Honeywell Searchline Excel Open-Path Technical Handbook
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Honeywell Searchline Excel Open-Path Technical Handbook

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Technical Handbook
Searchline Excel Infrared Gas Detectors
Open Path and Cross-duct

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Summary of Contents for Honeywell Searchline Excel Open-Path

  • Page 1 Technical Handbook Searchline Excel Infrared Gas Detectors Open Path and Cross-duct...

  • Page 2: Safety

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 SAFETY Ensure that you read and understand these instructions BEFORE operating the equipment. Please pay particular attention to the Safety Warnings. WARNINGS The Searchline Excel gas detector is certified for and intended for use in potentially hazardous areas.
  • Page 3 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 SAFETY CAUTIONS Use only approved parts and accessories with the Searchline Excel gas detector. To maintain safety standards, commissioning and regular maintenance of the Searchline Excel gas detector should be performed by qualified personnel. IMPORTANT NOTICES Zellweger Analytics Limited can take no responsibility for installation and/or use of its equipment if this is not done in accordance with the appropriate issue and/or amendment of the manual.

  • Page 4: Help Us To Help You

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 HELP US TO HELP YOU Every effort has been made to ensure the accuracy in the contents of our documents, however, Zellweger Analytics Limited can assume no responsibility for any errors or omissions in our documents or their consequences.

  • Page 5: Table Of Contents

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 CONTENTS SAFETY HELP US TO HELP YOU 1. INTRODUCTION 2. OVERVIEW Introduction Transmitter Receiver Adjustable Mountings 3. INSTALLATION AND OPERATION Introduction Siting and Mounting Electrical connections Power supply Unpacking Installation procedure Alignment and commissioning System Controller calibration Installation Checks/Tests 4.
  • Page 6 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 CONTENTS 6. PROBLEM SOLVING 7. SPECIFICATIONS System Detectable gases 8. CERTIFICATION General CENELEC CSA/FM APPENDIX A - HANDHELD INTERROGATOR A.1 Introduction A.2 Overview A.3 Connection to System A.4 Basic User Tasks A.5 Menus A.6 Problem Solving APPENDIX B - GLOSSARY B.1 Terminology...

  • Page 7: Introduction

    • Searchline Excel Cross-Duct Gas Detector Searchline Excel Open-Path Gas Detector (OPGD) consists of a Transmitter unit that sends an infrared beam to a Receiver unit up to 200 metres away, and can be located where a flammable hydrocarbon gas cloud is likely to occur.
  • Page 8 Provides useful/helpful/additional information. If more information beyond the scope of this technical handbook is required please contact Zellweger Analytics. Associated Documents Searchline Excel Open-Path Infrared Gas Detector Basic Installation Guide Part No: 2104M0510 Searchline Excel Cross-Duct Infrared Gas Detector Basic Installation Guide...

  • Page 9: Overview

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 2. OVERVIEW INTRODUCTION Each type of Searchline Excel gas detector consists of two units, a Transmitter and a Receiver. This separate Transmitter/Receiver configuration provides the most reliable basis for open path gas detection. There are no transceiver units or retro-panels available for the Searchline Excel, except for the Cross-Duct version, which is only for use between 0.5 and 5 metres path length.

  • Page 10: Transmitter

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 2. OVERVIEW There are five ranges of Searchline Excel gas detector. These are: Open-Path Short Range 5 — 40m (15ft — 130ft) Medium Range 20 — 120m (65ft — 390ft) Long Range 120 —...

  • Page 11: Receiver

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 2. OVERVIEW 160mm (SR) 417mm (SR) 211 (MR/LR) 433 (MR/LR) The Transmitter window is heated to minimise condensation, frosting and the build up of snow. During particularly cold operating conditions, the heating of the Transmitter window is increased to turbo levels.
  • Page 12 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 2. OVERVIEW 417mm 160mm The solid state, photovoltaic detectors used in Searchline Excel provide an exceptional dynamic range and superb temperature and long term stability. These features contribute strongly to the solar immunity and stability of Searchline Excel. The Receiver contains all of the electronics necessary to amplify, condition and process the signals received by the infrared detectors.

  • Page 13: Adjustable Mountings

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 2. OVERVIEW ADJUSTABLE MOUNTINGS The adjustable mountings are: • Purpose-built for Transmitter and Receiver. • Robust. • Rigid and stable. • Made from stainless steel. • Fully adjustable for alignment Coarse and fine settings in both horizontal and vertical planes. Adjustment range: ±45 Vertical...

