Quasar 900 Open-Path Gas Detection System User's and Maintenance Manual Factory Mutual Class I Div. 1 Groups B, C, D Class II Div. 1 Groups E, F, G ATEX, IECEx Ex II 2 (2) GD, Ex d e ib [ib Gb] IIB+H2 T4 Gb Ex tb IIIC T135°C Db Document Ref: TM 888200, Rev. I, January 2014 218 Little Falls Rd., Cedar Grove, NJ 07009 USA; Phone: +1 (973) 239 8398 Fax: +1 (973) 239 7614 Web-Site: www.spectrex.net ; Email: spectrex@spectrex.
SafEyeTM Quasar 900 Gas Detector ii
Legal Notice The SafEye monitoring system described in this document is the property of Spectrex, Inc. No part of the hardware, software or documentation may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language or computer language, in any form or by any means, without prior written permission of Spectrex, Inc. While great efforts have been made to assure the accuracy and clarity of this document, Spectrex, Inc.
SafEyeTM Quasar 900 Gas Detector Release History Rev Date Revision History Prepared by Approved by F February First Release Ian Buchanan Eric Zinn G June 2013 Second release Ian Buchanan Eric Zinn H August 2013 Third Release Ian Buchanan Eric Zinn I January 2014 Fourth Release Ian Buchanan Eric Zinn iv Release History
About this Guide This manual describes the Quasar 900 Open-Path Gas Detection System and its features and provides instructions on the installation, operation and maintenance. This guide includes the following chapters and appendices: Chapter 1, Scope, provides a general introduction and overview of the product and the guide, with a brief description of its content. Chapter 2, Technical Description, describes the Detector’s theory of operation.
SafEyeTM Quasar 900 Gas Detector Abbreviations and Acronyms vi Abbreviation Meaning ATEX Atmosphere Explosives AWG American Wire Gauge BIT Built In Test EMC Electromagnetic Compatibility EOL End of Line FOV Field of View HART Highway Addressable Remote Transducercommunication protocol IAD Immune at Any Distance IECEx International Electrotechnical Commission Explosion IPA Isopropyl Alcohol IR Infrared JP5 Jet Fuel Latching Refers to relays remaining in the ON state even after t
Table of Contents Quasar 900 Open-Path Gas Detection System User's and Maintenance Manual ....................................................................... i Legal Notice .................................................................................................... iii Release History ............................................................................................... iv About this Guide..............................................................................................
SafEyeTM Quasar 900 Gas Detector 3 Operating Modes...................................................................................... 13 3.1 Operational Modes ................................................................................13 3.1.1 Normal Mode .................................................................................. 13 3.1.2 Maintenance Call Mode (3mA Output) ................................................ 13 3.1.3 Fault Mode .............................................
TM 888200 Rev (I), January 2014 6 5.2.4 The Source and Detector ................................................................. 26 5.2.5 Guidance Tips for Gas Detector Locations........................................... 26 5.3 Preparations for Installation ...................................................................26 5.4 Certification Instructions ........................................................................28 5.5 Conduit/Cable Installation ..................................
SafEyeTM Quasar 900 Gas Detector B C Accessories .............................................................................................. 55 B.1 Tilt Mount P/N 888270 ...........................................................................55 B.2 Pole Mount (U-Bolt 5 inch) P/N 799225 ....................................................55 B.3 Commissioning Kit P/N 888247 ...............................................................55 B.4 RS485 Hand-Held Diagnostic Unit P/N 799810 .........
TM 888200 Rev (I), January 2014 List of Figures Figure 1: P/N Definition of Quasar 900 .................................................................. 9 Figure 2: Flash Source ....................................................................................... 10 Figure 3: Detector ............................................................................................. 11 Figure 4: Tilt Mount ...........................................................................................
SafEyeTM Quasar 900 Gas Detector List of Tables Table 1: Gas Concentrations Measurement Terms .................................................. 4 Table 2: Model Numbers and Installation Distances ................................................ 8 Table 3: Detector LED Indications ....................................................................... 15 Table 4: Source LED Indications ..........................................................................
1 Scope ➣ In this chapter… Product Overview 1.1 page 1 Product Overview The SafEye Quasar 900 IR Open-Path Gas Detector employs an advanced Xenon Flash Source and integrated electronics package, both housed in improved, Stainless steel housings to provide high quality and performance, fast response, line of sight gas monitoring. This high quality is backed by 3 years warranty for the complete SafEye system and 10 years for the Xenon Flash source bulb.
