Intelligent sensor for toxic gas detection (84 pages)
Summary of Contents for General Monitors FL4000
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General Monitors. Instruction Manual 04-09 General Monitors reserves the right to change published specifications and designs without prior notice. MANFL4000 Part No. MANFL4000...
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FL4000 This page intentionally left blank...
Field Wiring Procedure ......................26 Detector Mounting and Installation ..................27 Terminal Connections ......................29 Switch Selectable Options .......................36 Powering of the FL4000......................37 Power up Grounding of the Test and Relay Reset Lines............38 4.0 MODBUS INTERFACE ......................39 Introduction ..........................39 Communication Slave Address....................39 Baud Rate ..........................39...
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Cleaning the Sapphire Window....................57 Sensitivity Check........................58 Storage.............................58 6.0 TROUBLESHOOTING......................59 Troubleshooting Chart ......................59 Final Assembly.........................60 7.0 CUSTOMER SUPPORT ....................... 61 General Monitors’ Offices ......................61 Other Sources of Help ......................61 8.0 APPENDIX..........................62 Warranty...........................62 Specifications ...........................62 Regulatory Agency Approvals....................64 Response to False Stimuli .......................65 Spare Parts and Accessories....................66...
Figure 4: Bracket Assembly............................ix Figure 5: Field Terminations Showing Wiring for Fire Alarm Systems..............ix Figure 6: FL4000 Front View ..........................14 Figure 7: Test Lamp Flashing Option (Auto-detection) ..................19 Figure 8: Grounding of Test Wire or MODBUS Command Options..............20 Figure 9: Horizontal FOV –...
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FL4000 Table of Tables Table 1: Glossary of Terms ..........................12 Table 2: Sample Industry Applications ......................... 15 Table 3: LED sequence for each operating condition..................16 Table 4: Required Tools ............................21 Table 5: Maximum Specified Fields of View at High Sensitivity................22 Table 6: Sensitivity Settings for n-Heptane ......................
The following procedure should be used in conjunction with the housing diagram below to disassemble the Electronic Module Tube for wiring: Figure 1: FL4000 Housing 1. Loosen the Setscrew (A) located on the Compression Cap (B) and unscrew the Compression Cap (B) until Optical Module Assembly is completely removed.
FL4000 Figure 4: Bracket Assembly Figure 5: Field Terminations Showing Wiring for Fire Alarm Systems Applying Power to the Detector Two light emitting diodes (LED’s) are visible through the window. Immediately upon powering up the detector, both LED’s will start blinking alternately for 15 seconds. The unit will then enter the “Ready”...
General Monitors provides extensive documentation, white papers, and product literature for the company’s complete line of safety products, many of which can be used in combination with the FL4000. Many of these documents are available online at the General Monitors website at http://www.generalmonitors.com.
The FL4000 contains components that can be damaged by static electricity. In order to avoid static electricity, special care must be taken when wiring the system to ensure that only the connection points are touched.
Damage to the FL4000 housing where any internal components or protective seals are broken, compromises the safety and usability of the device. An FL4000 with a damaged or open housing should not be used in a hazardous environment. Such damage includes fractures in the housing, cracks in any internal components, or cracks in the protective seals.
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FL4000 Term / Definition Abbreviation National Pipe Thread Over voltage return OV Return Power Supply Common Ground 0VDC Combining with Oxygen Oxidation Printed Circuit Board Programmable Logic Controller Parts per million Radio Frequency Interference Root-Mean-Square Read Only Memory Room Temperature Vulcanization...
Dual Redundant MODBUS RS-485 User Interface (Standard FL4000 Configuration): Provides the capability to operate the FL4000 remotely, using 2 redundant channels. This interface allows the user to remotely change the alarm and warning relay settings, clear selected faults, clear error counters, change baud rates, and change formats for serial communication lines.
FL4000 Applications The FL4000 provides flame detection for a wide range of applications, including, but not limited to the following: Table 2: Sample Industry Applications Industries Sample Applications On and Offshore Platforms Oil and Gas Compressor Buildings Gas Pipelines Airplane Hangars...
NOTE: The FL4000 will not detect a flame while in Test Mode. The FL4000 has the ability to initiate a special Test Mode, which enables the user to test the response of the unit without the use of a flame source. Once the Test Mode has been activated, the unit will not detect a flame, but rather, responds to GM’s Test Lamp as a simulated flame...
