INSTALLATION INSTALLATION INSTALLATION INSTALLATION

4.3 ELECTRICAL INSTALLATION 6. The earth bonding arrangement must ensure that the maximum 4.3.2 Electrical Installation 4.3.4 Transmitter and Receiver Connections UL (DX100)
peak voltage between the unit case earth and any field cable
4.3.1 Electrical Connections conductor is less than 350V. Voltages in excess of this can cause 1. Isolate all associated power supplies and ensure that they remain
permanent damage to the unit’s RFI protection filters. OFF during this procedure. UL Certified
Junction Box DX100
All ranges of Searchline Excel comply with the EMC requirements
EN50081 and EN50082. In order to maintain compliance with these 7. The use of a single, screened cable for each gas detector ensures 2. Fit approved cable glands to the junction box cable entries to be used Controller
Controller
Connections AB
standards it is essential that the electrical installation of Excel is maximum screening and minimum crosstalk. Cabling arrangements for field wiring, using sealing washers where necessary to maintain Connections 1 4

engineered correctly. which use a single cable for connecting a number of field devices ingress protection rating. +24V
IS EARTH
0V
compromise screening, increase the potential for crosstalk and 0V 4-20mA
Electrical installation standards vary for different countries, companies prevent implementation of true star earthing. 3. Fit approved blanking plugs to all unused cable entries. GND +24V

and applications and it is the responsibility of the installation design Cable

Earth
Terminal TB Cable 4 TB2 1 Receiver
Connections
authority to determine the applicable standards and ensure compliance 8. Any electrical interference induced onto the 4-20mA loop conductors 4. Make appropriate electrical connections as shown in the following Sheild
Earth
Sheild
Earth Earth
with them. When designing electrical installations for Excel, Zellweger by the installation must be kept below the levels necessary to diagrams. Transmitter
Terminal
ORANGE A
Analytics Limited recommends that the installation design authority comply with the general requirements of EN50054. In practice, this Connections BLUE B

considers the following: means that peak noise currents induced on the current loop should 5. The mounting plate must be bonded to a protective earth, either RED +24V
GRN/YEL GND
BLACK 0V
be no greater than ± 0.25mA. through contact with the duct wall (if it is itself suitably earthed) or by BLACK 0V WHITE 4-20mA
1. Where possible, the unit cases should not be electrically connected direct connection. GRN/YEL GND RED +24V

to electrically noisy ( dirty) metalwork or conductors. An electrical 9. The 0V rail of the control card/control system is often directly
isolation kit is supplied (see Technical Handbook) to provide the connected to one side of the 4-20mA current sensing resistor. Note: Suitable crimps or ferrules must be fitted when connecting more
required electrical isolation between the unit’s mountings and its Electrical noise on such a rail is, therefore, directly connected to the than one wire to a single terminal.
mounting plate. The case is internally connected to the green / 4-20mA input. In order to avoid additional noise being induced on 4.3.5 Transmitter and Receiver Connections (Non DVC/DX100)
yellow GND wire which should preferably be connected to a low the 0V rail, it should not be commoned with the safety earth/ground,
noise (clean) earth line. See also 5 of this section. which frequently carries a high level of electrical noise. 4.3.3 Transmitter and Receiver Connections via DVC100 Ex d or Ex e, Junction Box
Temporary
SHC-1 SHC Connection, to SAC-1
Protection
2. The entire length of the field cabling connected to each unit should 10. All electrical equipment connected to the system should comply Device

be fully shielded with the shield connected to a low noise (clean) with EN50081 and EN50082.

A
m
20
earth line.

4-
BRN
2-Wire
11. The 24V supply should be free from large transients and fluctuations.
Crimp A 4-20mA
Ferrules BLU
B GND
3. The low noise ( clean) earth line should only be connected to safety
BLACK 0V
Transmitter 0V Controller
RED +24V Connections
earth (usually dirty) at a single point. This connection should be 12. The field cabling conductors should have sufficient cross sectional
Connections +24V
GRN/YEL GND
made in such a manner that it does not introduce noise onto the low area to ensure that the minimum supply voltage applied to the Cable
noise earth. Star earthing arrangements minimise earth current system is 18V at a current of 725mA. Earth
Terminal
Sheild
Earth Receiver
crosstalk. Connections

This corresponds to a maximum round loop impedance of

4. The shields of the field cabling should not be connected such that 8.25 ohms for a nominal 24V system supply. GRN/YEL GND
WHITE 4-20mA
earth loops are produced, or in a manner that will result in the ORANGE A
shields carrying large currents from heavy plant or equipment. 13. Receivers should not be installed in close proximity to the antennae BLUE B

of high powered radios, radar and satellite communication equipment.

