IPES-IR3 Flame Detector Operating Manual 80031-001 R02
Table of Contents INTRODUCTION 3 RELAYS INCLUDED AS A STANDARD FEATURE 3 APPLICATIONS 3 IPES IR3 FLAME SPECIFICATIONS 4 FLAME RESPONSE SENSITIVITY 5 CONE OF VISION 5 FALSE ALARM REJECTION 5 OPERATIONAL DESCRIPTION 6 GENERATION OF ALARM SIGNALS 6 ELIMINATION OF FALSE ALARMS 6 CERTIFICATIONS AND COMPLIANCE 7 CAUTIONS AND WARNINGS 8 IPES IR3 ENCLOSURE & SENSOR LOCATIONS 9 PHYSICAL INSTALLATION 10 COMPONENT PARTS AND DELIVERY SET 10 VISUAL EXAMINATION 10 PRE-INSTALLATION STEPS 10 POSITIONING THE DETECTOR 10 PROTECTION FROM MOISTURE DAMAGE 11 DISSASEMBLY 11 REASSEMBLY 12 GENERAL WIRING REQUIREMENTS 12 CABLING GUIDELINES 12 24 VDC REQUIREMENTS 12 EARTH GROUNDING 13 POWER CABLE CONDUCTOR SIZE AFFECTS CABLE LENGTH. 13 IR3 RECEPTACLES ERROR! BOOKMARK NOT DEFINED. IR3 RS-485 MODBUS WIRING DIAGRAM 16 MAINTAINING SIGNALS INTEGRITY 17 IPES IR3 OPERATING PROCEDURE 18 INITIAL POWER UP 18 POWER ON SELF TEST 18 FIRE DETECTION TEST 19 IR3 PHOTONIC DETECTOR LOCATIONS 19 DUST/OBSTRUCTION FAULT TEST 19 MAINTENANCE 20 CLEANING PROCEDURES 20 APPENDIX I: IPES IR3 RELAY STATES AND FUNCTIONS 21 APPENDIX II: IR3 CONE OF VISION 22 APPENDIX III: IPES IR3 ANALOG SIGNAL +4 TO 20MA INDICATIONS 23 APPENDIX IV TROUBLESHOOTING 24 APPENDIX V: IPES-IR3 CONFIGURATION SOFTWARE 25 APPENDIX VI: IR3 EXPLOSION PROTECTION MEANS 28 APPENDIX VII OPTIONAL TESTING LASER PEN 31
Important: Be sure to read and understand the entire instruction manual before installing or operating the flame detection system. Any deviation from the recommendations in this manual may impair system performance and compromise safety. Introduction The IPES-IR3 flame detector s advanced microprocessor based technology ensures rapid flame recognition and alarm signaling. In addition, IPES-IR3 selective, multiple spectrum technology virtually eliminates false alarms from a variety of sources including: Direct or indirect sunlight Arc welder flash, resistive heaters Fluorescent, halogen Incandescent light Nuclear radiation IPES-IR3 generates an alarm signal only when detection from three different IR wavelengths agree that a flame or fire is present in the field of view. Upon confirmation of flame or fire, the IR3 triggers alarm relays and provides alarm signals via RS-485 Modbus and industry standard +4 to 20mA current loop to the users receiving devices and alarm systems. For ease of operation status and alarm condition IR 3 provides an easily visible high illumination Tri State LED that follows an Industry Standard protocol: Green for normal operation Yellow for alarm condition Red for Fault Conditions Applications IR3 provides superior false alarm processing making it the detector of choice. Alarms occur instantly after our proprietary False-Positive Algorithm determines possible alarm states. This makes IR3 the industry standard for several industrial applications: Drilling and production Automated and manned ocean based platforms. Fuel loading and transfer facilities Refineries Bulk terminals Tank farms and storage facilities LNG/LPG processing and storage Compressor stations Piplines and pump stations Petrochemical processing facilities Fertilizer production Paint production Power Plants- Nuclear, Coal, Oil, Natural Gas, Solar Process, MHD Shipping Tankers, Freighters. Virtually any vessels that may have a potential fire hazard. Laboratory and Plasma Study/Process Transportation facilities, Airports, Subways, Aircraft hangers Oil and Gas Boilers Stage and entertainment special effects Relays included as a standard feature IR3 includes two Dry Contact relays that operate during alarm conditions and fault modes. Introduction Page 3 of 31
IPES IR3 FLAME Specifications Detection Type: Optical Detection Method: Multiple Spectrum Infrared Radiation Source Spectral Range: Three points in a range of 4.0 to 5.0 m Detection Process Time: 4.5 to 7 Second (Complies with FM Standard 3260) Refer to Table XXX Detection Distance: Minimum 41ft (12.5m) to 82ft (25m) depending on detected fuel. Refer to Table xx Detection Cone of Vision: Up to 90 0 (45 0 Left/Right of center) Sensitivity: User Selectable for distance and False/Positive process time Power requirements- 24VDC nominal (18-32VDC range) Power Consumption: 3 VA (3 Watt) Max Outputs: Industry Standard +4 to 20mA 2 Alarm Relays (SPDT/Form-C latching) 2 Fault condition (NO/Form-A) *Functionality of relays is switch selectable *All Relays Contact Rating 1 Amp@125VAC/30VDC Digital