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Each time the Test Mode is activated and the Test Lamp is successfully detected, regardless of which option is used, the FL4000 maintains a timestamp of the test. This timestamp is available to the user via MODBUS registers 0x6A, 0x6B, and 0x6C.
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FL4000 • After 5-8 seconds of the Test Lamp flashing in Phase 3, the FL4000 goes into Phase 4, indicating 1.5 mA (3.5 mA with HART) at the analog output, changing the LED flashing to indicate “Test Mode Running” shown in sequence #8 (Table 3).
- RESEND TEST MODE MODBUS COMMAND TEST LAMP FLASHING IN TL103 MODE FOR TL104 OR IN SWITCH POSITIONS 1-3 and 5 FOR Tl105 TEST LAMP TEST LAMP TEST LAMP IS POINTED ON FL4000 PHASE 0 FLASHING PHASE 1 LED FLASH ANALOG...
FL4000 IGNORED MISUSE CONDITIONS REPEAT GROUNDING OF TEST WIRE - HOLD TEST WIRE GROUNDED READY - RESEND TEST MODE MODBUS COMMAND - TEST LAMP FLASHING IN TL103 MODE FOR TL104 MODE OR IN SWITCH POSITIONS 1-3 and 5 FOR Tl105...
If any damage has occurred or there is any discrepancy in the order, please contact General Monitors. Refer to Section 7.0 for contact information. NOTE: Each FL4000 is completely tested at the factory; however, a system check is required upon initial start-up to guarantee system integrity.
30 ft (9 m) 90° Maximum specified FOV is the angle at which FL4000 can detect the flame at 50% of the maximum specified range. Maximum specified FOV is the angle at which FL4000 can detect the flame at 50% of the maximum specified...
FL4000 Figure 14: Vertical FOV – n-Heptane – Low Figure 13: Vertical FOV – n-Heptane – Medium Sensitivity. Sensitivity. 3.3.2 Optical Sensitivity Range The distance at which the detector will respond to a flame is a function of the intensity of that flame.
Avoid conditions of ice build up on the optical detector windows. Complete icing-over of the IR detector window can result in fault conditions. • Modulated reflected sunlight shining at the face of the FL4000 reduces flame detection distance. Field Wiring Procedure...
DAMAGE COULD OCCUR FROM IMPROPER ALIGNMENT. Detector Mounting and Installation The FL4000 is enclosed in an explosion proof assembly, which is rated for use in the environments specified in Section 8.3.2. •...
Water entering the housing through the conduit entry will damage the electronics and nullify the warranty. The FL4000 is mounted as shown in Figure 16 and the overall product dimensions are depicted in Figure 17. NOTE: Conduit seal must be within 18” of unit.
FL4000 Figure 17: Dimensional Drawing Terminal Connections All wire connections are made through the ¾ inch (1.9 cm) NPT openings in the Junction Module (C, Figure 15) to the Terminal Block. The Terminal Block is located on the Junction Module Assembly (F) and accepts 14 AWG (2.08 mm ) to 22 AWG (0.33 mm...
FL4000 3.6.1 Alarm Relay Table 8: Alarm Relay Terminals Terminal Block Connection Point Block Name User Relay Settings Normally De- Normally energized Energized Term 5 ALM2 Alarm NO Alarm NC Term 6 ALM1 Alarm NC Alarm NO Term 7 ALMC...
Description: These connections are to the SPDT WARN relay. The WARN output is immediate on the FL4000. The WARN output can be normally energized or de-energized, latching, or non- latching. These options are also set via MODBUS or by a dipswitch (Section 3.7 ). The WARN relay contact ratings are 8 A @ 250 VAC and 8 A @ 30 VDC.
P1 terminal 9 (GND), the user can put the unit into a special test mode. When the switch is first closed, the mode is set and the FL4000 goes to 1.5 mA and 3.5 mA with HART (ready mode) and remains at this value while detecting the Test Lamp. The relays are not activated.
FL4000 3.6.7 Alarm Test Terminals Table 13: Alarm Test Terminals Terminal Block Connection Point Block Name Setting Term 4 TEST_IO Test Mode Term 4 RLY_IO Relay Reset By connecting one contact of a DPST, normally open, momentary switch to each of the P1 terminal 4 and P2 terminal 4 simultaneously and the other contact to (GND), the user can perform an Alarm Test (Figure 22).