SafEyeTM Quasar 900 Gas Detector 2 Product Overview
2 Technical Description ➣ In this chapter… 2.
SafEyeTM Quasar 900 Gas Detector 2.2 Applications The Quasar 900 system may be used to monitor flammable gas concentration in various applications, such as: 2.3 Petrochemical, pharmaceutical and other chemical storage and production areas. Flammable and toxic chemical storage sites and hazardous waste disposal areas. Refineries, oil platforms, pipelines, refueling stations and fuel storage facilities.
TM 888200 Rev (I), January 2014 2.3.3 Optical Path The presence of hazardous airborne vapors, gases, or aerosols in a monitored area is detected when the defined substance crosses/enters the optical path between the radiation source unit and the detector. Hazardous gases /vapors present in the atmosphere cause absorption of the radiation pulse in the optical path between the radiating source and the detector unit at some specific wavelengths.
SafEyeTM Quasar 900 Gas Detector 2.3.8 Heated Optics SafEye Quasar includes heated optics for the Detector and source. The heater increases the temperature of the optical surface by 5-8°F (3-5°C) above the ambient temperature to improve performance in icing, condensation and snow conditions. The heated optics is configured to automatically operate when the change in temperature requires the heating (default).
TM 888200 Rev (I), January 2014 The handheld unit can be used: 1 For on-site function programming and set up changes to the Detector. 2 During installation, the handheld unit will display all the detector’s parameters and confirm that the installation has been completed successfully.
SafEyeTM Quasar 900 Gas Detector 2.4.2 FM / FMC The Quasar 900 is approved to FM / FMC Explosion Proof per: Class I, Div. 1 Group B, C and D, T6 -58°F (-50°C) ≤ Ta ≤ 149°F (65°C) Dust Ignition Proof – Class II/III Div. 1, Group E, F and G. Ingress Protection – IP66 & IP68, NEMA 250 Type 6P. IP68 is rated for 2 meter depth for 45 minutes. 2.4.3 SIL-2 The Quasar 900 Is TUV approved for SIL2 requirements per IEC 61508.
TM 888200 Rev (I), January 2014 Figure 1: P/N Definition of Quasar 900 2.6 Description The SafEye comprises two main units: The Flash Infrared Source (Transmitter) The Infrared Detector (Receiver) Quasar 900 detects gases over an open path transmitted from the Flash Source to the Detector.
SafEyeTM Quasar 900 Gas Detector 2.6.1 Flash Source Unit The Flash Source unit emits IR radiation pulses at the rate of two pulses per second. The pulse width (5-10µsec) is very powerful. The front of the source SafEye has a lens that collimates the IR beam for maximum intensity. The front window is heated to improve performance in icing, condensation and snow conditions.
TM 888200 Rev (I), January 2014 2.6.2 Detector Unit The Detector receives the transmitted pulsed radiation signals from the Flash Source. The signals are then amplified and fed into an analog to digital signal converter to be processed by the internal microprocessor. When the signals drop below a prescribed level, the internal microprocessor will compensate for them. This will allow the signal to be maintained even in severe weather conditions. The data is sent to the output interface section.
SafEyeTM Quasar 900 Gas Detector 12 Description
3 Operating Modes ➣ In this chapter… 3.1 Operational Modes page 13 Visual Indicators page 15 Output Signals page 15 System Setup page 16 Operational Modes The Quasar 900 has four operational modes: 3.1.1 Normal Mode, page 13 Maintenance Call Mode (3mA Output), page 13 Fault Mode, page 14 Zero Calibration Mode (1mA Output), page 14 Normal Mode This mode is used for gas detection.
SafEyeTM Quasar 900 Gas Detector 3.1.3 Fault Mode In the Fault status, there are three fault types: Fault 1 (2mA Output) – Non critical If this occurs, it is due to blockage, very low signal or in the case of partial obscuration or full beam block and detection is no longer possible. The Detector’s proper operation can be restored (Auto reset) during operation if the condition causing the problem is removed or resolved. This mode will occur after a delay of 60 sec. from the moment of the fault.
TM 888200 Rev (I), January 2014 3.2 Visual Indicators One 3-color LED indicator is located in the back side of the detector/source and can be seen through the back cover window. See Figure 2 and Figure 3, item 11. The detector statuses are listed in Table 3.
SafEyeTM Quasar 900 Gas Detector Table 5: Standard (default) 0-20mA Current for the Gas Channel Current Reading 3.3.2 Status and Description 0mA +0.3mA Fault in 0-20mA loop 1mA ±0.3mA Zero Calibration (In Progress), Fault 2 2mA ±0.3mA Fault 1 (non-Critical) 2.5mA ± 0.3mA Misalignment fault 3mA ±0.3mA “Maintenance Call” 4mA±0.5mA No gas present 4-20mA Continuous measuring of gas concentration at a range between 0 and full scale. For methane and propane This translates to 3.2mA per LEL.
