeable batteries, sensor elements, filter, lamps, fuses
etc. The Seller shall be released from all obligations under this
warranty in the event repairs or modifications are made by
persons other than its own or authorized service personnel or if
the warranty claim results from physical abuse or misuse of the
product. No agent, employee or representative of the Seller has
any authority to bind the Seller to any affirmation,
representation or warranty concerning the goods sold under
this contract. Seller makes no warranty concerning components
or accessories not manufactured by the Seller, but will pass on
to the Purchaser all warranties of manufacturers of such
components. THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESSED, IMPLIED OR STATUTORY, AND IS
STRICTLY LIMITED TO THE TERMS HEREOF. SELLER SPECIFICALLY
DISCLAIMS ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS
FOR A PARTICULAR PURPOSE.
2.
Exclusive Remedy- It is expressly agreed that Purchaser’s sole and
exclusive remedy for breach of the above warranty, for any
tortious conduct of Seller, or for any other cause of action, shall
be the repair and/or replacement at Seller’s option, of any
equipment or parts thereof, which after examination by Seller
is proven to be defective. Replacement equipment and/or
parts will be provided at no cost to Purchaser, F.O.B. Seller’s
Plant. Failure of Seller to successfully repair any
nonconforming product shall not cause the remedy
established hereby to fail of its essential purpose.
3.
Exclusion of Consequential Damage- Purchaser specifically
understands and agrees that under no circumstances will seller
be liable to purchaser for economic, special, incidental or
consequential damages or losses of any kind whatsoever,
including but not limited to, loss of anticipated profits and any
other loss caused by reason of nonoperation of the goods. This
exclusion is applicable to claims for breach of warranty,
tortious conduct or any other cause of action against seller.
Table of Contents
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Light Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detector unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1-1.
Light Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
1-2
1-4
1-4
1-5
1-5
1-5
Figure 1-2.
Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Unit of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Table 1-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Spectral Finger Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Optical Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Microprocessor Based . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Section 2
Installation and Set-up . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Unpacking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
! WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting and Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detector Wiring Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-2. Detector Terminals . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2-1.
Detector and Light Source Terminal Boards . . . . . . . . . . . . . . .
2-1
2-1
2-2
2-3
2-3
2-3
2-3
2-4
2-4
PC Communication Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
4-20 mA Wiring Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-2.
Address Dip Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
TOC-1
Table of Contents
Table 2-3. Gas Channel Standard 4-20 mA Current . . . . . . . . .
Light Source Wiring Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2-4. Light Source Terminals . . . . . . . . . . . . . . . . . . . . . . .
Table 2-5. Light Source Pulse Setting . . . . . . . . . . . . . . . . . . . .
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools and Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting and Wiring the Light Source and the Detector . . . . . . . . . . .
Figure 2-3.
Typical Wiring for UV, IR, Flame Detector Model . . . . . . . . . . .
2-7
2-7
2-8
2-8
2-8
2-8
2-8
2-9
2-9
Figure 2-4. Alignment Base and Telescope Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-5.
Housing Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
! CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conduit and Wiring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
! CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Optional Protective Cover . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Optional Alignment Telescope . . . . . . . . . . . . . . . . . . . . .
2-11
2-11
2-11
2-12
2-12
2-12
Section 3
Operation and Maintenance . . . . . . . . . . . . . . . . . . . . 3-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Power ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
! CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3-1. LED Status Indications . . . . . . . . . . . . . . . . . . . . . . .
Figure 3-1.
Alignment and Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
3-1
3-1
3-1
3-2
Normal Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alignment Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3-2. Alignment Indication LED Color . . . . . . . . . . . . . . . .
Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Built-in Test (BIT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Alignment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Initial Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flame Detector Initial Testing Procedures . . . . . . . . . . . . . . . . . . .
! WARNING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
! CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3
3-3
3-3
3-4
3-4
3-4
3-6
3-6
3-7
3-7
TOC-2
3-2
Table of Contents
IR Channel initial Testing Procedures . . . . . . . . . . . . . . . . . . . . . . 3-7
UV channel initial testing procedures . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-2.
Calibration Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Zero Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Span calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
IR Channel Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
UV Channel Span Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Maintenance Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Preventive Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
To Clean the Front Panel Glass . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Periodic Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Recommended Maintenance Schedule . . . . . . . . . . . . . . . . . . . . 3-14
Table 3-3. Recommended Maintenance Schedule . . . . . . . . . 3-15
Signal Intensity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Table 3-4. Signal Intensity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Flame Detector Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . 3-16
Section 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Table 4-1. Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . 4-1
Appendix A
Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
Figure A-1.
Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
TOC-3
SafEye Open Path Gas and Flame Monitoring System
Chapter 1, General Information
Section 1
General Information
Introduction
The SafEye Open Path Gas and Flame Monitoring System consists
of two units:
• a light source unit
• a detector unit.
Depending on the model, this system uses infrared and/or
ultraviolet light to detect:
• certain flammable gases
• certain toxic aerosols or vapors
• the presence of a flame.
The SafEye Open Path Gas and Flame Monitoring System can:
• detect gases at concentrations well below any explosive or
poisonous level
• monitor paraffins, aromatics, and other gases simultaneously.
Various models of the SafEye Monitoring System are available
with the following sensor configurations installed:
•
•
•
•
•
•
UV sensor
IR sensor
UV and IR sensor
UV sensor with flame detector
IR sensor with flame detector
UV and IR sensor with flame detector.
In addition to these various models, the relays within the IR or
UV detector can be assigned various functions; Normally:
• One relay is assigned to act as an Alarm relay to activate when
the unit detects gas above a preset threshold.
• If the detector contains a flame detector, one relay is assigned to
activate when flame is detected.
• These relays can be re-assigned with the SafEye Open
Path Gas and Flame Monitoring System Software.
1-1
Chapter 1, General Information
The SafEye Open Path Gas and Flame Monitoring System is a
natural choice for gas and flame detection, particularly in open
hazardous locations where highly flammable substances are used
or stored. The system’s speed and sensitivity provides a high
degree of gas or flame detection.
The SafEye Open Path Gas and Flame Monitoring System:
• has long range gas and flame detection capabilities:
• IR Channel up to 325 feet (100 meters)
• UV Channel up to 200 fee. (60 meters)
• Flame Detection up to 200 feet (60 meters)
• can detect both hydrocarbon and aromatic/toxic gases in a
single unit
• has high sensitivity (PPM or LEL) with simultaneous detection
of C1-C8 flammable gases
• has a fast response time to enable personnel to take appropriate
safety measures
• is CENELEC approved, rated for Division 1, Groups C and D
hazardous areas
• is highly reliable and easy to install, align and calibrate
• guards against false alarms via its:
• high signal-to-noise ratio
• automatic self-calibration circuitry
• is highly immune to industrial and environmental radiation
sources
• connects to control panels via its 4-20 mA output and dry
contact relays
• has an RS-485 output for connection to any computer operating
the optional SafEye software and can be networked with up to a
maximum of 256 systems in up to 16 areas
• provides LEDs visible through the front window which:
• alert the user to a detected alarm or fault
• Aide in system alignment and calibration
• flash during normal operation.
Terminology
It is important that you become familiar with the following
terminology used throughout this manual.
1-2
Chapter 1, General Information
abbreviation for ultra violet light or radiation. Certain fires
emit, and certain gases absorb, UV light. This light is invisible to
the eye but detectable by the SafEye Open Path Gas and Flame
Monitoring System.
UV-
abbreviation for infrared light radiation. Certain fires emit, and
certain gases absorb, IR light (invisible to the eye but detectable by
the SafEye Open Path Gas and Flame Monitoring System).