Term 9 Ground (COM) Table 17 shows the power connections for the FL4000. The supply voltage range is 20 to 36 VDC at the detector (low voltage is detected at 18.5 VDC). The following maximum cable lengths apply for a +24 VDC supply (maximum 20 Ω loop):...
3.7.1 Time Delay Settings Time delay set via dip switch guarantees that FL4000 will not go into ALARM mode (20 mA) if the flame source is removed within 50% of set delay time from the start of flame. The unit will...
WARN Normally Energized WARN Normally De-Energized Powering of the FL4000 After connecting to a 24 VDC power source, the unit will go through a power up delay of approximately 15 seconds. The LEDs will blink in alternating red – green sequence, the unit will output an analog signal of 0mA (3.5 mA with HART) and the fault relay will be in the de-...
FL4000 Power up Grounding of the Test and Relay Reset Lines During power up, grounding the reset relay line for approximately 1 second forces the MODBUS parameters on both channels to go to their default values of: 19,200 Baud, 8-N-1 format, and Unit ID = 1.
Communication Slave Address The FL4000 communication slave address is a unique ID used by the MODBUS protocol to identify each unit on a multi drop MODBUS communication bus. The address may contain the values 1 – 247. There are two communication channels on the FL4000. Each channel may have a separate slave address.
• Function Code 06 (Preset Single Register) is used to write a command to the slave unit. MODBUS Read Status Protocol (Query / Response) A master device reads registers from the FL4000 by sending an 8-byte message (Table 24). Table 24: MODBUS Read Register(s) Request...
Exception Code Field: In a normal response, the FL4000 returns data and status in the response data field. In an exception response, the FL4000 returns an exception code (describing the FL4000 condition) in the data field. Below is a list of exception codes that are supported by the FL4000:...
FL4000 Command Register Locations Table 30: Command Register Locations Register Data Address Parameter Function Data Range Access Type (Hex) Numeric 0-65535 0x0000 Analog Output 0-20mA current output Value (0-20.0mA) Numeric 0x0001 Operating Mode View operating mode Table 31 Value 0x0002...
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FL4000 Register Data Address Parameter Function Data Range Access Type (Hex) 1 = Alarm Remote Alarm Activates Warn & Alarm Numeric 0x0012 test, 0 = Test Relays Value done test. Clear COPM Fault Reset COPM Counters to Bit 1 =...
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FL4000 Register Data Address Parameter Function Data Range Access Type (Hex) Numeric 0x003F Line Voltage Line input voltage * 10.0 Value * 50 - 360 0x0040 – Reserved 0x0046 1 –99 year, Real Time Clock Read/Set year and month Numeric 0x0047 1–...
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FL4000 Register Data Address Parameter Function Data Range Access Type (Hex) Numeric 0x00A7 Reserved Reserved Value Warning Event Total Warning Event Numeric 0x00A8 0 - 65535 Count Count Value Running Time Hi for Numeric 0x00A9 Running Time Hi 0 - 65535...
0-65535 decimal. 4.10.2 Operating Mode (0x0001) A read returns the present mode of the FL4000. A write command changes the mode to the requested mode. NOTE: Returns an Exception Code 03 (Illegal Data Value) if an illegal write is requested.
Relay Reset Shorted NOTE: Bits set to “1” when errors occur. 4.10.4 Unit Type (0x0004) A read returns the MODBUS identification number for the FL4000. The identification number for the FL4000 is 3500. 4.10.5 Software Revision (0x0005) A read returns the software revision of the FL4000 as two ASCII characters.
NOTE: If the address is not in range an Illegal Data Value (03) is returned. By grounding the RESET input during the first 1 second of the power up cycle, the FL4000 Address will default to 1. The address will be set to a default of 1 when the red and green LED’s flash alternately after approximately 1 second, at which time the RESET input can be released from ground.
RESET input can be released from ground. 4.10.12 COPM Counts Sensor 1 (0x000D) A read indicates the number of COPM Faults that have occurred for sensor 1 in the FL4000. Please refer to Section 2.4.2 for more information on COPM and Section 6.0 for troubleshooting tips.
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FL4000 4.10.14 COPM Counts Sensor 3 (0x000F) A read indicates the number of COPM Faults that have occurred for sensor 3 in the FL4000. Please refer to Section 2.4.2 for more information on COPM and Section 6.0 for troubleshooting tips.
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CRC Errors Low – COM1 and COM2 (0x0025) A read indicates the total number of COM1 or COM2 CRC low byte errors in the FL4000. The maximum count is 65535, after which the counter resets to zero and begins counting anew.