RS-485 Modbus *Note HART interface is available as a custom / lead time order) Cable Distance: 6200ft (1900m) 18 AWG Ingress Protection: IP66 Vibration: Meets FM 3260: 200o Impact Resistance: 1.9 Joules Test Method: Class II Laser Light Pen RFI-resistant to interference by EMI and RFI: EMC Directive compliant with CE mark. Not susceptible to keying 5 watt walkie-talkie at distances greater than 1 foot. Optical Integrity: IR3 performs an automatic calibrated performance test once per minute to verify complete detector operation capabilities. Operating Temperature: -40 0 F to +185 0 F (-40 0 C to 85 0 C) Storage Temperature: -76 0 F to +185 0 F (-60 0 C to 85 0 C) Humidity Range: 0 to 95% relative humidity (can withstand 100% condensing humidity for short periods of time) Conduit Entry: ¾ NPT Enclosure Material: Stainless Steel Grade 316 Aluminum 6061 with red powder coat finish. Weight: Stainless Steel 11lbs (5.0kg) Aluminum 5.5lbs (2.5kg) Included Equipment: IPES-IR3 Fire Detector Adjustable Mounting Bracket Magnetic Test Collar Optional Equipment Sun Shade Hood Class II Laser Test Pen IR3 Configuration and Monitoring Software IR3 Specification Page 4 of 31
Flame Response Sensitivity When an IPES-IR3 detector is exposed to a series of test fires along the centerline of the sensor as described in the table below, the alarm response of the IPES-IR3 is below the 30-second response time required under FM Standard 3260. Fuel Distance (ft) Fire Size n-heptane 211 1 ft x 1 ft 9 Methanol 151 1 ft x 1 ft 9 Ethanol 151 1 ft x 1 ft 11 Diesel 151 1 ft x 1 ft 15 Diesel 151 2 ft x 2 ft 10 Gasoline 175 1 ft x 1 ft 10 JP-4 201 1 ft x 1 ft 10 JP-4 206 2 ft x 2 ft 10 Methane 151 Plume, 3/8 Dia x 3 High Average Time (sec) 10 False Alarm Rejection When the IR3 is exposed to fire from the fuel sources specified in Flame Response Sensitivity and are in the presence of the following false stimuli sources modulated at approximately 1.5 Hz, and un-modulated no false alarm activation or instability occurs at the minimum distances listed below. Source Distance 1.5 kw Heater 3 feet (0.9m) Arc welder, 200A, 3/16 7018 electrode Fluorescent, (2) 20W (6000 Lux) Halogen, 500W Incandescent, 100W 2000 LUX Direct sunlight Indirect sunlight 9 feet (2.7m) 0 feet (0 m) 3 feet (0.9m) 1 foot ot (0.3m) No alarm No alarm Cone of Vision IR3 has a 90 cone of vision (horizontal) with the highest sensitivity lying along the central axis X= Distance in Ft Y= Angle of Vision Refer to Appendix XX for testing method Sensitivity Page 5 of 31
Operational Description The IPES-IR3 consists of an explosionproof casing with sensors to detect electromagnetic radiation from flames at three points within a spectral window of 4.0 to 5.0μm. Detection is performed using Infrared Sensors that capture heat and radiating gas signatures emitted by fire. Significantly, the IR3 can detect fires fueled by hydrocarbon-based liquids and gases that may not be visible to the human eye. The basic technology is well tested and used for many devices designed for human interaction. These include night vision equipment, FLIR navigation assist, and Spectral Telescopes used in astronomy. The IR3 uses microprocessors with proprietary algorithms that transform the detected signal into industry standard analog and digital communication signals, alarms indicators. The IR3 response time detecting radiation emitted by test sources of n- Heptane combustion in a 12 x 12 (0.3m by 0.3m) pan, and ethyl alcohol combustion in a 12 x 12 (0.3m by 0.3m) pan, at a distance of 150 feet (46 meters) does not exceed 30 seconds. The sensitivity and response time can be varied in order to reduce unwanted noise when the IR3 identifies a fire, or the distance to the probable place of fire is short ( near/far and slow/fast modes). Generation of Alarm Signals The IPES IR3 takes the following parameters into consideration when generating an alarm signal: Magnitude of signals from different optical channels Ratios between the signal amplitudes of different channels Signal modulation frequency Phase relationships among the channels Elimination of False Alarms False alarms from detectors used for industrial applications can cost productivity in down time. This is especially noted for automated systems and processes. Conversely, failure to generate an alarm can be calamitous and deadly. The combination of microprocessor, algorithms, multiple sensors and wavelength range settings makes the IR3 an excellent choice for elimination of false positive indicators caused by nonflame sources of radiation such as artificial lighting, direct and indirect sunlight, lightning, electrical arcs, radiation (nuclear), arc welding and metal grinding. An Alarm condition will normally override a Fault condition unless a loss of operating power impairs the detector s ability to generate or maintain an alarm. The IPES-IR3 reports both Fault and Alarm conditions exclusive of each other. This means both a Fire and Fault can be reported at the same time if they occur simultaneously. Operation Page 6 of 31
