Micropack - Model FDS300 - Intelligent Visual Flame Detector - Manual

FDS300 FLAME DETECTOR SAFETY & TECHNICAL MANUAL – Ref: 2401.6000 Rev. Date ECN Prepared Checked Approved 1.0 19th May 2011 1st Release G Duncan E Campion K Keefe FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 2 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 HELP US TO HELP YOU Every effort has been made to ensure the accuracy in the contents of our documents; however, Micropack (Engineering) Ltd can assume no responsibility for any errors or omissions in our documents or their consequences. Micropack (Engineering) Ltd would greatly appreciate being informed of any errors or omissions that may be found in our documents. To this end we include a form, given in Appendix B, for you to photocopy, complete and return to us so that we take the appropriate action. Thank you. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 3 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 Table of Contents 1 Introduction ............................................................................................................................................. 5 1.1 Features ........................................................................................................................................... 5 2 Safety Instructions ................................................................................................................................... 6 2.1 Warnings .......................................................................................................................................... 6 2.2 Cautions ........................................................................................................................................... 7 2.3 Important Safety Notices ................................................................................................................. 7 3 Installation ............................................................................................................................................... 9 3.1 Detector Enclosure ........................................................................................................................... 9 3.2 Mounting & Orientation ................................................................................................................ 10 3.3 Wiring Procedure ........................................................................................................................... 12 3.3.1 4-20mA Output ...................................................................................................................... 13 3.3.2 Relay Output .......................................................................................................................... 14 3.3.3 Internal Inter-connections ..................................................................................................... 15 3.4 Installation Checklist ...................................................................................................................... 16 3.4.1 Mechanical ............................................................................................................................. 16 3.4.2 Electrical ................................................................................................................................. 16 4 System Design Guidelines ...................................................................................................................... 17 4.1 Power Supply ................................................................................................................................. 17 4.2 Cable Selection ............................................................................................................................... 17 4.2.1 DC Power ................................................................................................................................ 17 5 Application Guidelines ........................................................................................................................... 18 5.1 Positioning Requirements .............................................................................................................. 18 5.2 Detection Coverage ........................................................................................................................ 19 FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 4 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 5.3 Exposure to Flare Radiation ........................................................................................................... 19 5.4 Optical Contamination ................................................................................................................... 19 5.5 Enclosed Areas ............................................................................................................................... 20 5.6 Detector Sensitivity ........................................................................................................................ 20 6 Maintenance & Testing .......................................................................................................................... 