11066 Searchpoint Optima Plus v2.indd - Merkantile

MAN0551.P65 Issue 06 - 03/042108M0501TOTAL ENVIRONMENTAL SOLUTIONSEnsure that you read and understand these OperatingInstructions BEFORE installing or operating any part of theSearchpoint Optima Plus.Please pay particular attention to the Safety Warnings.WARNINGS1. For installations in the UK, the Code of PracticeSELECTION, INSTALLATION AND MAINTENANCEOF ELECTRICAL APPARATUS FOR USE INPOTENTIALLY EXPLOSIVE ATMOSPHERESshould be strictly observed. General recommendationsare given in BS5345: Part 1: 1989.Specific requirements for flameproof (Type 'd'),intrinsically safe (Type 'i') and increased safety (Type'e') protection are given in BS 5345: Part 3: 1979, BS5345: Part 4: 1977 and BS5345: Part 6: 1978 respectively.For installations in North America, the NationalElectrical Code (NFPA 70 - 1990) or later issuesshould be strictly observed.Elsewhere the appropriate local or nationalregulations should be used.2. The Code of Practice regarding SELECTION,INSTALLATION, USE AND MAINTENANCE OFAPPARATUS FOR THE DETECTION ANDMEASUREMENT OF COMBUSTIBLE GASES(OTHER THAN FOR MINING APPLICATIONS OREXPLOSIVES PROCESSING AND MANUFACTURE)must be complied with. Refer to BS6959:1988 in theUK or the appropriate local or national regulations.3. Operators must be fully aware of the action to be takenif the gas concentration exceeds an alarm level.2

MAN0551.P65 Issue 06 - 03/042108M0501TOTAL ENVIRONMENTAL SOLUTIONSCAUTIONS1. Use only approved parts and accessories with theSearchpoint Optima equipment.2. To maintain safety standards, a planned maintenanceprogramme is strongly recommended. Thismaintenance programme should take account of alloperational conditions and requirements. Maintenanceand service operations should only be performed bypersonnel qualified to work upon Searchpoint OptimaPlus.3. In order to maintain electrical safety, the unit must not beoperated in atmospheres with more than 21% oxygen.IMPORTANT NOTICES1. Zellweger Analytics Limited can take no responsibilityfor installation and/or use of its equipment if this is notdone in accordance with the appropriate issue and/oramendment of the manual.2. The user of this manual should ensure that it isappropriate in all details to the exact equipment to beinstalled and/or operated. If in doubt, the user shouldcontact Zellweger Analytics Limited for advice.3. If further details are required which do not appear in thismanual, contact Zellweger Analytics Limited or one oftheir agents.4. The Searchpoint Optima System is certified for andintended for use in potentially hazardous areas. Installand use the Searchpoint Optima System in accordancewith the latest regulations.Zellweger Analytics Limited reserve the right to change orrevise the information supplied in this document withoutnotice and without obligation to notify any person ororganisation of such revision or change.3

MAN0551.P65 Issue 06 - 03/042108M0501HELP US TO HELP YOUEvery effort has been made to ensure the accuracy in thecontents of our documents, however, Zellweger AnalyticsLimited can assume no responsibility for any errors oromissions in our documents or their consequences.Zellweger Analytics Limited would greatly appreciate beinginformed of any errors or omissions that may be found in thecontents of any of our documents and to this end we includethe form opposite for you to photocopy, complete and returnto us so that we may take the appropriate action.4

MAN0551.P65 Issue 06 - 03/042108M0501HELP US TO HELP YOUTo:Marketing Communications,Zellweger Analytics Limited,Hatch Pond House,4 Stinsford Road,Nuffield Estate,POOLE. Dorset.BH17 0RZ.United Kingdom.Tel : 44 1202 676161Fax : 44 1202 678011email : marketing@zelana.co.ukFrom :Address :Tel :Fax :email :I suggest the following corrections/changes be made to:Chapter ........... Section ...........Please inform me of the outcome of this change:Yes / NoFor Marketing Communications, Zellweger Analytics Limited:Actioned By:Date:Response:Date:THANK YOU FOR YOUR ASSISTANCE5

MAN0551.P65 Issue 06 - 03/042108M05016

MAN0551.P65 Issue 06 - 03/042108M0501CONTENTSSectionPage1. INTRODUCTION 111.1 General 111.2 Certification Label Details 132. INSTALLATION VARIATIONS 152.1 CENELEC Units 152.2 UL and CSA Units Only 163. INSTALLATION 173.1 Unpacking 173.2 Siting and Orientation 173.3 Installation Guide 183.4 Attachments and Options 223.4.1 General 223.4.2 Standard Weather Protection 223.4.3 Sunshade/Deluge Protection 223.4.4 Storm Baffle 233.4.5 Dust Barrier 233.4.6 Calibration Cap 243.4.7 Gassing Cover 243.4.8 Flow Housing 253.4.9 Remote Gassing Cell 263.4.10 Junction Box Adaptor Plate 273.4.11 Duct Mounting Kit 283.5 Duct Mounting Kit Assembly and Installation 297

MAN0551.P65 Issue 06 - 03/042108M0501SectionCONTENTSPage4. ELECTRICAL CONNECTIONS 314.1 General 314.2 Analogue Connection 364.3 Digital Connection 364.4 +24V Power Connection 374.5 Earth Connection 375. COMMISSIONING 415.1 General 415.2 Commissioning Procedure using SHC-1and Multimeter 425.2.1 Electrical Commissioning and Tests 425.2.2 Gas Response Testing 435.2.3 System Level Testing 445.2.4 Final Commissioning 465.3 Commissioning Procedure with MultimeterOnly 475.3.1 Electrical Commissioning and Tests(Multimeter) Only 475.3.2 Gas Response Testing (Multimeter)Only 495.3.3 System Level Testing 505.3.4 Final Commissioning (Multimeter) 515.4 Control System Setup 525.5 Functional Response Checking andCalibration 528

