OPERATION MANUAL E2T QUASAR Flare Monitors M8100PM-EXP • M8100FM-EXP • M8100SM-EXP
Confidential Information The material contained herein consists of information that is the property of LumaSense Technologies and intended solely for use by the purchaser of the equipment described in this manual. All specifications are subject to change without notice. Changes are made periodically to the information in this publication, and these changes will be incorporated in new editions.
Contents 1 General ............................................................................................................................. 7 1.1 Information about the user manual ...................................................................... 7 1.1.1 Legend ................................................................................................................. 7 1.2 Safety .................................................................................................................
.2.4 Powering with 115 Volts AC ........................................................................... 25 4.2.5 Powering with 220/230 Volts AC .................................................................... 25 4.2.6 Powering with 24 Volts DC ...................................................................... 25 4.3 Fusing ..................................................................................................................... 26 4.3.1 Mains .........................................
8.1.3 8.1.4 8.1.5 8.1.6 8.1.7 9 Power Fuse ........................................................................................................ 47 Instrument Loops............................................................................................... 47 Stopped Chopper Wheel ................................................................................... 47 Broken Wire Harness ......................................................................................... 48 Component Failure .....
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1 General 1.1 Information about the user manual This manual provides important information that can be used as a work of reference for installing, operating, maintaining, aligning, and/or troubleshooting your LumaSense Instrument. It is important that you carefully read the information contained in this manual and follow all safety procedures before you install or operate the system. To avoid handling errors, keep this manual in a location where it will be readily accessible. 1.1.
1.2.1 Explosion Proof Housing The housing is designed to meet the explosion-proof requirements of the National Fire Protection Association (NFPA) Article 500 for hazardous locations. This Instrument holds both CSA International and European (ATEX) certifications.
When unpacking and inspecting your system, you need to do the following: Check all materials in the container against the enclosed packing list. LumaSense Technologies cannot be responsible for shortages against the packing list unless a claim is immediately filed with the carrier. Final claim and negotiations with the carrier must be completed by the customer. Carefully unpack and inspect all components for visible damage.
1.6 Shipments to LumaSense for Repair All RMA shipments of LumaSense Technologies instruments are to be prepaid and insured by way of preferred carrier. For overseas customers, ship units air-freight, priority one. The instrument must be shipped in the original packing container or its equivalent. LumaSense Technologies is not responsible for freight damage to instruments that are improperly packed. Clearly indicate the assigned RMA number on the shipping package exterior.
2 Introduction 2.1 System Overview The Quasar 8100-EXP Pilot Monitor (PM), Flare Monitor (FM), and Smoke Monitor (SM) are unique monitoring and detection instruments designed for continuous duty monitoring of Pilot Flame, Flaring and Smoke on Flares.
A sight-through optical system and selection of various optical resolutions (fields of view) enable the QUASAR M8100-EXP to be positioned as far as 1/4 mile (400 m) from the stack being monitored. Alignment on the target is accomplished using exceptional sight-through optics and the M-3 Heavy Duty Swivel Mount. Figure 2: Quasar M8100-EXP The electronics allow for target movement, varying luminosity and a range of climate conditions.
2.3 Principle of Operation All objects above absolute zero emit infrared energy. The amount of energy emitted is proportional to the body’s temperature. The QUASAR M8100-EXP collects this energy by means of a focusing optical system concentrating the energy from a body onto a sensitive infrared detector. Specialized amplification circuitry converts the signal received by the detector into a DC level to activate relay and mA outputs for monitoring.
2.4.2 PM: Pilot Monitor’s Flame Sensitive Wavelength The QUASAR M8100PM-EXP uses a single select filter allowing the electronics to amplify the IR energy of interests over the background IR energy. This allows the Pilot Monitor to achieve high sensitivity and dynamic range. 2.4.3 FM: Flare Monitor’s Flame Sensitive Wavelength The QUASAR M8100FM-EXP uses a single select filter allowing the electronics to amplify the IR energy of interests over the background IR energy.