Certifications and Compliance Explosion-proof for Class 1, Div.1, Group B, C, D (T4 Hazardous (classified) locations per FM 3615, 6310 Dust ignition-proof for Class II, Div.1, Group E, F, G Hazardous (classified) locations per FM 3615, 6310 Non-incendiary for Class 1, Div.2, Group A, B, C, D (T4), Class 2, Div.2, Group E, F, G (T4) Hazardous (classified) locations per FM 3611 Explosion-proof for Class 1, Div.1, Group B, C, D (T4) Hazardous (classified) locations per CSA C 22.2 # 30 and Ex d IIC T4 per CSA E 60079-0-1 Dust ignition-proof for Class II, Div.1, Group E, F, G Hazardous (classified) locations per CSA C 22.2 # 25 Non-incendiary for Class 1, Div.2, Group A, B, C, D (T4), Class 2, Div.2, Group E, F, G (T4) Hazardous (classified) locations per CSA C 22.2 # 213 CE 0539 II 2 G Ex d[ia] IIC T4 (Tamb75 C) IP 66 Ex d [ia] IIC T4 (Tamb 75 C) IP 66 1 Ex d [ia] IIC T4 X T= -60 C...75 C IP 66 EN Standards EN 60079-0: 2006 EN 60079-1: 2007 EN 61779-1: 2000 EN 60529: 1991+A1: 2000 EN 50270: 2006. Compliance and Certification Page 7 of 31
Cautions and Warnings This user guide includes numerous cautions and warnings that are specifically included to prevent injury to personnel and prevent damage to equipment. Care is also taken to include notation of all applicable standards and best practices as appropriate information that may apply to any use or procedure associated with the product. Caution: The installation of IR3 must comply with relevant requirements of the latest edition of the national Electric Code (ANSI/NFPA 70) Caution: Connection Conduit, Barrier Glands, and Epoxy Sealants are to meet EN-50018/IEC 60079-1 Standards Caution: ESP Safety Inc. Recommends use of shielded cable with 14AWG conductors reaching a span no greater than 3,900 ft. (1200 meter) Caution: The IR3 detector has no user serviceable parts. If a problem should develop, refer to the Troubleshooting information. If it is determined that the problem is caused by a manufacturing defect, please return the device to the factory for repair or replacement. Caution: Observe precautions for transport and handling of electrostatic sensitive devices. Caution: IR detectors have been tested and approved for use in hazardous areas. However, it must be properly installed and used only under the conditions specified within this manual and the specific approval certificates. Any device modification, improper installation, or use in a faulty or incomplete configuration will render warranty and product certifications invalid. Cautions and Warnings Page 8 of 31
IPES IR3 Enclosure & Sensor Locations Enclosure and Sensor Locations Page 9 of 31
Physical Installation Caution: The installation of IR3 must comply with relevant requirements of the latest edition of the national Electric Code (ANSI/NFPA 70). Personnel trained in safety techniques that have electric-safety certificates and experience in dangerous explosive zones should install the IPES IR3. They should be familiar with the design of the IPES- IR3 and thoroughly read and understand this Operating Manual. Component Parts and Delivery Set The IPES-IR3 detector component parts and delivery set consists of the following: One IPES-IR3 Detector One mounting base. One Operating Manual Mounting Hardware Accessory Magnetic Test Collar Compare the contents of the set to the packing list to be sure all items were received. If any items are missing, contact ESP Safety Inc. Visual Examination Before installing the IPES-IR3, examine the detector to be sure that: The nameplates and warning labels are in place. The external surfaces of the elements and joined surfaces of the casing are free of dents or damage. The tamperproof screw is intact on the front cover Pre-Installation Steps Make sure all removable parts are joined to the casing as tightly as possible result in serious damage to the detector, which could go undetected, resulting in failure to detect