21 6.1 Maintenance .................................................................................................................................. 21 6.2 Functional Testing .......................................................................................................................... 22 7 Fault Finding ........................................................................................................................................... 23 7.1 Removal of the Electronics ............................................................................................................ 23 7.2 Replacement of the Electronics ..................................................................................................... 23 7.3 Diagnostics ..................................................................................................................................... 24 7.4 LED Indication ................................................................................................................................ 25 7.5 Power Fault .................................................................................................................................... 26 8 Technical Specification ........................................................................................................................... 27 8.1 Electrical Specification ................................................................................................................... 27 8.2 Mechanical Specification ............................................................................................................... 27 8.3 Environmental Specification .......................................................................................................... 27 8.4 Certification and Approvals ........................................................................................................... 28 8.5 Operating Specification .................................................................................................................. 28 Appendix A – Acronyms, Terms & Abbreviations .......................................................................................... 29 Appendix B – Help us to help you .................................................................................................................. 30 FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 5 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 1 Introduction The MICROPACK FDS300 is a flame detector that has unsurpassed false alarm immunity. The Micropack flame detection range are the safest and most advanced flame detectors on the market today, and their track record on the numerous facilities where they are installed has proven the technology to be robust, even in the harshest of environments. FDS300 flame detectors identify flame using certified flame recognition software. FM Approvals ensures that our flame recognition software is fit for purpose through rigorous research and testing in a range of difficult environments. Production losses caused by common sources of alarm from existing flame detection technologies are addressed by the FDS300 flame detector. The FDS300 has been designed for use in stand alone operation. 1.1 Features • The FDS300 has 120° horizontal x 80° vertical field of view with an increased range of 60 metres to an n-heptane 0.1m2 pan fire. • Single detection sensitivity setting because the FDS300 is unaffected by the background radiation experienced in industrial environments. • Superior False alarm immunity to common sources of unwanted alarms such as Hot process, Hot Work, Hot CO2 emissions and Flare Reflections. • Advanced optical verification test assuring readiness to perform when needed. • Outputs include both relay contact and 4-20 mA. • Separate termination chamber for ease of installation. • Flame simulation tester to verify operation from distances of 3-8 metres, removing the need for scaffolding or ladders. • FDS300 can operate via a standard 3 or 4 wire termination. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 6 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 2 Safety Instructions For the correct and effective use of this equipment, to maintain safety and avoid hazards it is essential that you read and understand these instructions fully, act accordingly BEFORE installing, operating or maintaining the equipment. PAY ATTENTION TO ALL SAFETY WARNINGS AND CAUTIONS-- 2.1 Warnings This equipment is certified and intended for use in potentially hazardous areas. Install and use the equipment in accordance with the latest regulations. For European (ATEX) installations IEC/EN60079-14 'Electrical Installations in Hazardous Areas' and ICE/EN60079-17 'Inspection and Maintenance in Hazardous Areas' should be strictly observed. For installations in North America the National Electrical Code (NEC) should be strictly observed. In other countries the appropriate local or national regulations should be observed. The equipment must be properly earthed to protect against electrical shock and minimise electrical