TM 888200 Rev (I), January 2014 3.4.2 Detection Setup Function See Detector Default Setup, page 18 for default settings. Setup includes the following options: 3.4.2.1 Gas Calibration, page 17 Zero Calibration, page 17 Address Setup, page 17 Heated Optic Operation, page 17 Gas Calibration Three gas types can be selected for maximum compatibility to the required measured gas(es). Gas Types: Methane – full scale 5 LEL.m. Propane – full scale 5 LEL.m. Ethylene – full scale 8 LEL.
SafEyeTM Quasar 900 Gas Detector 3.4.3 Detector Default Setup The Detector has 8 functions that can be programmed according to the customer requirement at factory or at customer facility using a software Host or a handheld unit.
4 Technical Specifications ➣ In this chapter… 4.1 General Specifications page 19 Electrical Specifications page 20 Mechanical Specifications page 21 Environmental Specifications page 22 General Specifications Detected Gases: Simultaneous detection of C1-C8 flammable gases Detection Distance range: Table 8 Table 8: Detection Distance Range Model No. Detector Source Min. Installation Distance Max.
SafEyeTM Quasar 900 Gas Detector Immunity to false alarm: 4.2 Does not produce false alarm and is not influenced by Solar Radiation, Hydrocarbon Flames and other external IR Radiation Sources. Electrical Specifications Operating Voltage: 4.2.1 18-32 VDC Power Consumption Table 9: Detector and Source Maximum Power Consumption Without Heated Optic (Max.) 4.2.2 With Heated Optic (Max.
TM 888200 Rev (I), January 2014 Through the HART Protocol the detector can: 4.3 Display set-up Reconfigure set-up Display detector status and definition Perform detector diagnostic Troubleshooting Mechanical Specifications Enclosure: The Detector, Source and tilt mount are St. St. 316 Electro chemical and passivized coating. Explosion Proof: ATEX & IECEx EX II 2 GD, FM/FMC Class I Div.
SafEyeTM Quasar 900 Gas Detector 4.4 Environmental Specifications The SafEye system is designed to withstand harsh environmental conditions. The source and detector units compensate for adverse conditions while maintaining accuracy. 4.4.1 High Temperature Designed to meet MIL-STD-810C, method 501.1 procedure II. 4.4.2 Operating Temperature: +149 ºF (+65 ºC) Storage Temperature: +149 ºF (+65 ºC) Low Temperature Designed to meet MIL-STD-810C, method 502.1, procedure I 4.4.
TM 888200 Rev (I), January 2014 4.4.
SafEyeTM Quasar 900 Gas Detector 24 Environmental Specifications
5 Installation Instructions ➣ In this chapter… 5.1 Introduction page 25 General Considerations page 25 Preparations for Installation page 26 Certification Instructions page 28 Conduit/Cable Installation page 29 Detector/Source Mounting page 29 Detector Wiring page 30 Detector Terminal Wiring page 34 Flash Source Wiring page 34 Introduction The Detector and Flash Source units can be installed and maintained with the use of general-purpose common tools and equipment.
SafEyeTM Quasar 900 Gas Detector 5.2.3 Site Requirements The installation position of the SafEye system must take into account if the gas being monitored is heavier or lighter than air, and the individual site requirements. The site selected must give the Detector a direct view to the Source. The mounting point for each item should be secure and stable with minimal vibrations. Equipment should be either mounted in a position where it cannot be knocked out of alignment, or guarded from physical impact. 5.
TM 888200 Rev (I), January 2014 The Commissioning kit includes Function Check Filter and the Telescope Kit, which is used during each SafEye installation and then removed. They can be reused for all other SafEye installations on the site. Therefore, only one set is provided for several detectors.
SafEyeTM Quasar 900 Gas Detector 5.4 Certification Instructions Warning: Do not open the detector, even when isolated, when flammable atmosphere is present. Use the following certification instructions: The cable entry point may exceed 182°F (83°C) suitable precautions should be taken when selecting the cable. The equipment may be used with flammable gases and vapors with apparatus groups IIA and IIB +H2 T4 in the ambient temperature range -67°F (-50°C) to +149°F (+65°C).