fires. Positioning the Detector Position the detector to provide an unobstructed view of the area to be protected. The detector s 90 viewing angle is most sensitive along the central axis; therefore, position the central axis so that it has the best-unobstructed view of the place of probable fire. Use line of sight or laser level for more precise targeting. Identify all high-risk fire sources, to determine the number of detectors needed for adequate coverage. Locate the detector(s) for ease of cleaning and servicing. Ensure that probable fire sources are within the detector(s) field of view and detection range. When installing multiple detectors in the same area, be aware of overlapping fields of view and detector hierarchy. Overlapping fields of view can be used to provide additional protection against false positives or false negatives, depending on the control system logic connected to the detectors. Note: To mitigate false positives, position the detector so that its field of view does not cover any areas outside the hazardous area. Mount the detector on a rigid surface, which minimizes vibrations. Use the mounting hardware provided along with the rubber bushings to further isolate the detector from vibrations (see Appendix A-1, Drawing 80029-001, Sheet 2). Warning: Do not separate casing when energized! Separating the casing can Physical Installion Page 10 of 31
Note: ESP Safety Inc recommends bolting the mounting base plate to the mounting surface. If bolting is not possible, the mounting base can be welded to the mounting surface if it is a similar metal (either 316 Stainless Steel or 6061 aluminum). Before welding, be sure to remove the detector from the base plate before attempting any weld operation. Protection from Moisture Damage It is the responsibility of the installer to take proper precautions during installation to protect the electrical connections and components from moisture. Anti-seize lubricant is provided for easy assembly and corrosion protection of the joints between the enclosure/cover and enclosure/base. After disassembly, wipe these surfaces clean with a soft cotton or wool cloth and then re-apply a thin layer of lubricant prior to assembly. Refer to Appendix VI If installing wiring cable in conduit, do not use conduit for wiring to other equipment. Care should be taken to not install the detector where heavy condensation, rain, or fog can cover the lens and reduce the sensitivity of the detector. If possible, conduct regular live fire tests to confirm detection. Dissasembly After attaching the base to a suitable location, the IR3 must be disassembled for wiring. The access to the wire receptacles requires removal of the back cover plate, which may be bolted to the mounting stand. Note that the rear cover has three 5mm hex head screws. Remove these for access to the wire recepticals. There are also 2 ¾ NPT threaded holes. It is strongly recommended if installed in a Class1 hazardous area the use of armored cable and or conduit and sealed cable glands for wire entrance/exit from the IR3. Wiring requirements Page 11 of 31
When the cover has been removed notice the O Ring that seals the attachment of the IR3 body and rear cover. Make every effort to keep the O Ring, it s insertion channel, and the rear cover mating area clean and scratch free to prevent moisture or dust from entering the IR3 enclosure. Caution: The IR3 contains some components that may be damaged by static electricity. Special care must be taken when wiring the system to ensure that only the connection points are touched. WARNING: Do not connect or disconnect the IR3 detector with power applied. This action is prohibited by regulations of operation in a hazardous area. Reassembly While assembling the IR3 check the condition of external surfaces of the explosion-proof enclosure to verify there are no dents, scratches or contaminating materials like dust, mud, grease, paint, etc.. The O ring seal for the rear cover and the adjoining mating area should be verifed for integretiy and reassmbled. General Wiring Requirements Caution: All cable/conduit entries must be sealed with an appropriate and certified sealing plug and cable gland. Failure to do this will jeapordize the explosion proofness of the IPES cable entries. The use of industrial grade, armored field cable is recommended. Cabling Guidelines If installing connection cables in an explosion proof conduit, do not use the same conduit to carry wiring for any other purpose or equipment. Minimum 14 AWG (2.08 mm2) shielded cable conductors are required for optimal performance. The gauge of the wire used determines the maximum distance between the 24VDC power sources. When using Modbus, power and signal must be separate shielded twisted pair conductors 24 VDC REQUIREMENTS Warning: The IR3 detector has a maximum power draw of 3VA/Watt in an active alarm state with all relays and optics heater active. (Fault, Alarm1) Select a power supply with adequate capability for the calculated load. Ensure that the 24VDC (+/-8VDC) power positive and common connections are from the same source. Wiring requirements Page 12 of 31