  • Page 14: Installation And Operation

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.1 INTRODUCTION Most of the information and recommendations given here only apply to the Open-Path version of Searchline Excel. See Chapter 4 for details about installing the Cross-Duct version of Searchline Excel.

  • Page 15: Siting And Mounting

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.2 SITING AND MOUNTING 3.2.1 General When designing an installation for a Searchline Excel gas detector it is important to give consideration to where it is to be located, what potential sources of problems may be encountered in this location and how the unit is to be mounted and supported.
  • Page 16 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Below this temperature, snow or ice blown onto the window will not be melted until the ambient temperature rises. If long-term, outdoor operation in very cold climates is intended, it is recommended that extra shielding/covers are employed to prevent snow/ice from being blown onto the windows and building up.
  • Page 17 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION The beam path and immediate surrounds should be kept free of obstructions that might hinder the free movement of air in the protected area or block the infrared beam. A clear beam path of 20cm diameter or greater is recommended.
  • Page 18 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.2.4 Supporting Structure The Transmitter and Receiver units should be fixed to a stable supporting structure using the mounting plates supplied. Note: The maximum movement of the supporting structure under all anticipated operating conditions must be ±...

  • Page 19: Electrical Connections

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.3 ELECTRICAL CONNECTIONS 3.3.1 General All ranges of Searchline Excel comply with the EMC requirements EN50081 and EN50082. In order to maintain compliance with these standards it is essential that the electrical installation of Excel is engineered correctly.
  • Page 20 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION The 24V supply should be free from large transients and fluctuations. The field cabling conductors should have sufficient cross sectional area to ensure that the minimum supply voltage applied to the gas detector is 18V at a current of 420mA. This corresponds to a maximum round loop impedance of 14 ohms for a nominal 24V system supply.
  • Page 21 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.3.3 Receiver Connections via DX100 (M) Control cabinet DX100 (M) Junction Box Receiver connections connections Cable shield Modbus A Modbus B Screen - Modbus Drain blue (B) Instrument (clean) earth orange (A) Cable shield...
  • Page 22 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.3.5 Remote Installations For remote or difficult-to-access installations, the DVC100/DX100/DX100 (M) can be positioned in a convenient location by using an intervening junction box (e.g. PL612/AKRON/Killark) attached to the Receiver’s mounting plate. A maximum cable length of 1km between the unit and the DVC100/DX100/DX100 (M) is permissible (RS485 compliant).
  • Page 23 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Wiring with DX100 (M) See also DX100 Termination Units Technical Handbook. Local junction box (mounted on Receiver mounting plate) Blue Receiver Orange A Black 0V White 4-20 +24V Green/ GND Yellow Safety/protective ground...

  • Page 24: Power Supply

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.4 POWER SUPPLY 3.4.1 General The Searchline Excel gas detector is designed to be operated from a nominal 24V DC supply. The supply voltage at the terminals must be within the range 18 to 32V. The unit maximum power consumption and cable lengths are as follows: Maximum Power Maximum Cable Length...

  • Page 25: Unpacking

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Transmitter Control cabinet Junction Box connections connections Reverse these connections Cable shield to disable turbo-heating +24V DC supply Black Tx +24V 0V DC supply +24V Tx 0V Green/ GND Instrument (clean) Yellow earth...
  • Page 26 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3. INSTALLATION AND OPERATION 2 x Mounting Plate 2 x Mounting Brackets (with grub screws) 2 x Pivot Blocks 4 x Adjustment Clamps (with grub screws) (with grub screws) 4 x Nyloc Self-locking Nuts 4 x Washers (M12 or M20) 6 x Mounting Bracket...
  • Page 27 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Basic Installation Guide 2 x Allen (Hex) Keys (3mm or 5mm) Ensure that the installer/end user of the equipment receives the technical documentation (operating instructions, manuals, etc.) contained in the packaging.