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4.10.32 COM2 Data Format (0x0031) A read returns the COM2 data format of the FL4000. A write changes the data format to the requested format. After changing the data format of the FL4000, it will be necessary for the controlling or master device to similarly change its own data format in order to once again communicate with the FL4000.
FL4000 The user is able to read the times of each of these by setting this event index followed by a reading of the desired event log. The event index is a number from 0 to 9. Zero refers to the most recent event and 9 refers to the least recent event stored in the log.
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FL4000 This time is in seconds since January 1, 2000. This register should be read before register 0xAA. 4.10.49 Alarm Running Time in Seconds, Low Word (0x00AA) This register reads the low word of the running time in seconds when the alarm event occurred.
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FL4000 4.10.61 Fault Code (0x00B6) This register is described in Table 32. 4.10.62 Reserved (0x00B7) This register returns the value 0. 4.10.63 Total Fault Event Counter (0x00B8) This reads the total number of fault events have been stored in the unit.
General Maintenance Once correctly installed, the unit requires very little maintenance other than regular sensitivity checks and cleaning of the window. General Monitors recommends that a schedule be established and followed. NOTE: The removal of particulate matter and any film buildup on the Sapphire Window and COPM Reflector is necessary to ensure proper sensitivity of the system.
ALARM TEST function (Section 3.6.7) should be used. Refer to Section 8.5 for details on Test Lamps. Storage The FL4000 should be stored in a clean, dry area and within the temperature and humidity ranges quoted in Section 8.2.5, Environmental Specifications.
This section is intended to be a guide to correcting problems, which may arise in the field. General Monitors should be contacted for assistance if the corrective action listed does not eliminate the problem. Defective units should be returned to General Monitors for repair with a complete written description of the problem.
General Monitors provides extensive documentation, white papers, and product literature for the company’s complete line of safety products, many of which can be used in combination with the FL4000. Many of these documents are available online at the General Monitors website at http://www.generalmonitors.com.
NOTE: Response Times and Field of View data were obtained from tests with a 1 square foot of heptane fire. These are typical values and different results may occur depending on the variation of each fire. Maximum specified FOV is the angle at which FL4000 can detect the flame at 50% of the maximum specified range.
FL4000 Regulatory Agency Approvals 8.3.1 Regulatory Agencies The FL4000 is certified by the following regulatory agencies: Standard Agency HART Configuration ATEX – Hazardous Locations Canadian Standards Association (CSA) CE Marking FM Approvals HART Communication Foundation (HCF) 8.3.2 Classification Area and Protection Methods The FL4000 is certified as follows: •...
FL4000 Response to False Stimuli The FL4000 detector is immune to a variety of false alarm sources. Below are representative samples of detector response in the presence of false stimuli. Table 38: False Alarm Immunity at High Sensitivity Distance Modulated...
FL4000 Table 39 shows the response characteristics of the FL4000 in the presence of false alarm sources. The detector is set at a high sensitivity in this illustration. Table 39: Flame Response in the Presence of False Alarm Sources (High Sensitivity) Max.
It is important to begin a series of flame detector checks with a fully charged Test Lamp. Stand between 10 and 35 feet from the FL4000 that is to be tested and aim the Test Lamp directly into the detector window. Press the ON button and be sure the high intensity pulsing beam strikes the detector face squarely.
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8.5.3 Mounting Bracket A mounting bracket is available to mount the FL4000 to a wall, pole, etc. The mounting bracket design allows for optical alignment adjustments when utilizing to a fixed installation. Please refer to Figure 16: Detector Mounting and Installation.
FL4000 9.0 Appendix A Rotary Switch shown in position 1 (for testing FL3100 Flame Detectors) Figure 27: Functional Board Located Under TL105 Lamp Assembly...
FL3110 triggers into FL3110 alarm mode FL3111 triggers into FL3111 alarm mode FL3112 triggers into FL3112 alarm mode FL4000 35 (High Sensitivity) FL4000 enters test mode 18 (Medium FL4000 FL4000 enters test mode Sensitivity) FL4000 8 (Low Sensitivity) FL4000 enters test mode...
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ADDENDUM Product Disposal Considerations This product may contain hazardous and/or toxic substances. EU Member states shall dispose according to WEEE regulations. For further General Monitors’ product WEEE disposal information please visit: www.generalmonitors.com/customer_support/faq_general.html All other countries or states: please dispose of in accordance with existing federal,...
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