Warning: System ground must be provided at the point of origination for 24VDC. Failure to do this may result in loss of range and/or signal integrity. Avoid low frequency, high voltage, and non-signaling conductors to prevent potential EMI problems. Earth Grounding The enclosure of the IR3 must be earthed/grounded for electrical safety and to limit the effects of radio frequency interference. An earth/ground point is provided on the outside of the IR3 Explosion Proof enclosure. Use 14 AWG copper (Stranded, or Solid), wire. Loosen the nut sufficiently to enable wrapping of the wire or wire terminated Wire Gauge 22 AWG 0.326mm 2 ) 20 AWG 0.518mm 2 ) 18 AWG 0.823mm 2 ) 16 AWG (1.31mm 2 ) Resistance Ω Max Meters with a crimped lug around the thread in a U shape. Raise the flat and lock washers and position the wire between the 2 flat washers and ground base. *Note: Earth and System Grounds are separated to prevent ground loop potential plus maintain signal and current output integrity. Power Cable Conductor size affects cable length. The IR3 detector must receive a nominal voltage of 24 VDC (+/- 8VDC) to operate properly. Wire size requirements are dependent upon power supply voltage and wire length. There are several possible methods to electrically connect an IR3 that are determined by each user s application. These can run from a single IR3 running on 24VDC that is operating as an isolated device and is connected directly to a warning system of alarms and/or lights to a network of devices that are connected in series that can provide any mix of RS-485 Modbus, +4 to 20 am, and relays to separate devices. Max Feet 40.5Ω 750 2460 40.8 1200 3936 40.7Ω 1900 6232 40.2Ω 3000 9840 Wiring requirements Page 13 of 31
Terminal block type A Terminal block type B Terminate wires using the included Screw Clamp Connectors Terminal block type A Terminal block type B Pin Function X1 X3 +24V 24VDC from system power source (External User Provided) GND System Ground from system power source (External User Provided) X2 +4/20 Industry Standard +4-20mA current loop output X3 RS485A RS485B R_WORK R_WORK RS-485 MODBUS RS-485 MODBUS Fault / Obstruction Relay Normally Closed (NC Type B) When Energized X1 X4 +24V Output to next device if required GND Output to next device if required X2 +4/20 Industry Standard +4-20mA current loop output X3 RS485A RS485B R_FIRE R_FIRE Output to next device if required Output to next device if required Alarm Relay Normally Open (NO Type A) When Energized Wiring requirements Page 14 of 31
IR3 3 Wire +4 to 20 ma Current Loop Wiring Diagram When using the current loop method of connection the circuit is a point-to-point connection between a single IR3 and a threshold detection device. In most cases the threshold device will provide the 24VDC power and will operate in a closed loop. Refer to Appendix III for interpretation of +4 to 20ma indications If 24VDC is from a common source, use of a connection bus-block is recommended to provide connect-disconnect capability without disruption to any other devices using the same power source. Wiring requirements Page 15 of 31
IR3 RS-485 Modbus Wiring Diagram When connecting the system using RS-485 Modbus, up to 255 devices can be attached in a series network. ESP Safety recommends the use of armored and environmentally protected terminal boxes with punch block style connections that can allow any device to be added or removed from the circuit with no interruption to the network. The terminal box should be located as close to the IR3 as possible since this distance will reduce the possible length of the network as the additional cabling required will cause power reductions by added wire electrical resistance. To determine over all power drops caused by wire resistance use the formula L (km) =25 ΔU(V) *S (mm2) /Imax(mА) ΔU(V) is permissible voltage drop in line Imax(mА) is maximum current consumption; Example: o (ΔU(V) = 6V at U nom = 24V: ΔU(V) = 12 V at U nom = 30V) o ( I max (ma) IPES = 150 ma N (pcs.) ) The terminal boxes must be designed to meet the protective requirement of the classified area of installation including cable glands and explosion survivability. Wiring requirements Page 16 of 31