  • Page 28: Installation Procedure

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.6 INSTALLATION PROCEDURE 3.6.1 General Searchline Excel is designed to allow installation and alignment to be performed by a single technician. The installation procedure is split into mechanical installation and electrical installation. Each unit needs to be mounted to a supporting structure before making the electrical connections.
  • Page 29 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 352.2 299.2 60x45 in 2 positions 133.2 Always mount plate this way up 174.7 6mm thick Stainless Steel Plate to BS1449:PT2:1983 316 Notes: Drawing is not to scale. Mounting plate fixing holes are clear.
  • Page 30 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION M6 tapped PL612/Bartec junction box mounting M6 tapped DVC100 junction box mounting. M10 tapped DX100/DX100 (M) junction box mounting. M6 tapped Killark/Akron junction box mounting. M6 tapped Sun/heat shade mounting. M8 tapped Short range Transmitter and all Receiver brackets.
  • Page 31 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 2.5in. U-bolt - 4-off (not supplied) using holes Mounting Plate Fixed to Twin Pipes/Poles Fit an adjustment clamp to the unit s pivot block mounting stud so that it sits on the stud s shoulder.
  • Page 32 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Ensure that the adjustment clamp's stub lever is approximately centrally positioned between the mounting bracket’s grubscrews. Adjust the screws if required. Fit an adjustment clamp to the unit s mounting stud so that it sits on the stud s shoulder. The correct orientation for the adjustment clamp is as follows: Stub lever Adjustment clamp...
  • Page 33 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Receiver Transmitter Note: For information about alternative types of junction box see section 3.6.2 Electrical Installation. (11) Measure and record the distance (in metres) between the Transmitter and Receiver units.

  • Page 34: Alignment And Commissioning

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.7 ALIGNMENT AND COMMISSIONING 3.7.1 General In order to avoid unnecessary problems, alignment and commissioning of Searchline Excel gas detectors should only be performed by personnel trained by Zellweger Analytics. To ensure optimum performance the gas detector Transmitter and Receiver units must be accurately aligned with a clear line of sight between them.
  • Page 35 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Initial coarse mechanical adjustment is first carried out by means of large self-locking clamping nuts and with the help of an alignment telescope. Fine adjustment is then achieved by means of mounting bracket and pivot block grubscrews which move levers on the adjustment clamps, fitted to the pivot block and unit studs, and hence the unit.
  • Page 36 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION 3.7.2 Alignment Procedure The following summarises the alignment procedure: • Basic gas detector alignment, see section 3.7.3. • Accurate alignment of Transmitter and Receiver using the appropriate alignment telescope, see section 3.7.4. •...
  • Page 37 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Excel unit Excel unit Alignment telescope assembly mounting pad (3 off) Trident-type Non-Trident-type After deciding from the table which alignment telescope to use for the Excel units being aligned the telescope assembly must be fitted to each of the units in turn starting with the Transmitter.
  • Page 38 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Telescope viewfinder Alignment telescope Cowl Datum mount Excel unit Mirror assembly Mounting latch assembly Latch (2 off) Locate the latch mounting hooks behind the back of the unit. Rotate the telescope to a comfortable viewing position, and then secure the latches as indicated by arrow 3.
  • Page 39 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Bayonet-style Trident-type telescope assembly Caution: This type of telescope assembly must only be used with Trident-type Excel units. This type of telescope assembly consists of a telescope and mirror attached to a datum mount. The mount features a bayonet fitting for attaching the assembly to the Excel unit.
  • Page 40 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION With the other hand use the datum mount’s locking handle to rotate the bayonet fitting in a clockwise direction until it is securely locked onto the cowl. The fitting is held tightly against the face of the cowl by means of hidden compression springs.
  • Page 41 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Use a viewing position that ensures that the full circular view is in sight. An ellipse will appear when slightly off axis. Off-axis view Caution: Do not try to adjust the cross-hairs using the telescope's elevation and windage adjusters as they have been factory set.
  • Page 42 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Distant Excel unit Cross-hairs After alignment When correctly adjusted, tighten both adjustment screws simultaneously. Ensure there is minimum movement whilst locking the assembly. Check alignment and repeat steps 5 to 7 as necessary. Remove the telescope assembly from the unit by reversing the fitting instructions.
  • Page 43 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION • via another type of junction box, e.g. Hawke PL612 - using the SHC Protection Device. See the following diagram and description and Appendix C - Spare Parts. IS connector Flying lead Notes:...
  • Page 44 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION This switches on the unit. Calibrator Type SHC1 Note: Full details of the SHC1 Handheld Interrogator can be found in Appendix A. Z - SHC1 EXCEL Interrogator 4V0 The Interrogator displays the following start-up message for approximately three seconds: Z - SHC1 EXCEL Interrogator 4V0...
  • Page 45 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Press Enter on the keypad and an initial set time display similar to the following appears: Time 09:26 The top line shows the current time and the second line shows the new hours setting. Set the hour using the up and down keys on the keypad.
  • Page 46 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION The following is displayed: System Type Shrt Range The second line shows the current gas detector type: Short Range 5 - 40m (15 - 130ft) Medium Range 20 - 120m (65 - 390ft) Long Range 20 - 200m...
  • Page 47 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Important Notes: The overall objective of alignment is to maximise the SIG level. Maximised SIG corresponds to optimal alignment. The Instrument Assisted Alignment (IAA) system only allows Excel to be initialised if the SIG level is greater than or equal to the TGT level when Enter is pressed.
  • Page 48 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION When the SIG level has been maximised in one plane, make small adjustments in the other plane until SIG has been maximised in this plane. Repeat steps (b) to (e) until the SIG level has been maximised in both planes. At this point, SIG must be bigger than the initial TGT level and any adjustment either side of the current alignment must result in a reduction in signal level.