Note: Secure power input lines together after connection to the Terminal block to prevent an accidental hazardous live condition in the unlikely event that a terminal screw becomes loose. Sleeve or tie wrapping is acceptable. b. Connect the instrument loops and alarm outputs: i. Connect the lines as needed for Normal Open (N.O.) or Normal Closed (N.C.) relay to the corresponding locations on TB2. ii. Connect the mA lines to the corresponding (MA-) and (MA+) outputs on TB2.
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3 Mechanical Installation 3.1 Getting Started Each LumaSense E2T QUASAR M8100-EXP instrument is configured as per customer’s request. The packing slip order number matches that of the instrument’s serial number. It is recommended to confirm that the instrument’s configuration meets expectation, by reviewing packing slip details. Once you have determined the unit you received is the unit you ordered and it is in acceptable condition, the unit is ready for installation.
Figure 4: Field of View Concept 3.2.2 Flare Monitor (FM) Sighting Recommended installation distance should be equal to the height of the flare stack from the base of the flare stack. The maximum vertical angle for sighting the monitor is 45 ° above horizontal. (See Appendix E Engineering Drawing 613-228.) Targeting should be just above the pilot flames, so that they are not included in the measurement, or if this is not possible, then the gain should be reduced until the pilot flames are not detected.
Figure 5: Pedestal Mounting Concept 3.3 Ambient Temperature Limits The ambient operating temperature limits of the QUASAR M8100-EXP are -40 °F (-40 °C) to 120 °F (50 °C). When the internal temperature drops below 40 °F (4 °C), an internal electric heater activates to keep the internal temperature at or above 40 °F (4 °C). If the ambient temperature is expected to be below -40 °F (-40 °C), additional heating or protection for the instrument is required.
Note: The cooling cavity is isolated from internal surface of explosion-proof enclosure. See Appendix E Engineering Drawing 613-816, Service Connections. 3.4.2 Vortex Air Cooling Connect a V208-15-H Vortex Air cooler to the cooling cavity built into the underside of the explosion-proof enclosure. Provide filtered, dry, compressed air from a minimum 90 psig source with a sustained flow rate capability of at least 10 SCFM to the vortex air cooler.
(1) Eyepiece Lens with Reticle (2) Focus adjust and Lens locking screw (3) Objective Lens Figure 6: Focus Adjustments E2T QUASAR Flare Monitors Operation Manual Mechanical Installation 21
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4 Electrical Installation 4.1 Electrical Installation Guidelines Be sure to reference Appendix E Engineering Drawing 613-816, Service Connections during this procedure. 4.1.1 Conduit/Connections Power and signal wires are fed through the 3/4 inch NPT conduit holes in the side of the housing. All wires exiting the enclosure must run through properly installed explosion-proof packing gland fittings to maintain the explosion-proof rating.
4.2.1 Service Markings Input Power service (i.e.120VAC, 220VAC, 24VDC) and Fusing type are factory set and marked on the Terminal Output PCB (See Figure 7). 4.2.2 Protective Ground Connection Connect the protective Earth conductor to the terminal lug located inside the housing as indicated by the symbol. 4.2.3 Cover Attachment Warning: At no time should the cover be removed unless power is switched off first.
4.2.4 Powering with 115 Volts AC Note: Voltage/fusing are factory set. Use a wire gauge appropriate to service installation. See Appendix A for Power and Fuse Requirements and Appendix E Engineering Drawing 613-816, Service Connections. To connect 115 VAC to Terminal TB1: AC Hot to terminal labeled L1/HOT AC Neutral to terminal labeled N/NEUT AC Ground to Safety Ground stud. 4.2.5 Powering with 220/230 Volts AC Note: Voltage/fusing are factory set. Use a wire gauge appropriate to service installation.
4.3 4.3.1 Fusing Mains Two fuses, F1 and F2, are each mounted within fuse holders on the Terminal Output PC Board, located directly under TB1. F1 is used for all power configurations. F2 is used only in 220/230VAC applications. Note: The factory installed F2 bypass jumper J1, is hardwired for 110VAC and 24VDC systems. Refer to Appendix A for Power and Fuse requirements. 4.3.