Maintaining Signals Integrity Note the following Guidelines for RS-485 Installations: The power-supply system determined subject to IR3 power consumption on the devices terminals which shall be not less than 16VDC and not more than 36 VDC. The analog informational network voltage drop on -24V wire between the Control system and IPES IR3 should not exceed 8 V. It is recommended to connect the Flame Detectors to network taps of a main interface line. The taps may require installation of repeaters with opto-isolation connections at the junction points. Each individual IR3 should be serviced by a separate network tap as diagrammed on the previous page. Signal runs in excess of 1200 feet may require installation of repeaters with opto-isolation connections at the junction point. ESP Safety recommends power be installed in a radial layout with a single cable run between the IR3 and power source. Wiring requirements Page 17 of 31
IPES IR3 Operating Procedure Initial Power Up WARING: Before the initial power up, remove power from or disconnect all output devices and alarms to prevent actuation. Apply power to the system. Power On Self Test After supplying power to the detector (24VDC +/-8VDC) the unit will perform a self-test procedure When power is applied, the status indicator led lights up for 3 seconds in a solid yellow color. In three seconds, the status led will blink yellow for 7-8 seconds, after this, the self-testing of the device starts (three self test lamps beneath the cantilevers of the optics window will flash three times). o The Working order' relay (R_WORK on the IR3 X3 receptacle) will be open (Fault Indication) during portions of the initial self test cycle. o The analog +4 to 20mA output will be at 2.0mA indicating the IR 3 is in the power on mode IPES IR3 in Self-test mode. 1: Indicator led 2: Test lamp After a successful test, the output signals of the IR3 will be in the following states: Actuation (closure of contacts) of Fault relay, indicating a Working order /operational condition. Indicator led has a solid green light, which corresponds to the Normal work /operational mode of the detector as detailed in the next image. The +4-20mA analog output will be at (4±0,1) am (Operational Status) After the self test, the led will glow with a solid color depending on the test results: yellow-test failed, green-the device is operable Maintenance Page 18 of 31
Fire Detection Test After installation is complete, conduct a fire detection test to ensure that the detector properly detects a fire condition. An optional Class II Laser Test pen and available magnetic Test collar are used to perform the test on the IR3. IR3 Photonic detector locations Dust/Obstruction fault Test Attach the Magnetic Collar with the Magnet placed into the slot on the enclosure. This will put the IR3 into Fault Mode and the status LED will change from Green to Yellow indicating a Test function. Point the laser beam at the Mid range sensor 4.45 um IR detector. This will set the IR3 into fire indication mode. The status indicator will now blink yellow-red indicating both Fault and Fire conditions. To prevent a false alarm during this test, the Fault relay will be actuated (In an open state) and the Fire relay will remain in a not active state (Open) The Analog +4 to 20mA will indicate 8mA for Test Mode Once testing is successfully completed, remove magnetic collar to return the IR3 into operation. Simulation of dust or obstruction on optical window of the IR3 is done by placing a non-transparent material with good reflective properties (white sheet of paper) in front of the optical window of IR channel for 15-20 sec. If the Dust/obstruction detection function is working properly, the FAULT Relay will activate (Open) and the status LED will alternate YELLOW-GREEN to indicate the fault. When the obstruction is removed, the status indicator will return to the GREEN-Operational State and the Fault Relay will return to the normal closed state. Testing Page 19 of 31