  • Page 49: System Controller Calibration

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION The following message is then displayed: Press Enter to Release 4-20 (14) Press Enter on the keypad. The following message is displayed for three seconds: 4-20 Released The display then changes to show the Calibrate menu. The Searchline Excel gas detector is now live.

  • Page 50: Installation Checks/Tests

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Press Enter on the keypad and a display similar to the following appears: 4-20 current 4.5 mA Use the up and down keys on the keypad to set the displayed output current to the desired value. The values can be changed in steps of 0.1mA in the range 1mA to 21mA.
  • Page 51 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION CUSTOMER/OPERATOR SITE / FACILITY SYSTEM TYPE: OPERATING RANGE GAS TABLE: METHANE ETHANE PROPANE BUTANE ETHYLENE PROPYLENE BUTADIENE PENTANE HEXANE PROPYLENE OTHER DETECTOR LOCATION: TAG NO. (RX): TAG NO. (TX): SER NO.
  • Page 52 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION The following notes are to help the installer enter the correct information onto the check sheet. Site/Facility Enter the name and geographical location of the site/facility, e.g. NAM F3 Platform, North Sea Operating Range Enter the distance (preferably in metres), between the Transmitter and the Receiver.
  • Page 53 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION If there is the possibility that such vibration sources could or are causing unacceptable movement, enter a brief description, e.g. Turbine nearby, Below conveyor Excess Heat Check the installation and its surrounds for potential sources of excessive heat. The unit is specified up to +65 C.
  • Page 54 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Contaminants Assess the installation and its surrounds for sources of contaminants that could build up on the unit s windows. Such contaminants could include oil mist, heavy sea spray, drilling mud, dirty exhaust fumes, wave splash etc.
  • Page 55 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Faults/Warning Enter any ACTIVE FAULTS or ACTIVE WARNINGS that could not be cleared from the log, e.g. BEAM BLOCK, E_ZERO_NOT_CALIBRATED Installation Satisfactory Only fully trained personnel trained by Zellweger Analytics or Zellweger Analytics authorised trainers can declare an installation satisfactory.
  • Page 56 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 3. INSTALLATION AND OPERATION Customer Notified Make sure that the relevant customer/operator is notified of the installation problem(s). Mark box accordingly. System Status Upon leaving, note the gas detectors status, i.e. operational or nonoperational.

  • Page 57: Cross-Duct Excel

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL 4.1 INTRODUCTION The Cross-Duct version of Searchline Excel gas detector is designed for applications where the path to be monitored is between 0.5 and 5 metres. It operates on the same principle as the Open-Path Excel, but instead of having the Transmitter and Receiver at opposite ends of the path, they are both located on the same mounting plate.

  • Page 58: Installation And Operation

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL 4.2.1 Transmitter The Cross-Duct Excel Transmitter produces an intense, collimated infrared beam from a Xenon arc flashlamp. It uses a different optical arrangement compared with the Open-Path Transmitter. This enables it to produce a beam with a uniform intensity distribution even at the shortest operating range.
  • Page 59 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL • Electrical interference due to proximity of radio or radar antennae • Flooding or frequent wave deluge • Direct heat e.g. from adjacent flare stack, intense sunlight The maximum certified operating temperature for Excel is +65 ° C Note: •...
  • Page 60 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL The unit maximum power consumption and cable lengths are as follows: Unit Type Maximum Power Maximum cable length (m) Maximum cable length (m) consumption with 1.5mm conductors with 2.5mm conductors (12ohms/km) (7.6ohms/km)