IR-
OPEN PATH- IR and UV light from the light source unit travels freely, in
open air, to the detection unit and is not contained within any chamber.
continues to signal an alarm condition once the alarm
condition is removed from the detector. This relay operation is
desirable when the alarm condition happens quickly or when an
extended alarm indication is necessary.
LATCHING RELAY-
self-test feature allows the flame detection portion of
the unit to check itself for proper operation.
BUILT IN TEST (BIT)-
normally powered to the ON state. This relay
operation is desirable when a fail safe condition is needed.
ENERGIZED RELAY-
AIR PURGE KIT- allows operation in extremely dirty or dusty
environments. Air Purge Kit (P/N 805406) directs clean compressed
air across the glass window of the detector. It requires a clean
compressed air source for its operation.
emits UV and IR radiation. It resembles a flashlight and
simulates the radiation of a fire or flame without the associated
hazards. The fire simulator is used for testing or verifying SafEye
Open Path Gas and Flame Monitoring System channel operation.
FIRE SIMULATOR-
begins and ends at a central location
where fire alarm or security devices are wired, in parallel, across
the loop wires. There is usually an end-of-line device at the end
of the loop.
FIRE OR SECURITY LOOP WIRING-
used at the end of a security or fire alarm
loop wiring to helps ensure loop wiring is intact and operational.
There is only one end-of-line device used per wiring loop.
END-OF-LINE DEVICE (EOL)-
relay contacts make electrical connections
when activated; otherwise, the electrical contacts are not made.
NORMALLY OPEN RELAY (NO)-
single-pole, single-throw relay. This relay has a single
common connection point with two possible electrical
connections: one that is normally open and the other that is
normally closed.
SPST RELAY-
1-3
Chapter 1, General Information
General Description
The SafEye Open Path Gas and Flame Monitoring System detects
gas and flame over a large area, in contrast to point type gas
detectors. The system is composed of two main units:
• Light Source Unit:
• Light from the light Source unit is directed toward the
Detector unit located up to:
• 100 meters (325 feet) away for IR applications
• 60 meters (200 feet) away for UV applications.
• Detector Unit:
• The detector then analyzes the UV and IR light contained
in the beam and determines the gas concentration within
the path between the units.
The Flame Detector:
• analyzes the IR light given off by any flame, since all
hydrocarbon-fueled flame emits IR light
• has a 90-degree cone of detection from the front of the unit
• must detect three different wavelengths of IR light before
issuing an alarm, thereby preventing most false alarms.
The Light Source Enclosure and Detector Enclosure:
• are made of an anodized aluminum housing with less than 1%
Mg and an epoxy enamel finish
• are equipped with "O" rings at the rear of the unit to seal the
unit and prevent intrusions of dust, salt sprays, and
fire-fighting agents
• printed circuit boards are conformally-coated, protected from
mechanical vibration, and can withstand any light impact
• housings are explosion-proof and water-tight per NEMA 250
type 6 (IP67) and meet MIL-STD-810C.
Light Source
The Light Source unit (FIGURE 1-1) flashes a wide spectrum of
light in a collimated beam (from 0.2 to 5.0 µ) to the detector unit.
This light beam:
• is collimated for maximum intensity
• is flashing to prevent false alarms caused by background
radiation sources
• does not interfere with other optical detectors to cause
undesirable false alarms.
1-4
Chapter 1, General Information
Figure 1-1.
Light Source
Optional Light Filter
If the bright flashes of light are undesirable, an optional UV light
and visible light filter can be installed on the front of the light
source. This filter blocks the visible and UV portion of the light,
yet allows the other necessary IR radiation to travel to the
detector.
This filter:
• can only be used when detecting gases with the IR channel only
• cannot be used when detecting gases with the UV component
of the light.
Detector unit
The Detector unit (FIGURE 1-2) receives the transmitted,
pulsed-light radiation from the light source. Within the detector
unit, there can be two pairs of sensors. Each pair of sensors is
made up of a reference and an absorption element, each with its
own filter.
• This filter makes each pair sensitive to a different component of
the received light:
• One pair is sensitive to IR light
1-5
Chapter 1, General Information
Figure 1-2.
Detector
• the other pair is sensitive to UV light.
Certain frequencies of light from the Light Source are absorbed
when passing through the gas of interest in the optical path:
• The IR component of the light is detected by the IR sensors
• The UV component of the light is detected by the UV sensors.
The signal is then correlated with a ratio from that channel’s
reference filter. See Appendix A for a list of detectable gases.
The signals from both pair of sensors are amplified and directed
into an analog-to-digital signal converter. Once converted into a
digital format, the internal microprocessor can then direct the
automatic gain control to increase the amplifier gain when input
signals drop below a preset level. This allows the system to
operate even in the most severe weather conditions.
The microprocessor continually integrates the signal data to find
if the gas concentration is higher than the alarm setpoint. The
signal is then directed to the output interface section, converted
to an analog 4-to-20 mA output and sent to the wiring terminal
connections. This milliamp signal can be used by many control
panels or computers.
The Detector unit houses three different IR flame sensors (if so
equipped), each sensing a different IR spectral frequency. This
triple sensing method provides fast flame detection without false
alarms caused by incidental radiation sources.
1-6
Chapter 1, General Information
Unit of Measurement
Gas, especially outdoors, does not uniformly diffuse between the
light source and the detector of the SafEye Open Path Gas and
Flame Monitoring System. Natural wind currents move the gas in
many different directions. Also, leaking gas is at a higher
concentration at the source of the leak and difffuses away the
further one gets from the source. These factors make a % LEL
(Lower Explosive Linmit) reading meaningless over a long open
path. The SafEye Open Path Gas and Flame Monitoring System
uses a unit of measurement called LEL - meter.
LEL - meter is equal to the product of the gas concentration and
the separation of the light source and detector.
Monitoring system output = gas concentration %LEL x separation of light source & detector
• For example, if the gas concentration is a uniform 10% LEL over
100 meters, that would be 10 LEL - meters.
• Similarly, 1 LEL - meter could be:
• 100% LEL over 1 meter or
• 50% LEL over 2 meters or
• 25% LEL over 4 meters or
• 10% LEL over 10 meters.
The term LEL - meter suggests the concentration within the path.
Some areas along the path will have a higher concentration of
gas, while others will have a lower reading.
• The default ALARM set point of the SafEye Open Path Gas and
Flame Monitoring System is 2.5 LEL - meters
• The default WARNING set point is 1.0 LEL - meter.
Applications
The SafEye Open Path Gas and Flame Monitoring System is
factory-calibrated and ready to monitor gas concentration and
flame detection at many locations. It has many industrial
applications, such as:
• Petrochemical, pharmaceutical, and other chemical storage and
production facilities
• Flammable and toxic chemical storage sites and hazardous
waste areas
• Refineries, oil platforms, pipelines, refueling stations and fuel
storage facilities
1-7
Chapter 1, General Information
• Hazardous loading docks, transportation depots and shipping
warehouses
• Engine rooms
• Compressor and pumping stations
• Engine or other test cells or work areas
• LNG-LPG Systems.
Accessories
There are various accessories that may make the operation and
installation of the SafEye Open Path Gas and Flame Monitoring
System easier.
SafEye Alignment Base (P/N 813277)
The alignment base is designed for SafEye Open Path Gas and
Flame Monitoring System detector and source units. It is essential
for accurate on-site alignment.