Maintenance IR3 regular maintenance should be performed as recommended by the following procedure: Visual examination of the IR3 should be performed daily checked for the absence of visible damages. The IR3 should be cleaned every six months or as required by environmental conditions. Cleaning Procedures Clean the IR3 enclosure with a soft brush, soft cotton or microfiber towel dampened with water. Optics Window A Fault may be generated if the IR3 optics surface is covered with dust or other obstruction. WARING: Before cleaning the optics window, remove power or disconnect all output devices and alarms to prevent unwanted or accidental actuation. Clean the IR3 window with: Commercially available optical lens cleaning pads Optical Lens Cleaning Solution and optical grade suede chamois Flushing the surface with Isopropyl Alcohol A clean soft cloth or cotton swab dampened with Isopropyl Alcohol. After wiping the surface with alcohol, wipe it again with a dry cloth in order to remove residual dirt Check the Earth ground system. Make sure that the connections are sufficiently tight and the contacts are free of oxidation. To prevent oxidization, coat the connections with an oxideinhibiting compound. Maintenance Page 20 of 31
Appendix I: IPES IR3 Relay States and Functions State IR3 status 1 No power supply voltage 2 After switching on during 45 sec. 3 Fault or optical interference (dust) 4 Normal (no faults or fires during operation) Fire Relay State Fault Relay Status Normally open Normally Output when closed when signal, energized energized am Open Open 0mA Off LED Status Condition Open Open 2mA Continuous green LED light for the first 10 sec. and then the green LED will begin flashing. Open Open 2mA Alternate flashing of the yellow and green LED lights. Open Closed 4mA Continuous lighting of the green LED light. 5 Fire Closed Closed 18mA Continuous lighting of the red LED light. 6 Fire & Fault Closed Open 8mA Alternate flashing of the yellow and green LED light. 7 Test mode (magnetic collar is on) Open Open 2mA Magnetic collar is on. fire relay is blocked. Appendix I: Relay States and Functions Page 21 of 31
Appendix II: IR3 Cone of Vision Fuel Flame Size Distance ft (m) Horizontal0 (Pan left/right) n-heptanes 11 foot 105 (32) JP4 11 foot 98 (30) Gasoline 11 foot 98 (30) Kerosene 11 foot 98 (30) Diesel 11 foot 75 (23) Methanol 11 foot 75 (23) Ethanol 11 foot 75 (23) Methane Plume Diameter 3/8 inch, height 3 foot 75 (23) Horizontal Response Seconds 4.4 6.4 4.2 13.5 5.7 10.4 6.3 18.9 6.5 18.6 2.7 4.2 3.0 3.7 2.5 2.8 Vertical 0 (Tilt up/down) Vertical Response Seconds 5.9 8.5 4.3 7.5 4.9 5.5 7.0 14.0 5.2 8.9 3.0 3.1 2.4 2.6 2.6 2.8 Appendix II: IR3 Cone of Vision Page 22 of 31
Appendix III: IPES IR3 Analog Signal +4 to 20mA Indications Analog Current Signal level 0mA 2mA 4 ma Normal operation Non-Functioning the circuit is open /not connected. Note relay state will still function if +24VDC is present at the detector. Failure Mode Fault Relay is Active (open). Check for dust or other obstruction on the optics window +18mA +2mA Fire Mode Fire relay active Test Mode Magnetic Collar is installed Appendix III: Analog Signals Page 23 of 31
Appendix IV Troubleshooting The IR3 is a very stable and reliable device that in most circumstances provides years of trouble free operation. If for any reason an unforeseen issue should arise, refer to the following table for possible solutions. Possible Problem Possible Source Remedy Red LEDs do not glow No power supply Detach the base with the cable entry from the IR3 enclosure and make sure that the terminals are supplied with a voltage of 24±8 VDC. Relay contacts Failure are open, signaling LEDs blink frequently. Optics Cover may have dust or and obstruction Clean the IR3 window with: Commercially available optical lens cleaning pads Optical Lens Cleaning Solution and optical grade suede chamois Flushing the surface with Isopropyl Alcohol A clean soft cloth or cotton swab dampened with Isopropyl Alcohol. After wiping the surface with alcohol, wipe it again with a dry cloth in order to remove residual film. WARNING: Before cleaning the optics window, remove power or disconnect all output devices and alarms to prevent unwanted or accidental actuation. IR3 does not react to a test flame Optics Cover may have dust or and obstruction Refer above procedure Appendix IV: Trouble Shooting Page 24 of 31
Appendix V: IPES-IR3 Configuration Software Appendix V: Configuration Software Page 25 of 31