  • Page 61: Installation Procedure

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL 1 x Retro-reflector 2 x Retro-reflector Nuts, Bolts, Washers Panel (Small Panel Shown) Mounting Straps (For Small Panel) OPTICAL CENTRE CUT OUT ‘H’ 120x160mm MOUNTING PLATE CUT-OUT 10 ‘G’ HOLES O7 TEMPLA TE 1 x Mounting Plate Cut-out Template 1 x Retro-reflector Panel Cut-out...
  • Page 62 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL 4.4.1 Mechanical Installation Verify that the equipment to be installed is correct for the type of installation required (i.e. short/ long range and normal/high temperature.) Identify the mounting holes using the following drawing and table: Identity Quantity Size...
  • Page 63 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL Support Bars Duct Wall Minimum 40mm Mounting Unobstructed Gap Plate Receiver Mounting Cell Transmitter 4.4.2 Transmitter and Receiver Stick the supplied self-adhesive mounting plate cut-out template onto the duct wall in the position chosen for the Transmitter/Receiver unit.
  • Page 64 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL (11) Run the Receiver s conduit into the junction box s cable entry. (12) Attach the Transmitter to the front face of the mounting cell following steps 10 and 11. 4.4.3 Retro-reflector Short range retro-reflector and mounting template Long Range retro-reflector and mounting template...

  • Page 65: Electrical Installation

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL 4.5 ELECTRICAL INSTALLATION CENELEC TX/RX Configuration CSA/FM/UL TX/RX Configuration UL TX/RX Configuration 4.5.1 Electrical Installation – Precautions and Recommendations Consult the recommendations for the Open-Path Excel in section 3.3.1 as they also apply to the Cross-Duct Excel.
  • Page 66 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL Installation Procedure Isolate all associated power supplies and ensure that they remain OFF during this procedure. Fit approved cable glands to the junction box cable entries to be used for field wiring. Use sealing washers where necessary to maintain ingress protection rating.
  • Page 67 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL 4.5.3 Connections using DX100 (M) DX100 (M) Junction Box Cross-Duct Control cabinet connections Receiver connections Cable shield Modbus A Modbus B Screen - Modbus Drain blue (B) Instrument (clean) earth orange (A) red (+24VDC)

  • Page 68: Initialising The Excel Gas Detector

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL 4.5.5 Commissioning This stage is similar to section 3.7.6 for the Open-Path Excel, except that there is no alignment adjustment required for the Cross-Duct Excel. The commissioning process consists of the following steps: •...
  • Page 69 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL Press on the keypad and the following message is displayed: Press Enter to Perform Checks (10) Press on the keypad and the unit now performs a self test check message. When finished the interrogator displays the following message for at least three seconds: Checks Passed The following message is now displayed:...

  • Page 70: Maintenance

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL 4.6.1 Disconnecting the Handheld Interrogator To finish the commissioning process: Select the Power Off option from the interrogator Main menu Press on the keypad Alternatively, press the and ESC keys simultaneously for a fast power off. Notes: The SHC1 Handheld Interrogator powers down automatically after five minutes of inactivity in order to preserve battery life.
  • Page 71 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL Ensure that before using the gassing cell for the first time, remove the ends of the plastic nozzles (with a knife or wire cutters). Rubber end caps are used to seal the tubes afterwards. Air Shield Gas In/Out Receiver...

  • Page 72: Problem Solving

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 4. CROSS-DUCT EXCEL 4.7.3 Display Gas Reading To check the gas reading from the Cross-Duct Searchline Excel, follow the procedure described in Chapter 5, section 5.2. 4.8 PROBLEM SOLVING Any problems encountered with the Cross-Duct Excel are likely to be similar to those affecting the Open-Path version.

  • Page 73: Maintenance

    2104M0506 5. MAINTENANCE The Searchline Excel Open-Path Gas Detector requires little maintenance other than occasional cleaning. Depending on the local regulations and site conditions, cleaning and functional testing of the gas detector can be carried as described in the following sub-sections. The gas detector should remain powered during these procedures.

  • Page 74: Calibration Check Using The Gassing Cell

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 5. MAINTENANCE 5.3 CALIBRATION CHECK USING THE GASSING CELL The gassing cell is designed to allow easy calibration checking using a high concentration test gas as opposed to the standard plastic test filters. The integrated LEL.m reading of the gas concentration in the cell can be calculated using the following formula: Int(lel.m) (Conc...