IR Calibration Filter
The calibration filter attaches to the Detector unit for on-site
periodic testing of the system.
Alignment Telescope (P/N 813276)
The alignment telescope is used for fast and simple on-site
alignment of both the detector and the light source.
Air Shield Kit for Light Source and Detector
There are two air shield kits, one for the Detector unit and one for the
Light Source unit. The air shield directs a constant flow of air on each
unit’s viewing window to protect the viewing window from debris
and dust in any harsh environmental conditions. The air shield must
be connected to an independent compressed air source.
Each air shield requires 2 BAR (30 PSI) compressed air with a
flow capacity of 3 Scfm. The compressed air source must be
clean, dry, and oil free.
UV and Visible Light Source Filter
The UV and visible light source filter blocks the UV and visible
light. This filter helps if the bright flash from the light source is a
nuisance. It allows the necessary light to pass to the detector and
can only be used with models with the IR detector only.
SafEye Open Path Gas and Flame Monitoring System Software
The SafEye System software:
1-8
Chapter 1, General Information
• provides complete real time data for one system or a network of
systems with a RS-485 output to connect to a PC
• allows easy monitoring of up to 16 areas, using up to 256
SafEye Open Path Gas and Flame Monitoring Systems
• has the required communication protocols for efficient
operation. A separate manual is provided
• allows access to the set-up parameters of the SafEye System.
Calibration Cell (P/N 813275)
This calibration cell provides precise adjustment and calibration.
It can be filled with a specific gas or gas mixture by the user.
Table 1-1. Specifications
DETECTED
GASES:
DETECTION
RANGE
SPECTRAL
RESPONSE
RESPONSE TIME
SENSITIVITY
RANGE
FIELD OF VIEW
DRIFT
TEMPERATURE
RANGE
POWER SUPPLY
POWER
CONSUMPTION
ELECTRICAL
CONNECTION
For a complete list of detectable gases see Appendix A
IR
Hydrocarbons
UV
Aromatics/Toxic
Up to 325 ft. (100 M) IR
GASES
Up to 200 ft. (60 M) UV
FLAME
Up to 200 ft. (60 M) for a 1 sq. ft. fire
GAS UV BAND
0.2 - 0.3 mµ
GAS IR BAND
2.0 - 4.0 mµ
FLAME IR BAND
4.0 - 5.0 mµ
5 Seconds (Standard)
GAS
1 Second (Fast Option)
FLAME
5 Seconds (Maximum)
0-20 LEL (Standard)
IR CHANNEL
0-2 LEL (High Sensitivity)
0-4,000 PPM (Standard) The possible range
UV Channel
can be changed depending on the measured gas
GAS
Line of Sight
FLAME
90o cone of vision
short term (24 hours) 2% Full Scale
ZERO DRIFT
long term (12 months) 5% FULL SCALE
SPAN DRIFT
long term (12 months) 1% FULL SCALE
ACCURACY
+2% FULL SCALE for all calibrated gases
-4oF (-20oC) to 131oF (55oC)
STANDARD
OPTION
DETECTOR
SOURCE
24 VDC
110 VAC, 220 VAC
225 mA @ 24 VDC
110 mA @ 24 VDC
Two standard 3/4" - 14 NPT conduits
1-9
Chapter 1, General Information
OUTPUTS
ENVIRONMENTAL
TESTS
EXPLOSION
PROOF
ENCLOSURE
DIMENSIONS
WEIGHT
• Two 4-20 mA output, source type
• Three(3) dry contact relays
• Normally open contacts: SPST 2A @ 30VDC or 2A @ 250 VDC
• RS-485 serial link output
MEETS
MIL-STD-810C
HUMIDITY
Method 507.1 - IV
SALT AND FOG
Method 509.1 - I
VIBRATION
Method 514.2 - VIII
EExd II B T6 per En 50-014 and En 50-018
CENELEC
APPROVED
SIRA Certification Service #Ex94C1020 A
Class I Div. 1 Groups C and D
DESIGNED PER
NFPA
Class II Div. 1 Groups E,F,G
DETECTOR AND
7" x 7" x 10.5" (18 x 18 x 27 cm.)
SOURCE
ALIGNMENT BASE 13" x 5" x 5" (34 x 13 x 13 cm.)
DETECTOR
21.5 lb. (9.8 Kg.)
SOURCE
22 lb. (10.0 Kg.)
BASE
10 lb. (4.95 Kg.) per unit
Principles of Operation
The SafEye Open Path Gas and Flame Monitoring System detects
gases, vapors, and aerosols through a dual spectral range for
continuous and reliable monitoring of the atmosphere.
Spectral Finger Print
Each gas outlined in Appendix A has a specific IR or UV
absorption pattern or spectral finger print. There are:
• one set of IR sensors used for combustible gas detection
• one set of UV sensors used for aromatics/toxic gases detection
• three IR sensors used for flame detection.
Each set of sensors uses two separate spectral filters which permit
only a certain wavelength or frequency of light to pass through them:
• One filter allows only certain wavelengths that are absorbed by
the particular gas
• the other filter (known as the reference filter or channel) allows
other wavelengths that are not absorbed by the gas.
Optical Path
The optical path is the path between the light source and the
detector in the monitored area. The presence of the airborne
vapors, gases, or aerosols (listed in appendix A) between the light
source and the detector unit absorbs some of the light in some
1-10
Chapter 1, General Information
specific wavelengths. This causes a change in the signal intensity
received by the detector.
The system analyzes the incoming light from the light source in
several different spectral bands. These bands are specific to the
gases being monitored. The Automatic Gain Control (AGC)
circuitry compensates for environmental disturbances such as fog
or rain by a constant comparison of the reference beam.
Microprocessor Based
The signals from all of the detectors are analyzed by the built-in
microprocessor. A sophisticated mathematical algorithm calculates:
•
•
•
•
•
•
•
the detected signal thresholds
its rate of rise
statistical information about the signal
ratio algorithms between different signals
correlations of the signals
data output communications
diagnostics.
1-11
Chapter 2, Installation and Set-up
Section 2
Installation and Set-up
Unpacking the System
1. Carefully remove the SafEye Open Path Gas and Flame Monitor
from its shipping container(s).
The entire system includes:
•
•
•
•
a Detector Unit
a Light Source Unit
an IR Calibration Filter
a Magnetic Mode Selector
Optional items that may be included within these shipping
cartons are:
• two Alignment Bases:
• one for the detector
• one for the light source
• two Protection Covers (used in place of the air shield for
outdoor environments)
• an Alignment Telescope (highly recommended for
aiming the units)
• an Air Shield Kit (recommended for dusty or
harsh environments)
• SafEye Open Path Gas and Flame Monitoring System
Software (for computer communications)
• a UV Visible Light Filter (blocks UV and visible
light flashes)
• a Calibration Cell (special chamber for
specific calibration)
2. Search through all packing material and containers to avoid
inadvertently discarding usable or valuable parts.
! WARNING
Do not operate the unit while it is encased in packing material;
otherwise, the unit will not operate properly.
2-1
Chapter 2, Installation and Set-up
3. Carefully inspect all units. If damage or shortage is evident,
advise the carrier promptly and file the proper claim with
the carrier.
Mounting and Wiring Guidelines
Only qualified personnel should install and wire the system;
they must be:
• familiar with all applicable codes and practices, such as
National Electrical Code (NEC)
• trained for gas detection and fire detection equipment
installation and maintenance.
The wiring and the installation should be inspected by a person
other than the installer.
These guidelines do not address all codes and standard practices
of installation, but emphasize general installation procedures.