TM 888200 Rev (I), January 2014 5.5 Conduit/Cable Installation The conduit and cable installation must comply with the following guidelines: 5.6 1 To avoid water condensation in the detector, it should be installed with the conduits/cable entries facing downwards. 2 Use flexible conduits/cables for the last portion connecting to the detector. 3 When pulling the cables through the conduits, ensure that they are not tangled or stressed.
SafEyeTM Quasar 900 Gas Detector 5.7 2 Place the Detector, with its conduit/cable inlets pointing downwards on the Detector holding plate of the Tilt Mount (item 2). Secure the Detector with M10 x 1.5 screw with No. M10 spring washers (9,10). Secure the detector to the Tilt Mount use Hex Key No. 7 for M10 x 1.5 screw (item 9). 3 Repeat steps 1 – 2 to install the Source.
TM 888200 Rev (I), January 2014 1 Tilt Mount Holding Plate 5 Vertical Fine Alignment Tightening Screw Vertical Crude Alignment Tightening Screw 2 Detector/Source Holding Plate 6 3 Horizontal Crude Alignment Tightening Screw 7 4 Horizontal Fine Alignment Tightening Screw 8 Vertical Find Alignment Screw Horizontal Fine Alignment Screw Figure 4: Tilt Mount Detector Wiring 31
SafEyeTM Quasar 900 Gas Detector 1 Tilt Mount Holding Plate 9 2 Detector/Source Holding Plate 10 3 Horizontal Crude Alignment Tightening Screw 11 4 Horizontal Fine Alignment Tightening Screw 12 5 Vertical Fine Alignment Tightening Screw 13 6 Vertical Crude Alignment Tightening Screw 14 7 Vertical Fine Alignment Screw 15 8 Horizontal Fine Alignment Screw Detector Tightening Screw Detector Tightening Washer Detector Telescope Telescope Tightening Bolt Detector Back Cover Detector Back
TM 888200 Rev (I), January 2014 1 Housing 5 Internal Earth Connection 2 Terminal Board 6 Connection to Handheld Unit 3 Earth Terminal 7 Detector Holding Plate 4 Inlet Conduit Figure 6: Detector with Cover Removed Detector Wiring 33
SafEyeTM Quasar 900 Gas Detector 5.8 Detector Terminal Wiring The Detector has six wiring terminals. The following describes the function of each electrical terminal of the detectors. Table 11: Wiring Options Terminal No. Function 1 Power +24V DC 2 Return +24V DC 3 0-20mA (Input) 4 0-20mA (Output) 5 RS-485 (+) 6 RS-485 (-) 5.9 Flash Source Wiring 5.9.1 Wiring ➣ To install the wiring: 34 1 Release the back screw bolt (item 15, Figure 5), and open the source back cover (item 14, fig. 4).
TM 888200 Rev (I), January 2014 5.9.2 Terminal Wiring The Flash Source contains six wiring terminals. Table 12: Flash Source Wiring Options Terminal No.
SafEyeTM Quasar 900 Gas Detector 36 Flash Source Wiring
6 Operating Instructions ➣ In this chapter… 6.1 SafEye Operation page 37 Alignment of Unit page 37 Powering up the System page 38 Safety Precautions page 39 Signal Verification page 39 Zero Calibration page 40 Functional Check of Unit page 41 SafEye Operation Once the system is positioned, it will monitor for possible specified gases automatically sending signals to a standard control panel or a PC. This section describes the alignment, calibration and operation.
SafEyeTM Quasar 900 Gas Detector 6.3 3 Install the Telescope Assembly (12) on the detector/source front. Fasten the Telescope with Fastening Screws (13).
TM 888200 Rev (I), January 2014 6.4 Safety Precautions After powering up, the Detector requires minimal attention in order to function properly, but the following should be noted: 6.5 1 Follow the instructions in the Manual; refer to the drawings and specifications issued by the manufacturer. 2 Do not open the detector/source housing while power is supplied. 3 Disconnect external devices, such as automatic extinguishing systems before carrying out any maintenance task warranty.
SafEyeTM Quasar 900 Gas Detector 6.6 Zero Calibration Zero calibration must be done after: Installation. Realignment. Window Cleaning. Any change in Detector or Source position. Precise alignment must be performed prior to the zero calibration procedure. Zero calibration should be performed in good weather conditions with insignificant gas concentrations in the surrounding environment or indoors.
TM 888200 Rev (I), January 2014 6.7 Functional Check of Unit The SafEye system has been calibrated at the factory for the User's specific gas or vapor detection requirements. The following procedure validates the functional operation of the system. The Functional Check Filter is a convenient operational check used to confirm that response has not changed from previous readings. The filter is not used for calibration, which is unnecessary, nor does it equate to a particular quantity of gas.