  • Page 75: Display Gas Reading

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 5. MAINTENANCE To get the best accuracy when using the gassing cell: Connect the gassing cell to the Searchline Excel. Zero Searchline Excel with the empty gassing cell. Apply the test gas to the gassing cell and allow sufficient time to fully flush the cell without pressurising it and check that the Searchline Excel output stabilises.

  • Page 76: Alignment Telescope

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 5. MAINTENANCE The second line shows the gas reading and measurement units along with a gas detector status indicator. The status character at the end of the second line indicates one of the following: Normal Operation A spinning line shows the unit is in the fully active state.

  • Page 77: Problem Solving

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 6. PROBLEM SOLVING The majority of gas detector problems/faults can be diagnosed and corrected using the installation and alignment kit. The alignment kit includes: • SHC1 Handheld Interrogator • alignment telescope • set of functional test filters An electrical multimeter is also useful when diagnosing electrical/wiring problems.
  • Page 78 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 6. PROBLEM SOLVING Fault/Problem Causes Remedies Electrical installation Check that the +24V supply is reaching the unit. problem Voltage at the unit should be between +18V and +32V. Check cables and connections to the unit, especially the 4-20mA loop connections.
  • Page 79 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 6. PROBLEM SOLVING Fault/Problem Causes Remedies Wrong communication mode 1) Select Change Mode option on the Interrogator. Comms Error reported by selected on the Interrogator Change the communication mode to Excel. Interrogator Interrogator software version Version 1V00 Interrogator software to be used with Excels software running 1V0 software.
  • Page 80 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 6. PROBLEM SOLVING Fault/Problem Causes Remedies Re-align the Receiver, first using the telescope and then using No signal or Receiver misaligned very low signal the Interrogator. at Receiver Transmitter misaligned Re-align the Transmitter using the telescope. Check that the beam path is clear from Transmitter to The beam path has become obscured...
  • Page 81 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 6. PROBLEM SOLVING Fault/Problem Causes Remedies Re-align the Receiver, first using the telescope and Diagnostics Receiver misaligned report then using the Interrogator. Neg Gas Re-zero the unit. Reading Check the Transmitter and Receiver windows for build Contamination of windows up of contamination.

  • Page 82: Specifications

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 7. SPECIFICATIONS 7.1 SYSTEM OPEN-PATH CROSS-DUCT SHORT RANGE MEDIUM RANGE LONG RANGE Available Gases All: Methane, Ethane, Propane, Butane, Pentane, Hexane, Ethylene, Propylene, Butadiene, Methanol, Ethanol. Range 0 - 5 LELm 0 - 5 LELm 0 - 5 LELm 0 - 100%LEL (%LEL/m) Recommended...

  • Page 83: Detectable Gases

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 7. SPECIFICATIONS 7.2 DETECTABLE GASES The Searchline Excel Open-Path gas detector (short, medium or long range) will detect the following hydrocarbon gases, individually or in a mixture, in the range 0 — 5LEL.m: Methane Ethane Propane...

  • Page 84: Certification

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.1 GENERAL The Searchline Excel system is certified to EEx d and has the following major CENELEC and UL and CSA approvals for worldwide acceptance: CENELEC II 2G, EEx d IIC T5 (T -40 to +65 II 2G, EEx d IIC T6 (T -40 to +40...
  • Page 85 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.2 CENELEC 8.2.1 Transmitter Details Open-Path Transmitter EEx d IIC T5 (-40 to +65 C) Standard Junction Box EEx d IIC T6 (-40 to +40 C) M25 gland EEx e or EEx d II 2G EEx e or EEx d V max.
  • Page 86 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.2.2 Receiver Details Open-Path DVC100 Termination Unit EEx ia e m IIC Certified M25 SHC1 Handheld T6 (-40 to +65 C) blank fitted Interrogator Receiver V max. = 50V, EEx ia IIC EEx d IIC T5 (-40 to +65 C) I max.
  • Page 87 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.2.3 Conduit Technical Characteristics Ingress Protection IP66 and 67. Temperature Rating -40 to +105 Construction A helically wound galvanised steel core with cotton packing and enhanced oil resistant PVC covering. Covering material displays good resistance to dilute acids, alkalis and hydrocarbon products.
  • Page 88 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION Open-Path Long/Mid Range See Open-Path Transmitter Short Range for label explanation. Cross-Duct See Open-Path Transmitter Short Range for label explanation. 8.2.4.2 Receivers Open-Path See Open-Path Transmitter Short Range for label details.
  • Page 89 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION Cross-Duct See Open-Path Transmitter Short Range for label explanation...
  • Page 90 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.2.5 System Diagram...
  • Page 91 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.3 UL 8.3.1 Transmitters Open-Path Transmitter Class I Div 1 Groups B, C & D and Class I Zone 1 AEx d IIB + UL approved explosion H2 (Tamb -40 to +65 C) proof junction box Conduit seal required...
  • Page 92 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.3.2 Receivers Open-Path DX100/DX100 (M) UL SHC1 Handheld Receiver Termination Unit Interrogator Class I Div 1 Groups B, C, D Class I Div 1 Class I Zone 1 AEx d IIB + H2 Class I Div 1 Groups B, C, D Groups B, C, D...
  • Page 93 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.3.3 Certification Label...
  • Page 94 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.3.4 System Diagram With DX100 Termination Unit...
  • Page 95 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION With DX100 (M) Termination Unit...