4.5 Connecting the Set Point Relay The set point relay provides a dry contact closure with a normally open and normally closed output. The relay is rated 1 amp resistive to 120 VAC max. Connect the relay to terminal TB2 as follows: Relay COMMON to COM Relay NORMALLY OPEN to N.O. Relay NORMALLY CLOSED to N.C.
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5 Operating the M8100PM-EXP This section covers the start-up procedures for operating the flare stack Pilot Monitor after the unit has been installed in accordance with Chapters 3 and 4. To provide insight into the logic behind the procedure, some background on the field operation of the instrument is provided. The Pilot (flame) Monitor is designed to continuously monitor the presence of a pilot flame under varied environmental and changing weather conditions.
Figure 8: Instrument Aiming Concept E2T QUASAR Flare Monitors Operation Manual Operating the M8100PM-EXP 30
1. Eyepiece Lens with Reticle 2. Status Red LED: Alarm 3. Status Green LED 4. AGC Compensation (PM) 5. System Gain Adjust 6. Gain/Setpoint Selector 7. Focus Adjust and Lens Locking Screw 8. Objective Lens 9. Delay Adjust 10. Set-Point Adjust 11. Gain/Setpoint Monitor 12. Heater Connection 13. Output PCB 14. Main Supply Connector to Electronics 15. Signal I/O to Electronics Figure 9: Opto-Electronics Module 5.
5.1.2 Initial Control Settings (Item numbers refer to and Figure 9: Opto-Electronics Module) 1. Adjust all Pots to full counterclockwise (Items: 5, 9, 10). 2. Set Climatic Compensation Selector Switch (Item 4) at 100X. 3. Move the Gain/Setpoint Switch (Item 6) to Setpoint position. 4. Verify the Setpoint Adjust Pot (Item 10) is set for 0.6 on analog meter (Item11). 5. Move the Gain/Setpoint Switch (Item 6) to Gain position after step 4 is accomplished.
5.1.6 Noise Amplification Once setup adjustments have been completed, confirm that the flame signal, and not the noise, is being amplified. Check for noise application. To check for Noise Amplification: 1. Completely cover the objective lens. 2. Ensure that the red LED activates with the anticipated delay time. If the red LED fails to activate or there is repeated green-red-green-red “chatter,” then too much noise is being amplified. In such cases, the following steps should be taken: a.
5.1.8 Delay Adjust The Delay Adjust (Figure 9, Item 9) can be configured from 2 seconds (completely counterclockwise) to approximately 2 minutes (completely clockwise). The Delay Pot postpones the Alarm condition once the set-point value is exceeded. This can prevent false alarms from temporary loss of signal due to wind. 5.1.9 Milliamp Output (+mA / -mA) Check the milliamp output signal at the instrument’s Terminal Output board.
6 Operating the M8100FM-EXP This section covers the start-up procedures for operating the flare stack Flare Monitor after the unit has been installed in accordance with Chapters 3 and 4. To provide insight into the logic behind the procedure, some background on the field operation of the instrument is provided. The Flare Monitor is designed to continuously monitor flared gases from remote locations up to ¼ mile (400 m) away in nearly any climate condition while ignoring Pilot Flames.
1. Eyepiece Lens with Reticle 2. Status Red LED: Alarm 3. Status Green LED 4. AGC Compensation (PM) 5. System Gain Adjust 6. Gain/Setpoint Selector 7. Focus Adjust and Lens Locking Screw 8. Objective Lens 9. Delay Adjust 10. Set-Point Adjust 11. Gain/Setpoint Monitor 12. Heater Connection 13. Output PCB 14. Main Supply Connector to Electronics 15. Signal I/O to Electronics Figure 11: Opto-Electronics Module 6.