interference. Do not drill holes in any housing or enclosure as this will invalidate the explosion protection. Ensure that the enclosure lid is fully tightened and locked into position before energising the equipment. Do not open the enclosure in the presence of an explosive atmosphere. All permits and proper site procedure and practises must be followed and the equipment must be isolated from the power supply before opening the enclosure in the field. Operators must be properly trained and aware of what actions to take in the event of a fire being detected. Cable to be used for installation is to be selected with a temperature rating of greater than 25 degrees Celsius above the maximum ambient temperature. The metric cable entries are fitted with an internal stop. This will result in threads of the cable gland being visible. Do not over tighten. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 7 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 2.2 Cautions Use only approved parts and accessories with this equipment. Do not attempt to replace the window as the glass and the front cover are individually matched pairs to meet the stringent requirement of the Hazardous area certification. To maintain safety standards, commissioning and regular maintenance should be performed by qualified personnel. 2.3 Important Safety Notices Pay attention to the guidelines given throughout this document. If in any doubt about the instructions listed within this manual then please contact Micropack (Engineering) Ltd. Micropack (Engineering) Ltd takes no responsibility for installation and/or use of its equipment if this it is not in accordance with the appropriate issue and/or amendment of the manual. Micropack (Engineering) Ltd reserve the right to change or revise the information contained herein without notice and without obligation to notify any person or organisation of such action. Only those parameters and configurations highlighted with the FM diamond (( ) have been tested and approved by Factory Mutual. Warning Do not open the detector assembly in a hazardous area when power is applied. The detector contains limited serviceable components and should never be opened except by trained personnel. Caution The wiring procedures in this manual are intended to ensure functionality of the device under normal conditions. Due to the many variations in wiring codes and regulations, total compliance to these ordinances cannot be guaranteed. Be certain that all wiring complies with the all local ordinances. If in doubt, consult the authority having jurisdiction before wiring the system. Installation must be done by trained personnel. Caution To prevent unwanted actuation or alarm, extinguishing devices must be inhibited/isolated prior to performance testing or maintenance. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 8 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 INSTALLATION Detector Orientation Detectors should be mounted with the earth stud/status led directly below the lens to ensure the 120° horizontal field of view is achieved. Detector Positioning Detectors should be positioned to provide the best unobstructed view of the area to be protected. The following factors should also be taken into consideration: • Identify all high risk fire ignition sources. Ensure that enough detectors are used to adequately cover the hazardous area. • Locate and position the detector so that the fire hazard(s) are within both the field of view and detection range of the device. • For best performance, the detector should be mounted on a rigid surface in a low vibration area. • Extremely dense fog or blizzard conditions could eventually block the vision of the detector. • For indoor applications, if dense smoke is expected to accumulate at the onset of a fire, mount the detector on a side wall (approximately 1 metre, 3 feet) down from the ceiling. • The FS301 flame simulator can be used to verify correct detector positioning and coverage. • The FDS300 has one sensitivity setting, this is factory set, no changes can be made to set-up except by fully trained Micropack engineers. • The detector carries out continuous internal hardware diagnostic testing to ensure correct operation is relayed to the control system. • The FDS300 is not designed to annunciate diagnostic failures of signal returns via external wiring. Control systems and fire panels generally have fault monitoring for such an eventuality. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 9 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 3 Installation The FDS300 design has been developed to allow simple installation. The detector comprises two key components, the detector enclosure and the detector internal assembly. The detector assembly located in the front of the enclosure should not be removed except by trained personnel. Unauthorised removal or disassembly of the detector assembly will invalidate the warranty. Only the rear end cap can be removed for terminal access. 