  • Page 96: Csa/Fm

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION 8.4 CSA/FM 8.4.1 Transmitters CSA Transmitter: Class 1 Div 1 Groups B, C & D T5 and Exd 11C T5 (Tamb -40 to -40 to +65 CSA/FM approved explosion proof FM Transmitter: junction box Class 1 Div 1, Groups B, C &...
  • Page 97 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION SHC1 Handheld SHC1 Handheld DX100/DX100(M) CSA CSA Receiver: Interrogator CSA/FM Receiver Interrogator Termination Unit Class 1 Div 1 Groups B, C, D DX100/DX100(M) CSA/FM Class 1 Div 1 Class I Div 1 Groups B, C, D Class I Div 1 Class I Div 1 Class 1 Zone 1 AEx d IIB + H2...
  • Page 98 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION CSA/FM Certification Label Standard Transmitter Standard Receiver Long-Range Transmitter Cross-Duct Transmitter Cross-Duct Receiver...
  • Page 99 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION...
  • Page 100 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 8. CERTIFICATION With DX100 (M) Termination Unit...

  • Page 101: Appendix A - Handheld Interrogator

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR A.1 INTRODUCTION This appendix provides reference information about the SHC1 Handheld Interrogator. The interrogator provides the user end of a two-way communication link between the Excel system and the operator. It features facilities which let the operator configure, align, functionally test and diagnose faults in the system.

  • Page 102: Connection To System

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR The interrogator is powered by a standard 9V battery and has a management system which reduces power consumption by placing the unit in an idle mode when it is waiting for user input or for a communication operation to complete.

  • Page 103: Basic User Tasks

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR A.4 BASIC USER TASKS Switching On Press for two seconds. The unit recalls its previously set operating mode, i.e. EXCEL, OPTIMA or OPTIMA PLUS, and displays the following message for approximately three seconds: Z - SHC1 EXCEL Interrogator 4V0 The unit then displays the top level of the menu style interface in the following way:...