SafEyeTM Quasar 900 Gas Detector 42 Functional Check of Unit
7 Maintenance Instructions ➣ In this chapter… 7.1 General Maintenance page 43 Periodic Maintenance page 43 General Maintenance The SafEye Quasar 900 requires only simple periodic maintenance to provide satisfactory service and achieve maximum performance. The Detector and Source units can be maintained with the use of common tools and equipment. Record the periodic test results in Maintenance Logbook with a copy of the delivery form inside. 7.
SafEyeTM Quasar 900 Gas Detector 7.2.1 Routine Optical Surface Cleaning The SafEye system, being an optical device, must be kept as clean as possible. The optical surfaces concerned are the Source and Detector viewing windows. ➣ To clean the optical window, proceed as follows: 1 Turn off the power to the SafEye detector and source. 2 In places where dust or dirt has accumulated on the optical surface, clean the surface with a small, soft-bristle brush.
8 Troubleshooting Table 14: Troubleshooting Problem Cause Solution “Maintenance call” status or R and S are below 2V DC at Gain 9 Poor alignment Perform alignment Dirt on the window Clean the window Poor light source Replace the light source Detector fault Replace/repair Detector NQRat below the permitted limit Gas in the path Make sure that the path is clean and the weather conditions are good NQRat above the permitted limit Poor alignment Perform alignment Temperature higher than 25° C
SafEyeTM Quasar 900 Gas Detector 46 Periodic Maintenance
Appendices Appendices 47
SafEyeTM Quasar 900 Gas Detector 48 Appendices
A Wiring Configurations ➣ In this appendix… RS-485 Communication Network page 53 Figure 9: Detector Wiring Terminal RS-485 Communication Network 49
SafEyeTM Quasar 900 Gas Detector Figure 10: Source Wiring Terminal 50 RS-485 Communication Network
TM 888200 Rev (I), January 2014 Figure 11: 0-20mA Sink 4-Wire Figure 12: 0-20mA Non-isolated Sink 3-Wire RS-485 Communication Network 51
SafEyeTM Quasar 900 Gas Detector Figure 13: 0-20mA Source 3-Wire 52 RS-485 Communication Network
TM 888200 Rev (I), January 2014 A.1 RS-485 Communication Network By using the RS-485 network capability of the SafEye Quasar 900 detector and additional software, it is possible to connect up to 32 Detectors in an addressable system with four (4) wires only (2 for power and 2 for communication). Using repeaters, the number of Detectors can be much larger (32 Detectors for each repeater) up to 247 on the same four (4) wires.
SafEyeTM Quasar 900 Gas Detector 54 RS-485 Communication Network
B Accessories ➣ In this appendix… B.
SafEyeTM Quasar 900 Gas Detector This is an I.S. approved Hand-Held with I.S. harness and converter to suit the detector and programmed with a special host for maintenance and commissioning. B.5 HART Hand-Held Diagnostic Unit P/N 888810 HART Hand-Held diagnostic unit fitted with harness to the quick plug connection which provides easy and economical connection. The HART Hand-Held will provide verification, status and instructions for correcting the detector’s parameters. This is an I.S.
C SIL-2 Features ➣ In this appendix… Safety Relevant Parameters for the Quasar 900 Open Path Gas Detector page 57 General Conditions for Safe Use page 58 This appendix details the special conditions to comply with the requirements of EN 61508 for SIL-2. The SafEye Quasar 900 IR Open-Path Gas Detector can be used in low and high demand mode applications, see IEC 61508-4:2010, Chapter 3.5.16. C.
SafEyeTM Quasar 900 Gas Detector C.2 58 General Conditions for Safe Use The SafEye Quasar 900 IR Open-Path Gas Detector shall consist only of the approved hardware and software modules. The application advice and the limitations of the manual must be taken into consideration. For calibration and maintenance, the regional and national regulations have to be taken into consideration. The 24V power supply must fulfill the requirements for PELV / SELV of EN 60950.
Technical Support For all technical assistance or support, contact: 218 Little Falls Road Cedar Grove, NJ 07009, USA Tel: +1 (973) 239 8398 Fax: +1 (973) 239 7614 Email: spectrex@spectrex.net Web-site: www.spectrex.net Your Local Office: SPECTREX INC. USA (Texas) Mr. Jay Cooley, Regional Sales Manager 16203 Park Row, Suite 150 Houston, Texas 77084 USA Phone: +1 (832) 321 5229 Email: jay@spectrex.net Europe Mr.
SafEyeTM Quasar 900 Gas Detector 60 Technical Support