6.1.2 Initial Control Settings (Item numbers refer to and Figure 11: Opto-Electronics Module) 1. Adjust all Pots to full counterclockwise (Items: 5, 9, 10). 2. Set the Climatic Compensation Selector Switch (Item 4) at 100X. 3. Move the Gain/Setpoint Switch (Item 6) to Setpoint position. 4. Verify the Setpoint Adjust Pot (Item 10) is set for 0.6 on analog meter (Item11). 5. Move the Gain/Setpoint Switch (Item 6) to Gain position after step 4 is accomplished.
the Pilot flame when the Flare is not present. Complete the procedure below and be sure to refer to Section 6.2, Considerations: Flare Monitor (FM) at the end of this procedure. 1. Set the Climate Compensation to 100x. 2. Aim the instrument at the target flame (See Figure 10). 3. Adjust the System Gain clockwise until the analog meter remains above 0.95. The green LED (Flame Detect status) should turn on. 4. Completely cover the Objective Lens. Verify that the meter remains below .35. 5.
b. Verify that noise amplification has not returned. If the noise has returned, proceed to step 5. c. If noise has not returned, the procedure is completed. (Proceed to 6.1.8, Relay Contacts.) 5. Reduce the delay time and repeat the above procedure. a. If noise amplification continues, repeat the setup adjustment procedures starting at Section 6.1.4, System Gain/Climate Compensation. b. If problems persist, contact the factory for further technical assistance. (Refer to Section 1.5 for more information).
3. Adjust the System Gain no more than 2 turns counter-clockwise so that the analog meter reads .35. Once adjusted, the red “Flame Out Alarm” LED should light after the expected delay. If this does not occur, proceed to step 5 below. 4. Verify that the analog meter reads at least .8 when the Flare is present. The procedure is complete. (Do not proceed to step 5.) 5. Adjust the set-point pot (Figure 11, Item 10) to be above the unacceptable condition observed in step 4 by .2 divisions on the meter. a.
7 Operating the M8100SM-EXP This section covers the start-up procedures for operating the flare stack Smoke Monitor after the unit has been installed in accordance with Chapters 3 and 4. To provide insight into the logic behind the procedure, some background on the field operation of the instrument is provided. The LumaSense E2T QUASAR M8100SM-EXP Smoke Monitor is designed to monitor the smoke (particulate) content in a flare flame.
Figure 12: Instrument Aiming Concept E2T QUASAR Flare Monitors Operation Manual Operating the M8100SM-EXP 42
1. Eyepiece Lens with Reticle 2. Status Red LED: Alarm 3. Status Green LED 4. AGC Compensation (PM) 5. System Gain Adjust 6. Gain/Setpoint Selector 7. Focus Adjust and Lens Locking Screw 8. Objective Lens 9. Delay Adjust 10. Set-Point Adjust 11. Gain/Setpoint Monitor 12. Heater Connection 13. Output PCB 14. Main Supply Connector to Electronics 15. Signal I/O to Electronics Figure 13: Opto-Electronics Module 7.
7.1.2 Initial Control Settings (Item numbers refer to Figure 13) 1. Adjust all Pots to full counterclockwise (Items 5, 9, 10). 2. Set the Climatic Compensation Selector Switch (Item 4) at 200X. 3. Move the Gain/Setpoint Switch (Item 6) to the Setpoint position. 4. Verify the Setpoint Adjust Pot (Item 10) is set for 0.7 on analog meter (Item11). 5. Set the Gain/Setpoint Switch (Item 6) to Gain position after step 4 is accomplished.
7.1.7 Milliamp Output (+mA / -mA) The milliamp output to the control room is a constant real time (not delayed) monitor. Once System Gain is setup, the operator will have approximately an 8mA (12mA to 20mA) span indicating normal flame condition to maximum upset condition. Check the milliamp output signal at the instrument’s Terminal Output board (+mA, -mA). The signal should be approximately 12mA when the analog meter is at mid-scale (0.5 volts).
MOST PREVALANT WORLD-WIDE STANDARD FLARE STACK VALUES OBSERVABLE DESCRIPTION METER READING VALUE mA OUTPUT VALUE (best seen at night) PILOT FLAME ONLY Blue pilots only 0.2 6mA Blue plume 0.3 10mA Prevailing blue flame with occasional faint orange 0.5 12mA Intermittent light orange flame with puffs of light smoke 0.6-0.7 13-14mA Continuous orange with smoke 0.7-0.81 14-17mA Intense orange w/heavy smoke 0.80-1.