  • Page 104: Menus

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR A.5 MENUS The interrogator top level menu structure and menu choices are as follows. All menu options are implemented by pressing the keypad key. The menu options and types are shown in the diagram: where: a single set of data is displayed.
  • Page 105 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR A.5.1 Main Menu This menu consists of the following sub menu options: Display Display gas and other unit readings. Calibrate Install and calibrate the system, force the analogue output, show the calibration coefficients or show the instrument status.
  • Page 106 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR Signal Magnitude Show the level of the sample and reference signals.The display is in the following format: Sample: aaaaaaa Ref: bbbbbbb where: aaaaaaa Signal magnitude for the sample channel. bbbbbbb Signal magnitude for the reference channel.
  • Page 107 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR Before the selected sub menu operation is started the following message is displayed for at least three seconds: Inhibiting 4-20 Please Wait The analogue output is inhibited and the chosen sub menu operation proceeds. After the sub menu operation is completed, or aborted by pressing the ESC key, the following message is displayed: Press Enter To Release 4-20...
  • Page 108 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR where: System type. The system type displayed is one of the following: tttttttt Display Text System Type 40m range system Short Range Medium Range 120m range system Long Range 200m range system Duct Mount...
  • Page 109 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR Alignment This starts the alignment process. The following message is displayed: Press Enter to Align Unit This message displays the system output and reference signal values. SIG: MAX: where: A bar graph representing the current signal magnitude - SIG:...
  • Page 110 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR Latch-style Trident-type telescope assembly If this type of alignment telescope was used with a Trident-type Excel gas detector, there is no need to further optimise the alignment using the SHC1 Handheld Interrogator. If this type of alignment telescope was used with a non-Trident Excel it may be necessary to further optimise the alignment in the following way in order to achieve best performance.
  • Page 111 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR Unit Initialised Note: The Searchline Excel system is live after a successful initialisation. Set Time This option lets you set the system s time and date. The initial display after SET Time is chosen is in the following format: Time HH:MM hh:mm where:...
  • Page 112 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR The following message is displayed while the calibration operation is being performed: Processing Data Please Wait... If the calibration is successful, the following message is displayed for a period of three seconds: Zero Calibrated Force mA This option allows the system s analogue output signal to be adjusted to a fixed level, e.g.
  • Page 113 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR The calibration status fields and values are given below: Calibration Status Fields Display Text False State True State Temperature Cal. Uncalibrated Calibrated Temp Sensor Zero Calibration Uncalibrated Calibrated Zero Ratio Span Calibration...
  • Page 114 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR Display Text Fault Description Meaning Bad 4-20mA Loop ERR_EXCEL_LOOP_FAULT A fault has occurred in the 4-20mA signal loop. DSP Fault ERR_EXCEL_DSP_FAULT Fault on the gas detector’s digital PCB. Hardware Fault ERR_EXCEL_HW_FAULT A hardware fault has occurred.
  • Page 115 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR The following message is displayed for three seconds at the end of a successful self test process. Checks Passed Soft Reset This option lets you reset the system. This message is displayed during the reset process: Processing Data Please Wait...
  • Page 116 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR Gas Units LELm, Gas Units PPMm, UEGm, or %LEL (Cross-Duct only) Effective Full Scale Gas Full Scale 0.1 100000 0.05 Show Config This option displays the configuration parameters the user can set in the same way as for the Show Gas option.

  • Page 117: Problem Solving

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX A - HANDHELD INTERROGATOR A.5.6 Chg Mode This menu option toggles the operating mode of the interrogator between Excel, Optima and Optima Plus to match the gas detector it is attached to. When invoked the mode is displayed in the identification banner (the same as the one displayed when the unit is switched on) for three seconds as follows: Z - SHC1 aaaaaa Interrogator 4V0...

  • Page 118: Appendix B - Glossary

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX B - GLOSSARY B.1 TERMINOLOGY Ex d Flame proof or explosion proof within the confines of European standards EN50014 and EN50018. An enclosure that can withstand the pressure developed during the internal explosion of an explosive mixture and that prevents transmission of the explosion to the explosive atmosphere surrounding the enclosure.

  • Page 119: Abbreviations

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX B - GLOSSARY An open path alarm set at 1 LEL.m would be triggered by any of the situations shown below: 100% 50% 10%LEL LEL.m monitoring is particularly beneficial while the Excel gas detector is protecting the perimeter of a plant or process, often reducing the quantity of point detectors required.
  • Page 120 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX B - GLOSSARY Instrument Assisted Alignment Ingress Protection Infrared Intrinsically Safe Factory Mutual Lower Explosive Limit Long Range Medium Range National Pipe Thread Radio Frequency Interference Sieger Handheld Calibrator Short Range Underwriters Laboratories...

  • Page 121: Appendix C - Accessories & Spare Parts

    MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX C - ACCESSORIES & SPARE PARTS C.1 SYSTEM UNITS The following table lists the different types of system units and provides the part numbers for the various certification options. All types of Transmitters and Receivers include conduit and glands. Open-Path Transmitters and Receivers do not include mounting plates and brackets.
  • Page 122 MAN0530 Issue 09 October 03 Searchline Excel 2104M0506 APPENDIX C - ACCESSORIES & SPARE PARTS Description Part Number Functional test filter, A2 butane 2104N2214 Functional test filter, A2 ethylene 2104N2231 Functional test filter, A2 methane 2104N2211 Functional test filter, A2 methanol 2104N2235 Functional test filter, A2 propane 2104N2213...
  • Page 123 Tel: +41 (0)44 943 4300 Fax: +41 (0)44 943 4398 sales@zelana.co.uk Customer business center A mericas Honeywell Analytics Distribution, Inc. 400 Sawgrass Corporate Pkwy Suite 100 Sunrise, FL 33325 Tel: +1 954 514 2700 Toll free: +1 800 538 0363...

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