1. Mount the monitor in areas free from shock, vibration and
excessive heat sources or where it may be knocked out of
alignment. Do not expose unit to direct solar heating.
2. Mount the unit so its front window is not blocked or obscured
from view. Ensure it has a clear view of the area it is monitoring
for fires or flames. Also, ensure that both units are in line of
sight of each other and have a clear view.
3. Do not use the SafEye Open Path Gas and Flame Monitor in
locations where the path between the light source and the
detector unit is routinely blocked or obscured.
4. Do not use the system where oil, films or other substances may
accumulate on its window.
5. Do not mount the system at an angle that allows dust, dirt or water
to accumulate on the windows and impair system performance.
6. Optimize detector location:
2-2
a.
Determine the critical areas where gas and/or fire is most
likely to occur, and direct the unit toward those areas.
b.
Walk the area to be monitored; determine specific application
requirements and hardware needed for the system location.
c.
Ensure accessibility for periodic maintenance and cleaning.
d.
Determine the natural characteristics of the gas being
monitored; is the monitored gas lighter or heavier than air?
Chapter 2, Installation and Set-up
Wiring Guidelines
The SafEye Open Path Gas and Flame Monitor can
operate independently or with controllers or fire detection
and suppression systems when the following guidelines
are observed:
1. Determine the number and the types of outputs needed.
2. Use color coded conductors or suitable wire markings or labels
when wiring.
3. Follow all local and national wiring codes and procedures.
4. The selection of wire size depends on the distances between:
• the power supply and the light source
• the power supply and the detector unit.
Both units accept wire from 12 to 20 AWG. Determine the wire size
needed to properly power the units.
Detector Wiring Description
General
The SafEye Detector Units are supplied with:
• a standard 4-20 mA sourcing type output per each IR and
UV channel
• three relays which can be configured as required; the standard
configuration uses:
• Two of the three relays for fire detection
• one for alarm
• one for fault
• One relay for any gas alarm requirements; the alarm
relay can be configured as latching, if desired.
The SafEye Open Path Gas and Flame Monitoring System
provides the following outputs:
• Standard 4-20 mA outputs for the UV and IR channels
• Three relays (two for flame detection and one for gas alarm)
• Optional RS-485 Output for PC Communications.
Detector Wiring
Detector unit and Light Source unit wiring connectors are shown
in FIGURE 2-1.
The Detector contains three terminal wiring connectors:
2-3
Chapter 2, Installation and Set-up
Figure 2-1.
Detector and Light Source Terminal Boards
• The top wiring connector is numbered 1 to 5
• The middle wiring connector is numbered 6 to 11
• The bottom wiring connector is numbered 12 to 16.
TABLE 2-2 outlines the Detector Unit wiring connections.
Table 2-2. Detector Terminals
TERMINAL #
16
15
13
12
14
3
2
10
9
8
11
6
7
4
5
1
DESCRIPTION
VIN
RTN
RS-485 (+) (OPTIONAL)
RS-485 (-) (OPTIONAL)
RS-485 GND
RET: 4-20 mA IR CHANNEL
OUT: 4-20 mA IR CHANNEL
OUT: 4-20 mA UV CHANNEL
RET: 4-20 mA UV CHANNEL
FIRE FAULT RELAY (N.O.)*
FIRE ALARM RELAY (N.O.)*
GAS ALARM RELAY (N.O.)*
FACTORY USE FOR MODE SELECTION
*CAN BE RE-CONFIGURED.
Connection 16 and 15
Input power is supplied to these terminals.
• Terminal 16 is for (+) or AC hot
2-4
Chapter 2, Installation and Set-up
• Terminal 15 is ground (-) or AC neutral.
NOTE: For 24 VDC models, check the terminal voltage with a
volt meter; ensure that the detector unit receives:
• a minimum of 18 Volts DC
• a maximum 32 Volts DC.
Connection 14, 13 and 12
These connections are for the optional RS-485 output.
• Terminal 12 (-) and 13 (+) are used for the communication
network
• Terminal 14 is used as a ground.
Connection 11 and 8
In the standard configuration, these connections are for the fire fault
relay, a single-pole, single-throw (SPST) relay. Relay contacts are:
• normally-open when unit is un-powered or detects a fault
• closed when the detector is operating normally.
This relay can be re-configured if the flame detector is not used.
Connection 10 and 9
These connections are for the analog, 4-20 mA current output of
the UV Channel.
• current is proportional to the concentration of the gas detected.
• Terminal 10 is (+).
Connection 7 and 6
In the standard configuration, these connections are for the fire alarm
relay, a single-pole, single-throw (SPST) relay. Relay contacts are:
• normally open (N.O.) when unit is un-powered.
• closes its contacts when unit detects an alarm.
This relay can be re-configured if the flame detector is not used.
Connection 5 and 4
This relay is a single pole, single throw (SPST). Relay contacts are:
• normally-open (N.O.) when unit is un-powered
• normally-open (N.O.) when gas concentration has not
exceeded the alarm setpoint.
NOTE: To protect all relay contacts from voltage surges or spikes
(especially when connected to reactive loads, electric
2-5
Chapter 2, Installation and Set-up
motors, sirens, etc.), connect a varister or surge
suppresser to these contacts.
Connection 2 and 3
These connections are for the analog 4-20 mA current output of
the IR Channel.
• current is proportional to the concentration of the gas detected.
• Terminal 2 is (+)
• Terminal 3 is (-).
PC Communication Set-up
A series of switches in the front half of the Detector (FIGURE 2-2)
set up the unit address for proper communication to a computer.
Figure 2-2.
Address Dip Switch
4-20 mA Wiring Description
The 4-20 mA output signals for fire or gas detection are:
•
•
•
•
•
•
Normal
Warning
Alarm
Obscuration
Misalignment
Fault
See TABLE 2-3 for exact output current that indicates these conditions.
2-6
Chapter 2, Installation and Set-up
Table 2-3. Gas Channel Standard 4-20 mA Current
CURRENT
0 mA
1 mA
2 mA
3 mA
4-20 mA
21 mA
STATUS AND DESCRIPTION
Disconnected
Fault
Obscuration (when longer than 15 seconds, but less than one minute; then, a
fault occurs)
Misalignment
Measures the gas concentration from 0 to 20 LEL in the IR channel for the
normal range. In the UV channel the standard range is of 0 to 4,000 PPM
Over the range limit, more than full scale concentration.
Concentrations can be measured in the gas channel by either of
two methods:
1) proportionally (standard) showing a continuous reading of the
exact gas concentration or
2) by sending an automatic warning or alarm signal at a defined gas
concentration per customer requirements.
Optional RS-485 Wiring Description
The optional RS-485 output sends complete data to a computer.
The following computer hardware is required:
• 286 PC using DOS Version 5.0 or higher
• 1 MB RAM
• 2 MB free hard disk space
• 1.2 or 1.44 MB floppy drive
• Color VGA
• Isolated RS-485 Interface Card to be defined as COM1 or COM2.
Light Source Wiring Description
The light source has a single wiring connector numbered 1
through 3 (see TABLE 2-4):
• Input or (+) power is connector to terminal 1
• Return or (-) power is connected to terminal 2
• There are no other connections within the light source.
2-7
Chapter 2, Installation and Set-up
Table 2-4. Light Source Terminals
TERMINAL #
1
2
3
DESCRIPTION
VIN
RTN
DO NOT USE
The light source has a bank of switches (see FIGURE 2-1)that set
the flash rate of the light (TABLE 2-5). A faster flash rate
increases the response time when units are used at short range. It
also decreases the expected life of the lamp within the unit.