8 Troubleshooting 8.1 Problem Isolation Checkout Procedure This is an outline of what to do if the LumaSense E2T QUASAR M8100-EXP is not performing correctly after initial installation. Follow the procedures below to determine the problem. Do not hesitate to contact the factory for assistance. (Refer to Section 1.5 for more information.) Warning: At no time should the cover be removed unless the power is switch-off first.
as it rotates. The output may produce a non-rising low reading even when looking at high levels. Inspect the wheel and motor for physical damage. If power is applied and the wheel will not rotate, check to see if the wheel is hanging up on any obstruction. Caution: DO NOT attempt to bend the wheel or motor bracket. Instead, loosen the bracket mounting screws and re-adjust it slightly until free movement is obtained. 8.1.
8.1.7 Component Failure Every QUASAR M8100-EXP is thermally cycled between 40 °F (4 °C) and 120 °F (50 °C) for a minimum of 48 hours during the pre-calibration procedure. Each detector is independently burned in until a stable output is achieved. Inspection and quality control procedures assure the highest standard of component reliability. However, electronic components do fail occasionally and may cause your instrument to function improperly.
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9 Maintenance 9.1 General Maintenance Refer to Chapter 10, Safety Assurances and Precautions, when performing the following procedures. Warning: At no time should the cover be removed unless the power is switch-off first. When it is necessary to service the instrument with the power applied, ensure that proper safe environmental conditions exist and that such maintenance is authorized and pursuant to safe conditions.
To clean the objective lens, remove the electro-optical package from the explosion-proof enclosure. Use facial tissue dipped in rubbing alcohol (Isopropyl 70%). If it is especially dirty, use a lens cleaning solution. Press softly or the lens may become loose or dislodged. Blow off lint, and then replace the electro-optical package in the explosion-proof housing.
10 Safety Assurances and Precautions 10.1 Hazardous Environment Safety The LumaSense E2T QUASAR M8100-EXP enclosure is designed to hold an explosion inside the housing and release the hot gases slowly enough to allow them to cool sufficiently to not ignite the explosive gases outside the housing. It is important to take care of the mating surfaces between the housing and its lid. Also be sure to torque the lid bolts to specification.
10.2.3 Transient Protection Transients must not exceed 2.5kV between any terminal or any terminal and GND. The electronics provide some protection against transient as per EN61326-1 EMC Immunity. However, if higher transients are expected, it is recommend that transient protection devices be included as part of service installation. 10.2.4 Wiring Confirm service type and check that service markings correspond to expectations. When wiring, follow the local code regulations.
Appendix A: Specifications and Parameter Settings Temperature Range Designed for Flares/Pilots of any intensity Working Distance 0 - 1320 ft. (0 - 400m) Response Time 100 mSeconds Outputs Red and Green status lights, mA and set point relay contacts Relay Contacts 120Vac 0.5A , 24Vdc 1A , Resistive Sensitivity Adjustment 0 - 1 VDC Focusing Range 20 in. (51cm) to infinity Sighting Visual aiming Target Size (Field of View) S (dia. of circle) = D (Distance)/37.
Explosion Proof, prevent flame propagation CSA/US Class 1, Division 1, Groups C and D Hazard Classification Class 1, Division 2, Groups A through D (See Appendix B, Area Temp code – T4A Classifications / Protection Enclosure Type – 4X Concepts.
Appendix B: Area Classification/Protection Concepts Label Markings European Markings and Classification for the M8100-EXP Equipment Group II and Equipment Category 2 Equipment Group II: Above ground, High level, Single fault protection required Equipment Category 2: Electrical in Hazardous areas, excluding Mining Explosive Atmosphere Type G: Gas, vapor or mist.
