General Monitors FL4000 Instruction Manual

Multi-spectral infrared flame detector
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Model FL4000
Multi-Spectral Infrared
Flame Detector
The information and technical data disclosed in
this document may be used and disseminated
only for the purposes and to the extent
specifically authorized in writing by General
Monitors.
Instruction Manual
General Monitors reserves the right to change
published specifications and designs without
prior notice.
Part No.
Revision
04-09
MANFL4000
MANFL4000
G/04-09

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Summary of Contents for General Monitors FL4000

  • Page 1 General Monitors. Instruction Manual 04-09 General Monitors reserves the right to change published specifications and designs without prior notice. MANFL4000 Part No. MANFL4000...
  • Page 2 FL4000 This page intentionally left blank...
  • Page 3: Table Of Contents

    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...
  • Page 4 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...
  • Page 5: Table Of Figures

    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 –...
  • Page 6 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 ......................
  • Page 7: Quick Start Guide

    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.
  • Page 8: Figure 2: Mounting Instruction

    FL4000 Figure 2: Mounting Instruction Figure 3: Wall Mounting Assembly viii...
  • Page 9: Applying Power To The Detector

    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”...
  • Page 10: Testing The Detector Using A Test Lamp

    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.
  • Page 11: 1.0 Before Installation

    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.
  • Page 12: Glossary Of Terms

    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.
  • Page 13 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...
  • Page 14: 2.0 Product Overview

    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.
  • Page 15: Applications

    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...
  • Page 16: Table 3: Led Sequence For Each Operating Condition

    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...
  • Page 17 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.
  • Page 18 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).
  • Page 19: Figure 7: Test Lamp Flashing Option (Auto-Detection)

    - 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...
  • Page 20: Figure 8: Grounding Of Test Wire Or Modbus Command Options

    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...
  • Page 21: 3.0 Installation

    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.
  • Page 22: Detector Location Guidelines

    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...
  • Page 23: Figure 9: Horizontal Fov - N-Heptane - High Sensitivity

    FL4000 Figure 9: Horizontal FOV – n-Heptane – High Sensitivity. Figure 10: Horizontal FOV – n-Heptane – Medium Sensitivity.
  • Page 24: Figure 11: Horizontal Fov - N-Heptane - Low Sensitivity

    FL4000 Figure 11: Horizontal FOV – n-Heptane – Low Sensitivity. Figure 12: Vertical FOV – n-Heptane – High Sensitivity.
  • Page 25: Figure 13: Vertical Fov - N-Heptane - Medium Sensitivity

    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.
  • Page 26: Field Wiring Procedure

    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...
  • Page 27: Detector Mounting And Installation

    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. •...
  • Page 28: Figure 16: Detector Mounting And Installation

    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.
  • Page 29: Terminal Connections

    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...
  • Page 30: Figure 19: Detector Housing And Terminal Blocks

    FL4000 Figure 19: Detector Housing and Terminal Blocks Table 7: Terminal Block Connections Terminal Block – P2 Terminal Block – P1 Pin # Description Pin # Description CHGND/CHASGND CAL_ IO (Chassis Ground) COM2-/DATA2- GND/COM COM2+/DATA2+ +24 V RLY_10 (Relay Reset)
  • Page 31: Figure 20: Terminal Connections

    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...
  • Page 32: Figure 21: Relay Contacts

    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.
  • Page 33: Table 10: Fault Relay Terminals

    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.
  • Page 34: Figure 22: Wiring Diagram - Reset Relays, Test Mode, & Alarm Test

    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).
  • Page 35: Table 15: Analog Output Levels

    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):...
  • Page 36: Switch Selectable Options

    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...
  • Page 37: Powering Of The Fl4000

    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-...
  • Page 38: Power Up Grounding Of The Test And Relay Reset Lines

    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.
  • Page 39: 4.0 Modbus Interface

    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.
  • Page 40: Supported Function Codes

    • 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...
  • Page 41: Modbus Write Command Protocol (Query / Response)

    FL4000 MODBUS Write Command Protocol (Query / Response) A master device writes to a FL4000 register by sending a properly formatted 8-byte message (Table 26). Table 26: MODBUS Write Register Request Byte MODBUS Range Referenced to FL4000 Slave Address 1-247* (Decimal)
  • Page 42: Table 28: Exception Response

    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:...
  • Page 43: Command Register Locations

    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...
  • Page 44 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 =...
  • Page 45 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–...
  • Page 46 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...
  • Page 47: Command Register Details

    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.
  • Page 48: Table 32: Modbus Error Codes

    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.
  • Page 49: Figure 24: Command Register

    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.
  • Page 50: Table 33: Com1 Baud Rate

    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.
  • Page 51 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.
  • Page 52 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.
  • Page 53 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.
  • Page 54: Table 35: Event Log Clock Time Format

    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.
  • Page 55 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.
  • Page 56 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.
  • Page 57: 5.0 Maintenance

    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.
  • Page 58: Sensitivity Check

    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.
  • Page 59: 6.0 Troubleshooting

    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.
  • Page 60: Final Assembly

    FL4000 Final Assembly Figure 26: FL4000 Cross-Section View...
  • Page 61: 7.0 Customer Support

    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.
  • Page 62: 8.0 Appendix

    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.
  • Page 63 FL4000 8.2.2 Mechanical Specifications Enclosure material: 316 Stainless Steel Color: Metal Finish: Polished /eggshell 8.2.3 Dimensions Height: 6.26" (159 mm) Diameter: 3.50" (89 mm) Weight: 6.9 lb. (3.1 kg) 8.2.4 Electrical Specifications Nominal supply 24 VDC voltage: Range: 20 to 36 VDC...
  • Page 64: Regulatory Agency Approvals

    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: •...
  • Page 65: Response To False Stimuli

    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...
  • Page 66: Spare Parts And Accessories

    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.
  • Page 67: Table 40: List Of Spare Parts

    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.
  • Page 68 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.
  • Page 69: Figure 27: Functional Board Located Under Lamp Assembly

    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...
  • Page 70: Table 41: Detector Test Mode Initiation Or/Detector Alarm Trigger With Test Lamp

    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...
  • Page 71 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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