Table 2-5. Light Source Pulse Setting
SW 1
ON
OFF
ON
OFF
SETTING
SW 2
SW 3
ON
ON
OFF
OFF
-
SW 4
-
PULSE RESPONSE
5 Seconds
2.5 Seconds (Standard)
1 Second
.5 Second
Typical Installation
There are various ways to connect the SafEye Open Path Gas and
Flame Monitor to control equipment. TABLE 2-3 identifies all
connections within the detector unit and FIGURE 2-2 shows the
typical connections to the detector unit. Your connections may
differ, depending on your model’s features. Consult your
controller manual for the proper wiring to that unit.
Tools and Equipment Required
The following tools and equipment are necessary to install the
SafEye Open Path Gas and Flame Monitoring System:
• a set of screw drivers
• a set of adjustable wrenches (1-5/8" or #41, and 3/4" or #19)
• two 5-mm Allen wrenches
• 1 standard
• 1 extra long
• multimeter.
Mounting the Bases
Set and secure the mounting base to a stable platform using four
1/2" bolts via the 13-mm holes in the bottom bracket of the base.
Ensure that the base is oriented correctly. For complete mounting
dimensions, refer to Appendix B, "Installation Outline."
2-8
Chapter 2, Installation and Set-up
Figure 2-3.
Typical Wiring for UV, IR, Flame Detector Model
Mounting and Wiring the Light Source and the Detector
1. Set the Light Source and the Detector on their respective bases.
The front of the units must face one another.
2. Secure both units to their bases by using the supplied Allen
screws and washers. Use the short screw in the front of the unit
and the longer screws in the rear of the unit (FIGURE 2-4); do
not over-tighten these screws
3. Using a screw driver, remove and retain the small plastic
threaded plugs from the front of both units
(FIGURE 2-5).
4. Using the supplied long handled hex tool, loosen the four Hex
screws that secure the two halves of the unit. Remove and retain
the screws.
5. Using a long hex tool; loosen the four screws found below the
plastic threaded plugs. (These screws are not removable.)
6. Carefully separate the two halves of the enclosure and place the
front half aside.
2-9
Chapter 2, Installation and Set-up
Figure 2-4. Alignment Base and Telescope Assembly
Figure 2-5.
Housing Screws
2-10
Chapter 2, Installation and Set-up
! CAUTION
Do not expose internal circuitry to the environment for an extended
period of time; otherwise, internal parts or circuitry corrosion may
make the unit inoperative. To reduce the amount of time the unit’s
housing is apart, proper planning of the wiring is required.
Conduit and Wiring Installation
• Determine the proper wiring configuration for your unit.
• If connecting the SafEye Open Path Gas and Flame Monitor to a
controller, consult the controller manual for wiring instructions.
• To avoid condensation collecting inside the detector, the
conduit must include drain plugs to enable proper draining.
• Use flexible conduit to connect the rigid conduit to the Light
Source or the Detector. For Class 1, Division I, Group C and D
applications, the conduit inlet at the enclosure must be sealed.
• Verify that no power is applied to any cables being wired to the units.
! WARNING
Do not wire the unit while power is applied; otherwise, a shock hazard
exists which can cause serious personal injury or death.
1. Remove the two plastic protective plugs covering the conduit access
on the side of both units; then, pull the cables through the supply
conduit, ensuring cables are not entangled or stressed. Extend the
cables about 12 inches (300 mm.) beyond the unit’s location.
2. Once the cable is pulled through the conduit, identify and mark
all cable conductors. Ensure that all electrical connections are
appropriate for the application environment.
4. Pull the wires into the base of both units through the conduit
access; secure the cables to the base using the cable ties. Use a
3/4" NPT, explosion-proof conduit connector to attach the
conduit to the unit. Seal any unused conduit port with an
explosion-proof 3/4" NPT plug.
5. The Detector and Light Source base contain the wiring
connectors. TABLE 2-2 outlines the connections to these
connectors. Refer to "Wiring Guidelines" earlier in this section
for additional wiring information.
6. Trim the wires to the exact length necessary; securely place and
tighten the wire in the appropriate wire slot.
2-11
Chapter 2, Installation and Set-up
NOTE: Each wire slot can securely hold two wires to enable
cascading in multiple detector systems.
! CAUTION
Verify the wiring. Improper wiring may damage the detector or the
electronic controls.
Always follow National Electrical Code (NEC) guidelines for installation
of equipment in hazardous atmospheres.
7. Check all wires for secure mechanical connection. Secure wires
against the terminal board with the cable ties.
8. Dress or tape all wires so they will not interfere when the front
half of the enclosure is replaced.
9. Seal the conduit inlet and outlet with the proper compound.
10. After wiring, re-install the front half of the enclosure and replace
and tighten all screws that were removed. Do not over-tighten
the screws.
7. If the area is extremely dirty or dusty, installation of the Air Purge
Kit may be necessary.
Installing the Optional Protective Cover
The protective cover is used in place of the air shield in outdoor
environments. The cover protects the Detector and Light Source
units’ front face from the weather. Slide the protective covers on
each unit from the front (cover only sides back to the midpoint of
the enclosure).
Mounting the Optional Alignment Telescope
The alignment telescope assists in the alignment of both units.
1. Set the telescope(s) on the unit(s).
2. Secure the telescope into position at the front of the unit(s) using
the two short hex screws and washers. Secure the telescope at
the back of the unit with the two longer hex screws and washers
(FIGURE 2-4).
3. After alignment, these telescopes can be removed and stored.
2-12
Chapter 3, Operation and Maintenance
Section 3
Operation and Maintenance
Operation
Initial Power ON
1. Before applying power to the SafEye System, ensure that power is
correct; the system operates from 24 VDC power, 110 VAC and
220 VAC (check your model).
! CAUTION
If unsure of available power voltage, contact your facility engineer
or safety officer. Damage may occur to the unit if incorrect power
voltage is applied.
2. Apply power to both units by turning the controller ON or
tripping the circuit-breaker or fuse that supplies power.
• The Detector and the Light Source units are not equipped
with power switches.
3. Wait approximately 30 seconds for automatic unit calibration and
stabilization:
• one or two Detector unit LEDs blink
• Light Source unit light bulb flashes.
4. Investigate and correct all trouble indications.
Operational Modes
The SafEye System has four modes:
•
•
•
•
Normal Operation mode: in use when detecting gas or flame
Alignment mode: helps to align the units
Calibration mode: helps to calibrate the units
Standby mode: permits units to initialize when power is
applied or when switching out of Alignment mode.
To place the Detector in the Alignment or Calibration modes, place
the provided magnet mode selector on the side of the Detector unit,
behind the wiring entries, for two seconds (FIGURE 3-1).
3-1
Chapter 3, Operation and Maintenance
Figure 3-1.
Alignment and Mode Selection
Two multi-colored LEDs on the Detector unit front panel
(FIGURE 1-2) indicate various system conditions. In each mode,
the LEDs indicate a different condition (TABLE 3-1).