Contains the explosion, prevents flame propagation Class 1, Division 1, Groups C and D; T4A Class 1, Division 2, Groups A,B,C&D; T4A Enclosure Type 4x Defined by Article 500 NEC; Class, Division and Gas Groups: Location Classification I (Class 1): flammable gases or vapors Hazard probability Division 1 (Div 1): Intermittent or High probability of explosive atmosphere present during normal operation Division 2 (Div2): abnormal conditions, low probability during operation Gas/Vapor Groups: A through D T4A: T
areas in the vicinity of spraying and painting operations where volatile flammable solvents are used; locations containing open tanks or vats of volatile flammable liquids; drying rooms or compartments for the evaporation of flammable sol-vents; locations containing fat and oil extraction equipment using volatile flammable solvents; portions of cleaning and dyeing plants where flammable liquids are used; gas generator rooms and other portions of gas manufacturing plants where flammable gas may escape; inade
centimeter. Dusts containing magnesium or aluminum are particularly hazardous and the use of extreme precaution will be necessary to avoid ignition and explosion. (b) Class II, Division 2.
Appendix C: Declaration of Conformity/ Certificate E2T QUASAR Flare Monitors Operation Manual Appendix C: Declaration of Conformity/ Certificate 61
E2T QUASAR Flare Monitors Operation Manual Appendix C: Declaration of Conformity/ Certificate 62
E2T QUASAR Flare Monitors Operation Manual Appendix C: Declaration of Conformity/ Certificate 63
ATEX KEMA Dekra Certificate Please contact the factory for a copy of the document.
Appendix D: Statement of Limited Warranty, New Instruments LumaSense Technologies, Inc., hereby warrants said instruments for a period of twelve (12) months from date of shipment from our facility, unless otherwise specified. Further, LumaSense Technologies, Inc.
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Appendix E: Engineering Drawings Page Dwg.
Drawing 613-107 E2T QUASAR M8100-EXP E2T QUASAR Flare Monitors Operation Manual Appendix E Appendix E: Engineering Drawings 68
Drawing 613-228 E2T QUASAR M8100-EXP E2T QUASAR Flare Monitors Operation Manual Appendix E Appendix E: Engineering Drawings 69
E2T QUASAR Flare Monitors Operation Manual Appendix E: Engineering Drawings 70
E2T QUASAR Flare Monitors Operation Manual Appendix E: Engineering Drawings 71
Drawing 613-812 E2T QUASAR M8100-EXP E2T QUASAR Flare Monitors Operation Manual Appendix E Appendix E: Engineering Drawings 72
E2T QUASAR Flare Monitors Operation Manual Appendix E: Engineering Drawings 73
Drawing 613-816 E2T QUASAR M8100-EXP E2T QUASAR Flare Monitors Operation Manual Appendix E Appendix E: Engineering Drawings 74
E2T QUASAR Flare Monitors Operation Manual Appendix E: Engineering Drawings 75
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Index 4 4-20mA Outputs 13, 26 A Accessories 12 AGC Compensation 29, 35, 41 Alarm Set Point 13 Ambient Temperature Limits 19 B Broken Wire Harness 48 C Chopper Motor Repair 51 Cleaning the Optics 51 Component Failure 49 Conduit/Connections 23 Connecting the Set Point Relay 27 Connection for mA Output 26 Cooling Requirements 19, 20 Vortex Air Cooling 20 Water Cooling 19 Cover Attachment 24 D Delay Adjust 29, 34, 35, 39, 41, 44 Delay Setting 32, 37 Disposal / Decommissioning 10 E Electrical Installation G
N Noise Amplification 33 O Objective Lens 29, 35, 41 Opto-Electronics Module 29, 35, 41 Oscillation on the Analog Meter 32, 37 Output PCB 29, 35, 41 P Pilot Monitor 11, 14, 17, 29, 31 Delay Adjust 34 Milliamp Output 34 Noise Amplification 33 Oscillation on the Analog Meter 32 Relay Contacts 33 Sighting 17 Start-up Checklist Getting Started 31 System Gain/Climate Compensation 32 Power Connections 23 Power Fuse 47 Power Input 47 Powering with 115 Volts AC 25 Powering with 220/230 Volts AC 25 Powering with 2