RED +24V
BLACK 0V
5. Ideally, the field cable shield should be connected to the unit’s
green/yellow GND wire, providing a single, continuous earth shield.
This connection must not be allowed to complete an earth loop.

11 12 13 14

Installation Guide CONTENTS 1. INTRODUCTION

MAN0593.P65 Issue 01 - 10/00
2104M0511
1. Introduction 2 This guide provides the installation personnel with the basic information UNITED KINGDOM & BELGIUM MIDDLE EAST
INTERNATIONAL Zellweger Analytics nv/sa Zellweger Analytics
2. Safety 3 necessary to mechanically install the Searchline Excel system units and ENQUIRIES Leuvensesteenweg 392A Middle East Regional Office
3. Mechanical Assembly 4 make the necessary electrical connections. Zellweger Analytics Limited Chée de Louvain PO Box 52196

SEARCHLINE EXCEL
Hatch Pond House B - 1932 Zaventem Dubai, UAE
4 Stinsford Road Belgium Tel: +971 4 3458338
3.1 General 4 This guide is not intended to replace the associated Searchline Excel Nuffield Estate Tel: +32 2 714 0311 Fax: +971 4 3458778
3.2 Transmitter and Receiver 4 Technical Handbook (2104M0505) which contains the full safety, Poole Fax: +32 2 714 0344 Email:
3.3 Short Range Retro-Reflector 6 installation, commissioning, maintenance and fault finding instructions. Dorset [email protected]
CROSS-DUCT INFRARED GAS DETECTOR 3.4 Long Range Retro-Reflector 6 BH17 0RZ, UK
Tel: +44 (0) 1202 676161
FRANCE
Zellweger Analytics SA NETHERLANDS
These procedures assume that consideration of the location and mounting Fax: +44 (0) 1202 678011 33 rue du Ballon Zellweger Analytics BV
4. Installation 7 of the system units has already been taken into account in accordance Email: [email protected] ZI des Richardets Postbus 157
basic installation guide

Sales enquiries: F-93165 Noisy le Grand NL-3740 AD Baarn

with the guidelines in the Technical Handbook. +44 (0) 1202 675900 Cedex Tel: +31 (0) 35 54 35 646
4.1 General 7 Service enquiries: France Fax: +31 (0) 35 54 35 929
4.2 Mechanical Installation 7 The following diagram shows a typical system configuration and identifies +44 (0) 1202 645772 Tel: +33 1 48 15 80 80
Fax: +33 1 48 15 80 00 SPAIN
4.3 Electrical Installation 11 the main parts. CORPORATE Zellweger Analytics SA
HEADQUARTERS GERMANY Avda Remolar 31
4.3.1 Electrical Connections 11 Zellweger Luwa AG Zellweger Analytics GmbH 08820 El Prat de Llobregat
Wilstrasse 11 Sollner Strasse 65b Barcelona
4.3.2 Electrical Installation 13 Double-glazed Find CH-8610
out more Uster D-81479 München Spain
4.3.3 Transmitter and Receiver Connections via DVC100 13 Retro-reflector Switzerland
www.honeywellanalytics.com Germany Tel: +34 93 379 9611
Mounting
4.3.4 Transmitter and Receiver Connections UL (DX100) 14 Plate
Tel: +41 1943 2211 Tel: +49 89 791 920 Fax: +34 93 379 8551
Fax: +41 1940 7079 Fax: +49 89 791 9243
4.3.5 Transmitter and Receiver Connections USA
(Non DVC/DX100) 14 ASIAbusiness
Customer PACIFICcentre ITALY Zellweger Analytics Inc
Zellweger Analytics Ltd Zellweger Analytics srl 4331 Thurmond Tanner Road
Mounting Europe and the rest of the world
Asia Pacific Regional Office Via F. Primaticcio 168 Flowery Branch
Cell Path Honeywell Analytics AG
84 Tuas Avenue 11 I-20147 Milano Atlanta
0.5m - 5m Singapore
Wilstrasse 11-U11 639098 Italy Georgia 30542
Tel: Uster
CH-8610 +65 862 7701/2/3 Tel: +39 0248 3391 USA
Fax: +65 862 3858
Switzerland Fax: +39 0248 3023 14 Tel: +1 770 967 2196
Email: Toll Free: +1 800 535 0606
Tel: +41 (0)44 943 4300
Transmitter [email protected] Fax: +1 770 967 1854
Fax: +41 (0)44 943 4398 Email: [email protected]
[email protected]