Table 3-1. LED Status Indications
MODE
STATUS
COLOR
Alarm
Red
LEDs blink at a rate of 2.0 Hz (twice per
second)
Warning
Red
LEDs blink at a rate of 1.0 Hz (once per
second)
Fault
Orange
LEDs blink at a rate of 2.0 Hz (twice per
second)
Normal
Green
Gas concentrations normal (once every two
seconds); LEDs blink at a rate of .5 Hz
Alignment
Mode
Align
see TABLE
3-2
color represents signal intensity (see the
alignment procedures)
Calibration
Mode
Calibrate
Green
LEDs blink at a rate of 2.0 Hz (twice per
second)
Standby Mode
Standby
Green
Upper and Lower LEDs blink alternately at a
rate of 2.0 Hz (twice per second)
Normal Mode
3-2
DESCRIPTION
Chapter 3, Operation and Maintenance
Normal Operation Mode
This mode enables units to detect flame and/or gas. Unit LEDs
indicate status of the detected gas concentration or flame:
• Green LEDs - indicate signals received from gas and flame
detection are below pre-set levels.
• Red LEDs - indicate warning level was exceeded for either gas
concentration or flame detection.
• Red LEDs - indicate alarm level was exceeded for either gas
concentration or flame detection.
• Orange LED - indicates gas and/or flame detection is disabled or
non-functional due to blockage, poor alignment, or unit
electrical failure.
Alignment Mode
This mode enables precise unit alignment during initial setup or
when alignment must be checked.
Detector unit, front-panel LEDs indicate received signal status:
• LED flashes 1 to 10 times, with 10 representing the highest
possible signal intensity. This received signal intensity is given
in a decimal number represented by LED flashes:
• Upper LED represents the "tens" unit of the signal intensity
decimal number
• Lower LED represents the "ones" unit of the signal
intensity decimal number.
• LED color indicates the gain of the Detector amplifier
(TABLE 3-2):
Table 3-2. Alignment Indication LED Color
UPPER LED
LOWER LED
GAIN
RED
ORANGE
RED
ORANGE
3
2
GREEN
ORANGE
1
GREEN
GREEN
0
• Zero is the lowest gain setting
• Three is the highest gain setting
• It is good practice to align units to maximize signal
intensity at the lowest possible gain setting.
3-3
Chapter 3, Operation and Maintenance
When leaving the Alignment mode, the unit temporary enters the
Standby mode, allowing user the option of switching directly to
the Calibration mode.
Calibration Mode
This mode allows zeroing of the unit gas detection reading. It
should only be performed when there are no combustible gases
between the Light Source and Detector units. After unit
calibrations are complete, the user can switch to the Normal
Operation mode.
Built-in Test (BIT)
The system includes an automatic, continuous Built-in Test (BIT).
to monitor:
• optical integrity (for the fire channel, the optical integrity test is
performed by the white light that appears between the LEDs)
• sensor and electronic functioning
• power supply
• software.
Successful BIT operation:
• does not activate any indication lights; the optional Fault relay
is not released, but remains in its normal position.
Unsuccessful BIT operation:
•
•
•
•
•
detection is disabled
fault relay is opened
4-20 mA current decreases to the fault signal
front panel LED indicates a fault
BIT operation returns unit to Normal Operation mode when the
problem is corrected.
Initial Alignment Procedures
Alignment of the SafEye Open Path Gas and Flame Monitoring
System is essential for proper operation. The optional telescope is
recommended for proper alignment; it enables initial physical
alignment while the Detector front panel LEDs enable final, fine
alignment adjustment. These LEDs indicate:
• intensity of received signal
• gain of Detector’s internal amplifier.
3-4
Chapter 3, Operation and Maintenance
Intensity of the received signal is affected by environmental
conditions and the distance between the two units. If units are
mounted outdoors, alignment must be performed in clear weather.
NOTE: To align the units, it may be necessary to position two
people within communication range:
• one person at the Light Source unit
• a second person at the Detector unit.
1. Mount the telescope assembly on the Light Source unit with the
front facing the Detector unit.
2. Loosen the general and fine tightening nuts and bolts on the base
(FIGURE 3-1).
3. Look through the telescope; adjust the horizontal and vertical
adjustments on the base until the cross hairs within the telescope
fall upon the top center of the Detector unit.
4. Tighten the nuts to secure the base and keep it from moving.
5. If using one telescope, move and mount the telescope to the
Detector unit.
6. Look through the telescope on the Detector unit; adjust the
horizontal and vertical adjustments on the base until the cross
hairs within the telescope fall upon the top center of the Light
Source unit.
7. Tighten the nuts to secure the base and keep it from moving.
8. Set the Detector unit in the alignment mode by placing the Magnetic
Mode selector on the side of the Detector and behind the conduit
entries for two seconds. The LEDs on the Detector should blink at a
rate of twice per second, within a 5.0 second period.
9. The following must be done on both the Detector and the Light
Source units:
a.
Adjust the fine horizontal ("Left/Right") alignment screws
by turning the fine alignment screws while observing
the Detector LEDs. The number of flashes indicates the
intensity of the received signals while the color
represents the gain (TABLE 3-2).
• The upper LED shows the "tens" unit of the intensity
value
• The lower LED displays the "ones" intensity value.
• Each LED blinks 1 to 10 times, with 10 representing
the maximum possible signal intensity.
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Chapter 3, Operation and Maintenance
b. Turn the fine adjustment screws to reach the maximum
signal with the lowest gain. When the upper LED
indicates the highest signal intensity, observe the lower
LED flashes to help in the fine adjustment.
c. Repeat steps (a) and (b) for fine vertical (Upper\Lower)
alignment.
d. Verify that you have obtained the maximum signal
intensity at the lowest possible gain setting.
10. When unit alignment is complete, tighten the fine alignment
screws and tightening bolts on the base. Ensure that tightening
nuts are tight. It is good practice to apply locking liquid to these
nuts to ensure that they do not move.
11. Record the signal intensity number and gain LED color in your
maintenance log book.
• Signal intensity number is the number of LED flashes
• Gain is the Detector front panel LED color.
12. Return to Normal Operation mode by placing the Magnetic
Mode Selector on the side of the Detector for two seconds
(FIGURE 3-1).
Initial Testing Procedures
Perform only the testing procedure applicable to your unit,
depending on whether your system contains an IR sensor, a UV
sensor or a flame detector.
Every SafEye Open Path Gas and Flame Monitoring System is
factory-calibrated for your specific gas or vapor detection
requirements. The initial testing procedure validates this
calibration and checks the operation of the installed unit.
Prior to beginning the initial testing:
• Disconnect or disable all alarm devices connected to the units
being calibrated.
• Do not separate or open the enclosure while power is ON.
• Ensure that the units are properly powered.
Flame Detector Initial Testing Procedures
All flame detectors must be tested before the entire system is
operational. To simulate a flame, use the MSA Flame Simulator.
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Chapter 3, Operation and Maintenance
! WARNING
Do not use an uncontrolled open flame to test the Flame Detector.
Since the area where the flame detector is mounted may be classified
as a hazardous area, any open flame or fire from any source may
cause an explosion resulting in injury or death.
The Flame Simulator triggers a fire alarm from the Flame
Detector. Depending on the particular application, some devices
may activate as a result of the fire alarm. To prevent activation,
remove power and disable these devices prior to testing.
! CAUTION
When SafEye Open Path Gas and Flame Monitoring System Flame Detector
relays or the associated controller are wired to external devices (e.g.,
horns, and fire suppression systems), the external devices may activate
during this procedure. To prevent their activation during testing, disconnect
wiring from the relays or disable the devices. When testing is completed,
reconnect relay wiring or enable the devices.
1. Place the Fire Simulator on the face of the Detector.
• The simulator resembles a flashlight and fits into the recessed
portion of the Detector, directly in front of the window.
2. Turn on the Fire Simulator by sliding its switch to the ON position.
• The Fire Simulator activates the Flame Detector within the
unit within two seconds.