3.1 Detector Enclosure The detector electronics are housed in an enclosure certified for use in hazardous areas. For the exact certification and conditions of use see certification label on the device, or the example drawing below: The enclosure comprises the front enclosure cover (including the faceplate window), the rear enclosure cover, the enclosure body (with certification label), and the mounting bracket. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 10 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 3.2 Mounting & Orientation The mounting bracket allows the detector’s vertical orientation to be adjusted from 0 to 45°, and allows a horizontal rotation of +/-45°. Figure 1: Detector Mounting Bracket & Orientation FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 11 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 Figure 2: Ceiling Mount Figure 3: Wall Mount Firm, vibration free mountings are essential for trouble free operation of optical systems and the detector should, wherever possible, be fixed to comparatively rigid mountings. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 12 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 3.3 Wiring Procedure The wiring terminals are located in the rear section of the detector enclosure and are accessible by removal of the end cap. The front section of the enclosure should only be accessed by trained personnel. The terminal schematic (figure 2) detailed below shows the view looking inside the detector following removal of the end cap. The detector has two types of alarm output available simultaneously ? 4-20mA (source) ? Relay (Alarm & Fault) Listed below are wiring options dependant on the functional requirements of the detector. Figure 4: Terminal Schematic FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 13 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 3.3.1 4-20mA Output The following wiring connection diagram shows wiring the detector when a 4-20mA output is required. Table 1: Current Level Output Indicators Factory Fixed Values Current Output Event 0mA Power/Detector Fault 2mA Optical Fault 4mA Healthy 18mA Alarm 21mA Over-range Figure 5: 3 Wire Termination FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 14 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 3.3.2 Relay Output The following wiring connection diagrams shows wiring the detector when a relay output is required. Figure 6: 2 Pair Termination FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 15 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 3.3.3 Internal Inter-connections The following diagram shows the internal inter-connections of the alarm and fault relay contacts and jumpers. Each field connection is listed on this diagram for clarity. Figure 7: FDS300 Internal Inter-connections FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 16 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 3.4 Installation Checklist Experience has shown that poor installation and commissioning practice may result in an unreliable fire detection system that fails to meet the site performance targets. Before installing the detector it is important to take into account where it is to be located and how it is to be mounted. 3.4.1 Mechanical Notes When locating the detector consideration should be given to maintenance access to the detector. The detector mounting should be secure and vibration free. It is advisable to check the detection locations, prior to fabrication of the mounting supports, as changes are frequently made during construction at site which can affect detector coverage. The installation should allow subsequent space for detector removal, for maintenance or repair, to be easily achieved. 1 The detector should be fixed to a stable supporting structure using the mounting bracket provided. The supporting structure must allow for horizontal adjustment of the detector orientation. The support structure should be in place prior to detector installation. Information on mounting is available from Micropack (Engineering) Limited. 2 The threaded flame path of the enclosure cover and body must be protected from damage during installation. Any such damage can destroy the validity of the enclosure. 3 The detector electronics shall be protected from mechanical damage and external sources of EMI such as X-rays, RFI and electrostatic discharge. The detector should not face directly towards the sun. 4 Fit the mounting bracket to the support structure using 8mm bolts (not provided). The detector (bracket) should be oriented to provide the desired coverage. 5 The detector enclosure body should be fitted to the mounting bracket. The bolts locate into the bracket. Twist the enclosure to locate the bolts; these are then tightened using a 6mm Allen key. 6 Ensure the detector is orientated such that the status led/earthing stud is directly beneath the lens. 7 Glanding should be carried out by trained personnel. The gland should be fitted in line with installation standards for potentially explosive atmospheres, that is 5 full threads minimum with the IP seal washer fitted at the bottom of the thread. The gland should be torqued between 15 to 20 N·m (11 to 15 lbf·ft). 