Customer business center

Americas
Honeywell Analytics Distribution, Inc.
400 Sawgrass Corporate Pkwy
Conduit
Suite 100
Sunrise, FL 33325
Searchline Excel Receiver USA
DVC100
Cross-duct Infrared Gas Detector Tel: +1 954 514 2700
Toll free: +1 800 538 0363
Fax: +1 954 514 2784
This publication is not intended to form
Issue 01 –the basis of a contract, and the company reserved the right
12/2005
[email protected]
to amend the design and specification of the instruments without notice.
H_MAN0593.P65_V1

11064
2104M0511
www.honeywell.com © 2005 Honeywell Analytics

1 2
2. SAFETY 3. MECHANICAL ASSEMBLY MECHANICAL ASSEMBLY MECHANICAL ASSEMBLY
Ensure that you read and understand these instructions BEFORE 3.1 GENERAL 3.3 SHORT RANGE RETRO-REFLECTOR
handling or operating the equipment.
This section details the mechanical assembly information and important The short range retro-reflector is suitable for use from 0.5m to 2.5m.
Please pay particular attention to the Safety Warnings. dimensions necessary for installing the system units.

WARNINGS 3.2 TRANSMITTER AND RECEIVER 25mm 210mm Duct cut-out template
for retro-reflector

The Searchline Excel System is certified for and intended CENELEC TX/RX Configuration
for use in potentially hazardous areas. Install and use the Duct cut-out template
for TX/RX J J
Searchline Excel System in accordance with the latest
regulations. G G

322 284

210mm
X X*
For installations in the UK, the Code of Practice SELECTION, J J
OPTICAL
INSTALLATION AND MAINTENANCE OF ELECTRICAL G CENTRE G
OPTICAL
CENTRE
APPARATUS FOR USE IN POTENTIALLY EXPLOSIVE CUT OUT ‘K’
125x125mm
ATMOSPHERES should be strictly observed. General G
CUT OUT ‘H’
G
J J
120x160mm
recommendations are given in BS5345:Part 1:1989. Specific 6 ‘J’ HOLES O7 RETRO PANEL
requirements for flameproof (Type ‘d’), intrinsically safe (1 TILE) CUT-OUT
TEMPLATE
G G
(Type ‘I’) and increased safety (Type ‘e’) protection are

310
given in BS 5345: Part 3: 1979, BS 5345:Part 4:1977 and MOUNTING
PLATE
BS 5345: Part 6:1978 respectively. 10 ‘G’ HOLES O7
CUT-OUT
TEMPLATE
3.4 LONG RANGE RETRO-REFLECTOR
For installations in North America, the national Electrical G G

Code (NFPA 70 - 1990) or later issues should be strictly The long range retro-reflector is suitable for use from 1m to 5m.
observed.
25mm 335mm
Elsewhere, the appropriate local or national regulations Duct cut-out template
should be used. for retro-reflector

J J
The Code of Practice regarding SELECTION,
INSTALLATION, USE AND MAINTENANCE OF
APPARATUS FOR THE DETECTION OF COMBUSTIBLE
GASES (OTHER THAN FOR MINING APPLICATIONS OR

335mm
EXPLOSIVE PROCESSING AND MANUFACTURE) must J X* J
UL TX/RX Configuration
be complied with. Refer to BS6959:1988 in the UK or the OPTICAL
CENTRE
appropriate local or national regulations. RETRO PANEL
(4 TILE) CUT-OUT
TEMPLATE
Zellweger Analytics Limited reserves the right to change or revise the J
CUT OUT ‘K’ 250x250mm
J
information supplied in this document without notice and without 6 ‘J’ HOLES O7
obligation to notify any person or organisation of such revision or
change. If further details are required that do not appear in this document,
contact Zellweger Analytics Limited or one of its agents.