3. After flame detection, slide the Fire Simulator switch to the OFF position.
4. Remove the Fire Simulator from the Flame Detector on the unit
and observe the lower LED through the window.
• LED flashes at a rate of 2.0 Hz or two times per second
• If the output or the alarm loop is latched, turn power to the
flame detector OFF and then ON again to turn OFF the LED
and reset the Detector.
5. Reconnect all system components disconnected or disabled prior
to testing.
IR Channel initial Testing Procedures
The initial testing procedures for the IR channel uses the 4-20 mA
output. Ensure that the units are powered and the 4-20 mA
output for the IR channel is steady, not noisy.
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Chapter 3, Operation and Maintenance
1. Connect an ammeter to the IR channel 4-20 mA output and read
the 4-20 mA current. Record the 4-20 mA output reading.
2. Locate the IR Calibration Filter (FIGURE 3-2).
3. Place the IR Calibration Filter on the front face of the Detector unit.
• This filter must be centered over the Detector window.
4. Wait 20 seconds for the unit to acquire a reading.
5. With the ammeter connected to the IR channel 4-20 mA output,
read the 4-20 mA current.
6. Subtract this reading from the reading obtained in step 1.
• This difference is called the 4-20 mA current variance.
7. Record this 4-20 mA current variance in the Maintenance Log Book.
8. Record the Calibration Filter number in the Maintenance Log Book.
9. If the variance is more than 20% of the factory setting (located on
the delivery information), repeat the alignment procedure.
10. After alignment procedure is completed, repeat above
procedure. If the current variance is still more than 20% of the
factor setting, perform the Zero Calibration procedure given in the
next section.
5. Reconnect system components disconnected or disabled prior
to testing.
UV channel initial testing procedures
To perform the initial testing of the UV channel, the optional
calibration cell is used. Also, the UV channel’s 4-20 mA output
is used. Ensure that the units are powered and the 4-20 mA
output for the UV channel is steady, not noisy.
1. Locate the optional calibration cell.
Figure 3-2.
Calibration Filter
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Chapter 3, Operation and Maintenance
2. Also, locate the proper span or check gas cylinder.
3. With an ammeter connected to the UV channel 4-20 mA output,
read the 4-20 mA current. Record the 4-20 mA output reading.
4. Place the optional calibration cell within the optical path of the
units. Ensure proper orientation.
5. Fill the calibration cell with the gas from the span or check
gas cylinder.
6. Calculate the proper 4-20 mA output for the gas concentration
being placed into the calibration cell.
7. With the ammeter connected to the UV channel 4-20 mA output,
read the 4-20 mA current. Record the 4-20 mA output reading.
8. Add the reading obtained in step 3 to the calculated output
obtained in step 6.
#. The reading obtained in step 7 must be within 20% of the sum
obtained in step 8.
#. If the current is more than 20% of the sum in step 8, repeat the
alignment procedure.
#. After the alignment procedure is completed, redo the above
procedure. If the current is still more than 20% of the sum in step
8, perform the Zero Calibration in the next section.
5. Reconnect system components disconnected or disabled prior
to testing.
Calibration
As with any type of gas monitor, the only true check of its
performance is to apply gas directly to the system. The frequency
of the calibration gas tests depends on the operating time and
chemical exposures to the system. A newly installed system
should be calibrated or checked more often until the calibration
records prove system stability. The calibration frequency can then be
reduced to the schedule set by the safety officer or plant manager.
Zero Calibration
Before zero calibration of the SafEye Open Path Gas and Flame
Monitoring System, accurate and precise Light Source and Detector
alignment must exist. If the units are mounted outdoors, zero
calibration must be done on a clear day with insignificant gas
concentrations in the surrounding environment. If the units are
mounted indoors, no gas must exist in the optical path.
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Chapter 3, Operation and Maintenance
If gas exists or other mist or fog obscures the optical path, zero
calibration must be:
• done at a different site at the same distance or
• delayed until conditions improve.
It is necessary in the following procedure to change Detector unit
modes. To change modes, place the Magnetic Mode Selector on
the Detector (behind the conduit entries) for two seconds
(FIGURE 3-1). When changing modes, wait five seconds and
observe the LED indication.
The Standby mode is a temporary mode:
• lasting about 20 seconds
• used to help with mode selection.
If the Magnetic Mode Selector is not placed on the unit and
removed during the 20 seconds of the Standby mode, the
Detector switches to the Normal Operation mode.
If the received signal is weak or obscured during zero calibration:
• Detector automatically returns to the Alignment mode.
• 4-20 mA output current goes to the fault level.
1. Using the Magnetic Mode Selector, place the Detector in the
Alignment mode.
• The last alignment indication is visible on the front panel LED.
2. With the Magnetic Mode Selector, place Detector in the Standby mode.
• The front panel LEDs blink alternately with a green color.
3. During the 20 seconds while the unit is in the Standby mode,
place the Detector in the zero Calibration mode.
• The front panel LEDs blink simultaneously green.
4. Wait 30 seconds until the Detector automatically changes to the
Normal Operation mode.
• The detector output is now set to zero at 4 mA.
5. Perform an initial calibration check.
• If the signal is greater than 20% of the factory indication
shown on the response form, call MSA for service.
6. Reconnect system components disconnected or disabled prior to testing.
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Chapter 3, Operation and Maintenance
Span calibration
Of the three possible sensors within your SafEye Open Path Gas
and Flame Monitoring System, the UV and the IR sensors may
need periodic span calibration checks. The recommended time
period for these checks is given under the Maintenance section of
this manual.
IR Channel Span Calibration
Pick one of the following two methods and check the IR channel
span calibration:
• an easy way is to use the calibration filter
• another way is to use the calibration cell with actual span gas.
IR Channel Span Calibration Using the Calibration Filter
1. Ensure that:
• units are powered
• 4-20 mA output for the IR channel is steady, not noisy.
2. Using an ammeter connected to the IR channel 4-20 mA output,
read and record the 4-20 mA current.
3. Locate the IR Calibration Filter, (FIGURE 3-2).
4. Place the IR Calibration Filter on the front face of the Detector unit.
• The IR Calibration Filter must be centered over the
Detector window.
5. Wait 20 seconds for the unit to acquire a reading.
6. With the ammeter connected to the IR channel 4-20 mA output,
read the 4-20 mA current.
7. Subtract this reading from the reading obtained in step 2.
• This difference is called the 4-20 mA current variance.
8. Record the 4-20 mA current variance and the calibration Filter
number in the Maintenance Log Book.
9. If the variance is more than 20% of the factory setting, (located
on the delivery information), repeat the alignment procedure.
10. After the alignment procedure is completed, redo the above
procedure. If the current variance is still more than 20% of the
factor setting, perform the Zero Calibration in the next section.
11. Reconnect all system components disconnected or disabled prior
to testing.
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Chapter 3, Operation and Maintenance
IR Channel Span Calibration Using the Calibration Cell.
1. Ensure that:
• units are powered
• 4-20 mA output for the IR channel is steady, not noisy.
2. Locate the optional calibration cell and the proper span or check
gas cylinder.
3. With an ammeter connected to the IR channel 4-20 mA output,
read and record the 4-20 mA current.
4. Calculate the proper 4-20 mA output for the gas concentration
being placed into the calibration cell.
5. Place the optional calibration cell within the optical path of the
units; ensure proper orientation.
6. Fill the calibration cell with gas from the span or check gas cylinder.
7. With the ammeter connected to the IR channel 4-20 mA output,
read and record the 4-20 mA current.