3.4.2 Electrical In order to maintain compliance with the EMC regulations it is essential the electrical installation be engineered correctly. Notes It is advisable to check the detection locations, prior to fabrication of the mounting supports, as changes are frequently made during construction at site Detector cabling must be segregated from cables carrying high-speed data or high energy and/or high frequency signals and other forms electrical interference The detector requires a clear unobstructed view of the local hazard. In order to avoid local obstructions, such as pipe-work and cable trays, a 2m helix should be allowed in the detector cabling The detector should only be fitted just prior to commissioning the detector. Experience shows that the detector can be damaged due to cable testing operations (Insulation Tests, etc) 1 Isolate all associated power supplies. Ensure that they remain OFF until required for commissioning. 2 The threaded flame path of the enclosure cover and body must be protected from damage during installation. Any such damage can destroy the validity of the enclosure. 3 The electronics subassembly shall be protected from mechanical damage and external sources of EMI such as X-rays, RFI and electrostatic discharge. 4 The enclosures external earth stud should be connected to a local earth point. 5 Remove the blanking plug(s) from the enclosure body gland entries. 6 Fit approved cable glands. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 17 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 4 System Design Guidelines The following guidelines are intended to assist with the electrical design and engineering of systems where it is intended that flame detectors will be used. 4.1 Power Supply The detector requires an absolute minimum supply voltage of 18V, as measured at the detector terminals. The system power supply voltage and power distribution should be arranged such that on the longest cable run the detector(s) has a supply voltage of greater than 18V. 4.2 Cable Selection Cable to be used for installation is to be selected with a temperature rating of greater than 25° Celsius above the maximum ambient temperature. The metric cable entries are fitted with an internal stop. This will result in threads of the cable gland being visible. Do not over tighten. The installation and local regulations and standards determine the overall cable specification. This section specifies suitable cable characteristics to ensure correct operation of the flame detector. 4.2.1 DC Power NOTE: Table 2 shows absolute maximums for cable lengths; try not to approach these values. Table 2: Maximum Cable Lengths (24V supply) Installation based on 24V nominal supply Number of Flame Detectors Maximum Power (W) Maximum Cable Length (m) with 1.5mm2 Conductors (12?/km) Maximum Cable Length (m) with 2.5mm2 Conductors (7.6?/km) Detector 1 2.4 1,000 1,578 Table 3: AWG Conversions Cross Sectional Area (mm2) American Wire Gauge (AWG) Typical Conductor Resistance per km (3280 ft) DC Ohms /km @ 20°C (approximate) 0.5 22 36 1 18 19 1.5 16 12 2.5 14 7.6 FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 18 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 5 Application Guidelines In considering the application of the detector it is important to know of any conditions that may prevent the detector from responding. The detector provides reliable response to visible flames within its field of view, and insensitivity to common false alarm sources. Solid obstructions or a direct view of intense light sources may result in a reduction in the coverage and/or a reduction in the detector sensitivity. Scaffolding or tarpaulins in the detector's field of view may reduce coverage. Contamination of the detector window may result in a reduction in sensitivity. The detector has a horizontal field of view of 120° and a vertical field of view of 80°. The location and orientation of the detector in relation to the protected area determines the actual footprint. Achieving the desired coverage depends on congestion within the protected space, the location of the detector(s) and the distance of the detector from the hazard. It may be necessary to install more than one detector within an area in order to achieve adequate coverage. The detector sensitivity, expressed as fire size at a distance, is determined visually by the apparent size of the fire. This is a function of the fuel source, how it is released and distance from the detector to the fire. The detector response time is relatively independent of fuel type and/or distance. In common with other forms of flame detection the detector’s sensitivity is reduced and potentially blinded by dense obscurants such as smoke, fog and other airborne particulates. The detector is insensitive to arc welding, however this should not be conducted within 1m of the detector. 5.1 Positioning Requirements The following guidelines have been based on operational feedback, reflecting commonly experienced problems which can be traced to a failure to observe the following: • Ensure the mounting position is free from vibration or movement. • Prevent accidental knocking or forcing out of alignment. • Isolate as far as possible from local electrical interference sources. • Ensure sufficient detection to achieve adequate coverage for all likely hazards. • Minimise exposure to contamination of the detector face plate. • Ensure ease of maintenance access to detector (i.e. direct, ladder or scaffold access). All these issues are of crucial importance to a successful installation and they should be afforded great attention during the detailed design, construction and commissioning phases of the work. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 19 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 5.2 Detection Coverage Detector locations can be chosen from computer models or from site surveys. The detectors should be aligned to view the intended hazard taking into account any obstruction and congestion. Software analysis of the actual detector coverage may be required to ensure adequate coverage of the hazards. This analysis can also be used to optimise the number of detectors and the loop configuration. 5.3 Exposure to Flare Radiation Flame detectors are frequently used where hydrocarbon fire hazards are expected; these are quite often processing plants where a flare stack is in use nearby. The detector should not have a direct view of the flare. 5.4 Optical Contamination There are many sources of contamination such as oil, water (deluge water, rain and sea-spray), snow, ice, and internal misting. Excessive contamination of the detector faceplate may result in an increased maintenance requirement and potentially reduce the detector’s sensitivity. Where detectors are mounted at low level, care should be taken to avoid contamination (such as water and oil) from equipment above the detector. Care should be taken in sighting the detector to minimise the likelihood of such contamination. Figure 8: FDS300 Coverage & Field of View FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 20 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 5.5 Enclosed Areas In enclosed areas, if dense smoke is expected to accumulate at the onset of the fire, the detector should be mounted 1 to 2 metres below the ceiling level. 5.6 Detector Sensitivity The detector’s response to a fire is a function of the fuel source and how it is released, fire size and distance, orientation to the detector and local ambient conditions. The typical figures are based on in-house tests except where marked with the FM logo these tests were conducted and certified by Factory Mutual. As with all tests the results must be interpreted according to the individual application taking into account all possible variables. The detector sensitivity to different fuel sources is dependent on the apparent size of the flame, the detectors typical response is shown below (see table 4). Table 4: Typical FDS300 Response Characteristics Fuel Fire Size Distance Methane Jet Fire 3ft plume 26m (86 feet) Ethanol 0.3m x 0.3m pan 30m (100 feet) Diesel 0.3m x 0.3m pan 50m (165 feet) Crude Oil (heavy fuel oil) Pan Fire 0.5m x 0.5m pan 50m (165 feet) Wax Inhibitor (Clear 10) Pan Fire 0.3m x 0.3m pan 50m (165 feet) Anti Foam (Surflo AF-300) Pan Fire 0.3m x 0.3m pan 50m (165 feet) Wood Stack 0.3m x 0.3m crib 50m (165 feet) n-Heptane Pan Fire 0.3m x 0.3m pan 60m (200 feet) n-Heptane Pan Fire in direct sunlight 0.3m x 0.3m pan 60m (200 feet) n-Heptane Pan Fire in modulated sunlight 0.3m x 0.3m pan 60m (200 feet) n-Heptane Pan Fire in the presence of modulated black body radiation 0.3m x 0.3m pan 60m (200 feet) n-Heptane Pan Fire in the presence of Arc welding 0.3m x 0.3m pan 60m (200 feet) n-Heptane Pan Fire in the presence of a 1000watt lamp 0.3m x 0.3m pan 60m (200 feet) Gasoline pan Fire 0.3m x 0.3m pan 60m (200 feet) JP4 0.6m x 0.6m pan 90m (300 feet) FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 21 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 6 Maintenance & Testing 6.1 Maintenance This maintenance schedule is intended for guidance only. The actual level of maintenance required will depend on the severity of the operating environment and the likelihood of damage or the rate of contamination from oil, sea spray, deluge system etc. It is advisable to regularly review maintenance reports and adapt the maintenance period to the operating environment. Step Periodic Inspection and Maintenance Suggested Interval 1-6 General Inspection and maintenance of the detector and faceplate 6 monthly 6-14 Specific inspection and maintenance of the detector enclosure 12 monthly 15 Detector function testing 6 monthly Step Activity Key Points 1 Detectors that require maintenance should be taken off line and inhibited. Detectors which require to be opened up will need to be isolated electrically Ensure that panel wiring and terminations associated with all units under test are in good order 2 Ensure that detector mounting arrangements are secure and undamaged 3 Ensure that the detector enclosure is intact and undamaged 4 Ensure that all associated cables and glands are correctly made up, secure and undamaged 5 Clean the enclosure faceplate (outside) with a mild detergent solution and a soft cloth until the window is clear of all contamination. Wash the window thoroughly with clean water and dry with a clean lint free cloth or tissue Assess requirement for opening the enclosure, for maintenance or cleaning, follow steps 