3 4 5 6

4. INSTALLATION INSTALLATION INSTALLATION INSTALLATION

4.1 GENERAL 5. Measure the distance (metres) between the two walls of the duct.
This distance will be required for commissioning. Identity Quantity Size Used For Duct Wall Support Bars
Searchline Excel is designed to allow installation to be performed by a
single operator. A 4 M6 tapped Mounting cell mounting.
Minimum 40mm
Unobstructed Gap
The installation procedure is split into mechanical installation and B 8 ∅ 6.5mm Mounting plate to support bar Mounting
electrical installation. The transmitter and receiver assembly needs to mounting. Plate
be fully assembled and mounted to the duct structure before making
C 2 ∅ 14mm Clearance for support bar fixing nuts.
the electrical connections.

D 1 ∅ 10mm Drain for mounting cell.

4.2 MECHANICAL INSTALLATION
E 1 ∅ 25mm Cross duct optical measurement Reciever
Select the location on the duct where the Searchline Excel system will path. Mounting Cell
be mounted. There must be sufficient clearance to enable the retro-
reflector to be mounted directly opposite the transmitter and receiver F 3 M6 tapped DVC100 mounting.
assembly. Ensure that the duct structure is sufficiently rigid to support
the weight of the Searchline Excel system without sagging. Fit additional G 4 M6 tapped BARTEC terminal box fixing
Transmitter
supports prior to installation if necessary.
H 2 M10 tapped DX100 fixing
Verify that the equipment to be installed is correct for the type of
installation required (i.e., short/long range and normal/high temperature). 7. Attach the mounting plate, mounting cell and junction box assembly
to the duct wall using M6 x 16 cap head screws and washers.
4.2.1 Transmitter and Receiver
8. Place an O ring in the groove on the right hand face of the mounting 2. Drill 6 mounting holes (7mm diameter) in the positions marked J on
1. Stick the mounting plate cut-out template onto the duct wall in the cell. the template.
position chosen for the transmitter/receiver unit.
9. Attach the receiver unit to the right hand face of the mounting cell, 3. Following outline K, cut a square aperture in the duct wall.
Note: The intersection of the bold horizontal and vertical lines on the making sure that its flange is flush with the cell’s face. (Take care
template (Point X) corresponds to the centre of the unit’s IR not to pinch the O ring between the mounting surfaces.) 4. Insert the two retro-reflector panel support bars through the aperture
beam. and attach them to the inside of the duct using M6 washers and nuts.
10. Run the receiver’s conduit into the chosen junction box’s cable Ensure that the threaded holes in the support bars line up with the
2. Drill 10 mounting holes (7mm diameter) in the positions marked G entry. holes drilled in the duct.
on the template.
11. Repeating steps 8 to 10, attach the transmitter to the front face of 5. Fit four M6 x 16 cap head screws into the holes in the support strips
3. Following outline H, cut a rectangular aperture in the duct wall. 6. Insert the two mounting plate support bars through the aperture and the mounting cell. but do not tighten. Leave approximately 5mm of thread exposed on
attach them to the inside of the duct using M6 washers and nuts. the outside of the duct.
4. Check that the path from the aperture to the opposite wall of the Ensure that the threaded holes in the support bars line up with the 4.2.2 Retro-reflector
duct is clear and unobstructed. holes drilled in the duct. 6. Slot the retro-reflector assembly over the heads of the screws and
1. Stick the retro-reflector cut-out template to the outside of the duct allow its weight to be supported on the exposed sections of thread.
wall opposite the transmitter/receiver, ensuring that point X* is Tighten the four screws to clamp the retro-reflector assembly in
directly opposite point X on the other template. (This will ensure position.
that the transmitter’s IR beam hits the centre of the retro-reflector.)
7 8 9 10