8. Add the reading obtained in Step 3 to the calculated output
obtained in Step 6.
9. The reading obtained in Step 7 must be within 20% of the sum
obtained in Step 8.
10. If the current is more than 20% of the sum in Step 8, repeat the
alignment procedure.
11. After the alignment procedure is completed, redo the above
procedure. If the current is still more than 20% of the sum in
Step 8, perform the Zero Calibration procedure.
12. Reconnect system components disconnected or disabled prior
to testing.
UV Channel Span Calibration
1. Ensure that:
• units are powered
• 4-20 mA output for the UV channel is steady, not noisy.
2. Locate the optional calibration cell and proper span or check
gas cylinder.
3. With an ammeter connected to the UV channel 4-20 mA output,
read and record the 4-20 mA current
4. Place the optional calibration cell within the optical path of the
units; ensure proper orientation.
5. Fill the calibration cell with the gas from the span or check gas cylinder.
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Chapter 3, Operation and Maintenance
6. Calculate the proper 4-20 mA output for the gas concentration
being placed into the calibration cell.
7. With the ammeter connected to the UV channel 4-20 mA output,
read and record the 4-20 mA current.
8. Add the reading obtained in Step 3 to the calculated output
obtained in Step 6.
9. The reading obtained in Step 7 must be within 20% of the sum
obtained in Step 8.
10. If the current is more than 20% of the sum in Step 8, repeat the
alignment procedure.
11. After the alignment procedure is completed, redo the above
procedure. If the current is still more than 20% of the sum in step
8, perform the Zero Calibration.
12. Reconnect system components disconnected/disabled prior to testing.
Maintenance
The Detector can be maintained by using common tools and
equipment. Only qualified personnel familiar with local codes
and practices, and trained for fire and gas detection equipment
maintenance should work on the system.
Maintenance Records
Maintain a record of every maintenance operation performed on
the system. If the unit is returned to MSA for service, also
include a copy of the maintenance record. This record must
include information identifying the following:
•
•
•
•
•
•
•
system identifying number or code
system location and installation date
installer or contractor name
date and time of maintenance
maintenance person’s name or ID
maintenance operation performed
maintenance person’s signature/initials
Preventive Maintenance Procedures
Since the system must receive or transmit UV and IR radiation
through the unit front panel glasses, it is important that both
glasses be kept as clean as possible. Always clean the glass with a
mild, non-abrasive detergent; cleaning frequency depends on the
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Chapter 3, Operation and Maintenance
environmental conditions at the installation site. If glass is fogged
or abraded, the Detector must be replaced.
To Clean the Front Panel Glass
1. Using a small, soft-bristle brush, wipe clean the entire front panel
surface including the glass portion.
2. With mild non-abrasive cleaner, carefully wipe the entire glass
surface until all dirt and oil film is removed. It may be necessary to
use a small soft bristle brush to remove difficult dirt and grime.
2. Thoroughly rinse the glass with clean water, ensuring no residue
is left behind.
3. Dry the glass with a clean dry cloth.
4. Enter the appropriate information into the Maintenance Log.
Periodic Maintenance Procedures
The SafEye Open Path Gas and Flame Monitoring System must
be checked periodically. As with any type of gas monitor, the
frequency of the maintenance depends on the operating time and
chemical exposures of the system. Newly installed systems should
be checked more often until the calibration records prove system
stability. The following chart and recommended maintenance time
period is only for guidance; your maintenance schedule may be quite
different than this. Your maintenance frequency must be set by the
safety officer or plant manager.
The Detector and Light Source units are maintained with
common tools and equipment. Record all maintenance done on
the system in a maintenance log book.
Recommended Maintenance Schedule
Cleaning the optical surfaces of all units at least once a month.
However, the frequency of the cleaning operations are dependent
upon the environmental conditions and exposures and the applications
of the units.
The alignment procedures must be performed each time the Light
Source or the Detector units are opened or moved for any reason.
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Chapter 3, Operation and Maintenance
Table 3-3. Recommended Maintenance Schedule
PERIODIC CHECKS
SIGNAL
INTENSITY
CHECK
1 MONTH
CLEAN
OPTICAL
WINDOW
√
3 MONTHS
6 MONTHS
√
√
√
√
APPROXIMATE
INTERVAL
MAINTENANCE
CALIBRATION
CHECK
ALIGNMENT
ZERO
CALIBRATION
√
√
√
Signal Intensity Check
The Signal Intensity Check:
• determines if units are misaligned
• checks the light source bulb; the bulb may weaken over time.
Clean the optical surfaces prior to performing this check. If the
units are mounted out of doors, this procedure must be
performed in clear weather.
1. Enter the Alignment Mode by placing the magnet on the side of
the Detector for two seconds (FIGURE 3-1).
2. Count the number of front-panel LED flashes:
• upper LED shows the "tens" unit of the intensity value
• lower LED displays the "ones" intensity value
• each LED blinks 1 to 10 times, with 10 representing the
maximum possible signal intensity.
3. Note what color LED is flashing.
4. Add the number obtained in Step 2 to the number found in
TABLE 3-4.
Table 3-4. Signal Intensity
LED COLOR
ADD
Red-Red
Orange-Orange
0
62
Green-Orange
124
Green-Green
186
5. Subtract the number from the original intensity number found in
the maintenance book.
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Chapter 3, Operation and Maintenance
6. If this number is greater than 15, perform an alignment; then,
redo this Signal Intensity Check procedure. If the number
obtained in Step 5 is:
• between 15 to 30, perform Zero Calibration.
• over 30, call MSA for service.
Signal Intensity Check Example
The following is an example of a Signal Intensity Check:
At initial installation:
• Green-Orange with three green upper LED flashes and 6 orange
lower LED flashes.
• initial signal intensity number is 36 + 124 = 160. (This is
recorded in the Maintenance Log).
During the next periodic maintenance of the unit, the LEDs are
flashing differently:
• front panel LEDs are Orange-Orange with eight orange upper
LED flashes and eight orange lower LED flashes.
• new signal intensity number is 88 + 62 = 150. Subtracting the
two: 160 - 150 = 10.
Since this number is less than 10, the signal intensity is still
within acceptable limits.
Flame Detector Periodic Maintenance
Test the Flame Detector periodically. Perform a functional test each
time the Detector is opened for any maintenance operation. Follow
the Section, Initial Test Procedure to perform a functional test. If
any problems are encountered, refer to the Section 3,
Troubleshooting Guidelines in this manual.
• Since the unit is approved, return it to MSA for all repairs.
Mine Safety Appliances Company
Service and Repair Department
300 Walden Road
Cranberry Township, PA 16066-5296
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Chapter 4, Troubleshooting
Section 4
Troubleshooting
Table 4-1. Troubleshooting Guidelines
INDICATION
Disconnected
(0 mA)
Fault (1 mA)
CAUSE
Power is not supplied to the Detector
Supply power to the Detector
Power is not supplied to the Light Source
Supply power to the Light
Source
The optical open path beam is blocked
Dirt has accumulated on the detector’s
window or on the Light source’s window
At least one of the units has been
moved or tilted
Remove the obstruction
Electrical problem
Misalignment
(3 mA)
SOLUTION
There was some movement to at least
one of the units
Clean the optical windows
Perform Realignment
If the Light Source is not
flashing, bring it to a
technician for service
If the light source is
flashing bring the detector
unit for service
Perform Realignment
4-1
Appendix A, Outline Drawing
Appendix A
Outline Drawing
Figure A-1.
Outline Drawing
A-1