6 to 14 6 Open up the detector enclosure if required, by removing the enclosure cover. This exposes the enclosure flame path and detector lens. Avoid damage to the flame path, faceplate and lens 7 Clean the enclosure cover and body flame paths with a dry clean cloth to remove any contamination. If the flame path or threads are badly pitted the component should be replaced 8 Check the 'O' ring seal on the enclosure cover is not damaged or perished, replace as required. Note the ingress protection is compromised if the seal is not correct 9 Clean the enclosure faceplate (inside) with a mild detergent solution and a soft cloth until the window is clear of all contamination. Wash the window thoroughly with clean water and dry with a clean lint free cloth or tissue 10 No-setting waterproof grease should be evenly applied to the flame path on both the enclosure cover and body 11 Clean the detector lens. This should be done with a soft, dry and clean cloth Avoid touching the optics or electronics 12 Clean the detector enclosure faceplate. Use a degreasing agent on the outside in order to remove deposits 13 The enclosure cover must be screwed on to a minimum of 5 full turns or until fully tight and secured using the locking screw provided 14 Reinstate the detector back into service. 15 Ensure that inhibits are applied, then, using the flame test torch, function test the detector. Note the detector LED indicator, within the detector housing, changes colour to RED Check the complete display system for correct function and indication. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 22 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 6.2 Functional Testing The detector can be function tested using the FS301 Flame Simulator, which has been specifically designed to provide a convenient means of field testing the detector. Refer to the FS301 Flame Simulator user manual (ref. 2301.6042) for instructions on its use. Failure of the detector to respond to the FS301 flame simulator should be reported to Micropack (Engineering) Limited (info@micropack.co.uk). It should be ensured that the flame detector and flame simulator are being used correctly in the first instance by referring to their manuals. Detector/simulator returns along with a written statement describing any fault should be sent to the address listed below: Micropack Engineering Repairs Ltd Brookfield House Tarporley Road Cheshire WA4 4EA FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 23 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 7 Fault Finding 7.1 Removal of the Electronics Warning there is no user replaceable parts within the electronic module any attempt to repair or dismantle the electronic sub-assemblies will void the warranty. If any fault is suspected within the electronics module the module is to be returned to Micropack for investigation and repair if required. Any faults should be reported to Micropack as per the instruction in section 6.2. Removal of the electronics should only be performed by competent personnel. The following is the procedure for removal of the electronic module:- 1. Loosen the allen screw that secures the lens cap to the housing. 2. Un-screw the lens cap assembly and remove. 3. Gently un-screw the three screws indicated on the label until they freely turn. 4. Please note these screws are not removable. 5. Grasp the two screws positioned at the bottom of the detector and pull the electronics module out of its housing. 7.2 Replacement of the Electronics The following is the procedure for Installation of the electronic module:- 1. Insert the electronic module with the LED positioned at the bottom of the housing. 2. Rotate the module clockwise and anti-clockwise until the locating pins click into position. 3. Push the electronic assembly into the housing until the face plate is flush with the front of the housing. Note: This should take minimum force if the locating pins are in position. 4. Gently screw the three screws in indicated on the label in until they bottom into their counter sinks Note: Do not over tighten. 5. Grease and replace the lens cap. 6. Tighten the lens cap Allen locking screw. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 24 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 7.3 Diagnostics It is impossible to provide fault diagnostics for every possible detector fault. The following flowchart represents the most likely faults. In all cases it is advised that the following best practise is followed: • Only make one change at a time (changing more than one thing makes diagnosis very difficult). • Check the most obvious possible causes first. • Work systematically through the problem. • Keep good notes on the original problem, each step taken and the results observed. FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 25 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 7.4 LED Indication The detector LED indicator is used to reveal the detectors current state, as shown below: Table 5: LED Status Diagnostic Chart LED Colour Status Indicator Green Healthy Steady OFF 24V/0V Terminals Polarity Reversed Steady OFF No Power/Major Internal Fault Steady Yellow Fault Red Alarm