Functional Setup Using IPES Program Active Status Display (left to right) Parameter Displayed Address Modbus device from 1 to 247 4.00 µм Amplitude value (90 to 300) of the low wavelength IR detector 4.45 µм Amplitude value (90 to 300) of the mid-wavelength IR detector 5.00 µм Amplitude value (90 to 300) of the high wavelength IR detector Ratio Ratios between the signal amplitudes of the three IR detectors (90 to 125) Ut Current temperature in degrees Celsius Fire Fault Dust Fire when flame is detected, otherwise blank Fault activity status is detected, otherwise blank Dust or other obstruction is detected, otherwise blank U Dust Current value of detected dust (1500 to 3000 c.u.) Thr_Dust 3000 8000 threshold value for dust detection Time response Fast/slow Sensitivity Far/close Fix Fixed measuring distance GA 4.00 Analog to digital conversion of low wavelength detector (0 to 255) Appendix V: Configuration Software Page 26 of 31
IPES IR3 Configuration program: 1. Run the program on PC and in box Connecting parameters choose: computer COM-port number for connecting; rate of exchange (on default = 9600); number of information bits keep without changes; parity check keep without changes; number of stopping bits keep without changes. 2. In box "Device number set MODBUS address of device being checked, and press Connect button. When the detector response on requests the following values will display in boxes State and Service data and commands : - in box State state of device for the present time ( fire indicator and Fault indicator) as well as operation modes: "far near slow fast latching not latching fault no fault And additional information about activation of automatic optic heater. - in box Service data and commands the following data are displayed (from left to right) - U (dc) signal value of dust channel in c.u. (value range 0-7000); - Uthr (dc) threshold value of the dust channel in c.u. (value range 0-7000); - U(T) device internal température; U (4.0), U (4.5), U(5.0) signal value levels in IR channels 4.0, 4.45, 5.0 mkm.appendix B.5. IPES IR3 configuration program: Run the program on PC and in box Connecting parameters choose: - computer COM-port number for connecting; - rate of exchange (on default = 9600); - number of information bits keep without changes; - parity check keep without changes; - number of stopping bits keep: without changes. 3. In the box "Device number set MODBUS address of IR3 being configured, and press Connect button. When the detector responds the following values will display in boxes State and Service data and commands : - In the box State state. Appendix V: Configuration Software Page 27 of 31
Appendix VI: IR3 Explosion Protection Means Feature Enclosure of Current Carrying Parts Case Mechanical Strength Manufacturing Control Of Casing Ignition Temperature Securing of Bolts, Joints and Grounding Joined Parts Protection Casing Ingress Protection Sealing Cables at Conduit Entry Protection Means The casing includes spigot joints with controlled gaps to meet explosion-proof requirements for installation in Class I, Division I, Group B, C and D, and T5 locations. The high mechanical strength of the case is able to withstand high explosive pressures without rupture or failures of mechanical parts. The case design is in accordance with FM 3600 and FM 3615. Refer to Appendix A1 for manufacturing details. Important parameters include: Maximum width and minimum length of spigot joints Surface roughness of the joined parts The number of complete intact threads at the conduit entry point The ignition temperature of the surrounding environment is limited by the outside surface temperature of the housing, which does not exceed 275 F (135 C). Spring washers, lock washers, and lock nuts maintain the integrity of the bolted connections by preventing loosening of the bolts. Anti-seize lubricant is applied on the critical joints as described on Appendix A1. The design of the casing is protection class IP 66 in accordance with IEC 60529-004. Use approved hazardous location sealed conduit fittings. For outdoor installations, ensure sealing meets IP66 requirements. Appendix VI: Explosion Protection Means Page 28 of 31
Appendix VI: Explosion Protection Means Page 29 of 31
Appendix VI: Explosion Protection Means Page 30 of 31
Appendix VII Optional Testing Laser Pen Certifications and compliance for the optional ESP Safety Laser Test Pen (ESP part number: 30173-001) CE 0539 II 1,2 Gas Group C Ex d[ia] 21 T4 (Tamb130 C) Laser Class 2 Appendix VII: Optional Laser Testing Pen Page 31 of 31