Figure 9: FDS300 Fascia - Status LED FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 26 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 7.5 Power Fault If the detector LED indicator is OFF then there may be a power supply fault, as shown below: When investigating power supply faults it is important to check that all voltages are within the detectors operating range (18V to 32V) under full load conditions as the voltages measured under no load conditions can be misleading. Figure 10: Power Supply Diagnostic Chart FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 27 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 8 Technical Specification 8.1 Electrical Specification Parameter Units Min Max Comment Power Supply Supply Voltage V 18 32 Inc. ripple Supply Ripple Vpk-pk - - 1 Detector Power Consumption W - - 3.2 2.4W Nominal @ 24Vdc Detector shutdown voltage (low supply) V <17 8.2 Mechanical Specification Parameter Units Value Comment Enclosure Overall Dimensions mm 100 Diameter x 220 Length Shipping Weight Kg 2.5 5.5 Material HE30 Aluminium 316SS Coating Colour Red Epoxy Coated Finish Cable Entries mm/inches M25, 3/4 NPT Other variants on request Terminal Wire Size mm2 2.5 Ingress Protection IP 66 (NEMA 4X) Mounting Bracket Support Fixings mm 2 x M8 Vertical Adjustment Degrees 0 to 45 Horizontal Adjustment Degrees 0 Provided by support Axial (horizontal) Rotation Degrees +/-45 8.3 Environmental Specification Parameter Units Min Max Comment Operating Ambient Temperature °C - 60 + 85 T4 Storage Ambient Temperature °C - 60 + 85 Relative Humidity % RH 0 90 Non Condensing FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 28 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 8.4 Certification and Approvals Parameter Authority/Standard Approval Certificate Hazardous Area Certification ATEX Ex II 2 GD EExd II C T4 IP66 FM07 ATEX 0033 Hazardous Area Certification NEC 505 Class1 Zone 1 AExd 11C T4 3029978 Hazardous Area Certification NEC 500 Class1 Div 1 Groups B,C and D 3029978 Hazardous Area Certification IECEx Ex II 2 GD EExd,11C T4 IP66 FME07.0002 Fire Service Listing FM Class 3260, 3600, 3615, 3810 3009845 CE Marked (Emissions) EN61000-6-3:201 UKS 9567TC2/9762TC2 CE Marked (Immunity) EN50130-4+A1:1998+A2:2003 UKS 9567TC2/9762TC2 8.5 Operating Specification Parameter Units Min Max Comment Detector Range (depth of field) m 2 60 Horizontal Field of View Degrees 120 - - Vertical Field of View Degrees - - 80 Detector Response Time Seconds 4.2 30 Power on reset delay Seconds - - 5 FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 29 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 Appendix A – Acronyms, Terms & Abbreviations Term Description AC Alternating Current ATEX Atmosphere Explosive AWG American Wire Gauge BS British Standard CCTV Closed Circuit Television CE European Commission (approval) CO2 Carbon Dioxide CSA Canadian Standards Association dB Decibel DC Direct Current EMC Electromagnetic Compatibility EN European National (standard) FM Factory Mutual FOV Field of View I or A Electrical Current or Ampere JB Junction Box Km Kilometre kW Kilo Watt LED Light Emitting Diode MEL Micropack (Engineering) Ltd mH Milli Henry – Inductance MOR Meteorological Optical Range NEC National Electrical Codes nF, pF Nano Farad, Pico Farad – Capacitance PC Personal Computer (IBM PC Compatible) R or ? Ohms (electrical resistance) V Voltage Vs Versus W Watts (Wattage) FDS300 Flame Detector FDS300 Safety and Technical Manual Ref: 2401.6000 Page 30 of 30 Rev: 1.0 This document is strictly private and confidential, reproduction without Micropack approval is prohibited. © Micropack Engineering Ltd, 2012 Appendix B – Help us to help you TO: QA Department Micropack (Engineering) Limited Fire Training Centre Schoolhill, Portlethen AB12 4RR Tel : +44 (0) 1224 784055 Fax : +44 (0) 1224 784056 Email : info@micropack.co.uk From: Tel : Fax : Email : I suggest the following corrections/changes be made to Section …………… Marked up copies attached (as appropriate): Yes/No Please inform me of the outcome of this change: Yes/No For Micropack (Engineering) Limited : Action by: Date: Response: Date: 1 Introduction 1.1 Features 2 Safety Instructions 2.1 Warnings 2.2 Cautions 2.3 Important Safety Notices 3 Installation 3.1 Detector Enclosure 3.2 Mounting & Orientation 3.3 Wiring Procedure 3.3.1 4-20mA Output 3.3.2 Relay Output 3.3.3 Internal Inter-connections 3.4 Installation Checklist 3.4.1 Mechanical 3.4.2 Electrical 4 System Design Guidelines 4.1 Power Supply 4.2 Cable Selection 4.2.1 DC Power 5 Application Guidelines 5.1 Positioning Requirements 5.2 Detection Coverage 5.3 Exposure to Flare Radiation 5.4 Optical Contamination 5.5 Enclosed Areas 5.6 Detector Sensitivity 6 Maintenance & Testing 6.1 Maintenance 6.2 Functional Testing 7 Fault Finding 7.1 Removal of the Electronics 7.2 Replacement of the Electronics 7.3 Diagnostics 7.4 LED Indication 7.5 Power Fault 8 Technical Specification 8.1 Electrical Specification 8.2 Mechanical Specification 8.3 Environmental Specification 8.4 Certification and Approvals 8.5 Operating Specification Appendix A – Acronyms, Terms & Abbreviations Appendix B – Help us to help you