MAN0551.P65 Issue 06 - 03/042108M0501CONTENTSSectionPage6. CALIBRATION 536.1 General 536.2 SHC-1 Hand-Held Interrogator 546.2.1 Connecting the Hand-HeldInterrogator 556.2.2 Hand-Held Interrogator OperatingModes 566.2.3 Other Hand-Held Features 606.3 Calibrating the Controller 646.4 Calibrating the Sensor 677. ROUTINE CHECKS 757.1 General 757.2 Inspection and Functional Response CheckProcedure 757.2.1 Response Check Using Gassing Coverand %LEL Concentration Gas 777.2.2 Response Check Using RemoteGassing Cell & High %VV Gas 817.3 Inspection and Testing of Units Installedin Ducts 867.4 Removal and Refitting of Flow Housing 887.4.1 Removal of Flow Housing 887.4.2 Refitting of Flow Housing 889

MAN0551.P65 Issue 06 - 03/042108M0501CONTENTSSectionPage8. FAULT FINDING 918.1 Troubleshooting 918.2 Diagnosis of Warning and Fault Messages 979. REPLACEMENT OF HAND-HELDINTERROGATOR BATTERY 10510. ACCESSORIES/REPLACEMENT PARTS 10711. SPECIFICATION 10911.1 Searchpoint Optima Plus Specification 10911.2 Cross Interference to Other Gases andVapours 11211.3 Hand-Held Interrogator SHC-1Specification 11311.4 SHC Protection Device 11411.5 Termination Unit DVC100 Specification 11512. CERTIFICATION DETAILS 11713. WARRANTY 12310

MAN0551.P65 Issue 06 - 03/042108M05011. INTRODUCTION1.1 GENERALSearchpoint Optima Plus is designed for use in potentiallyhazardous areas where it provides gas and vapour detectionwhich is free from poisoning and independent of thepresence of oxygen. The gas measuring parts ofSearchpoint Optima Plus are illustrated below.Optical BlockHeaterGas Measuring PathWindow Heater MirrorSearchpoint Optima Plus uses the dual wavelength infraredabsorption principle to detect hydrocarbon gases andvapours in various concentration ranges. The instrumentmeasures the number of molecules of the target gas in thelight path, which depends on the concentration of the targetgas. In addition to the relatively long and open measuringchamber, Searchpoint Optima Plus can be fitted with a shortenclosed flow through-cell as part of the chassis. This isfitted with separate inlet and outlet ports and allows theapplication of high concentrations of gas for test purposes.11

MAN0551.P65 Issue 06 - 03/042108M05011. INTRODUCTIONSearchpoint Optima Plus is a micro-processor controlled,Infrared Gas Detector with comprehensive built-in selfdiagnosticand fault finding facilities. An analogue 4 to 20mAoutput and digital communications are provided as standard.Full two way communication allows calibration and advancedself checking procedures to be used. To take advantage ofthese features a Hand-Held Interrogator unit may beconnected to the Termination Unit DVC100 or via the SHCProtection Device to other junction boxes.Searchpoint Optima Plus contains no moving parts and isavailable in a robust Stainless Steel explosion proofenclosure which has a M25 (CENELEC) or 3/4 NPT (UL andCSA) mounting thread. The unit operates over a widetemperature range and has a high degree of protectionagainst dust and water ingress. It is designed to operate inthe most arduous conditions and is supplied with a choice ofweather protection assemblies.Searchpoint Optima Plus can be In-Duct Mounted, used inSampling Systems, is easily confidence checked and mayeasily replace an existing sensor. Provided that existingcabling has three appropriately rated cores and theinstallation is correctly screened and earthed, it should not benecessary to replace the field cables or junction boxes. (Acurrent to bridge converter may be required if the controllercannot be configured to accept 4-20mA signals).No special tools are required for installation. Correct functionof the detector as installed can be easily confirmed using aHand-Held Interrogator. Maintenance amounts to occasionalcleaning, zeroing and response checking for confidence.12

MAN0551.P65 Issue 06 - 03/042108M05011. INTRODUCTION1.2 CERTIFICATION LABEL DETAILSAn explanation of the information shown on the equipmentcertification label is shown below:ManufacturesTrademark &AddressExplosion ProtectionMark & EquipmentGroup CategoryProductNameCertification Codeas EN50014 1992Certified AmbientTemperature Rangezellweger analytics SEARCHPOINT EEx d T4 (TAMB -40 to +65 C)Exsieger POOLE DORSET. ENGLAND OPTIMA PLUS ll 2 G T5 (TAMB -40 to +55 C)PART No. 2108B2001Ex1 2 3 4 5BAS 99ATEX2259X Vmax=32V dc Pmax=8WWARNING DO NOT OPEN WHEN AN EXPLOSIVEGAS ATMOSPHERE IS PRESENT.THIS APPARATUS MUST BE OPERATED &SERVICED BY QUALIFIED PERSONNEL. READ &UNDERSTAND INSTRUCTION MANUAL COMPLETELY.Serial Number& Year ofManufactureMOD StateTest HouseTrademarkIdent Number ofATEX Notified BodyCertificationNumberWarningCE Mark - Conformsto all applicableEuropean Directives13

MAN0551.P65 Issue 06 - 03/042108M050114

MAN0551.P65 Issue 06 - 03/042108M05012. INSTALLATION VARIATIONS2.1 CENELEC UNITSReplacing existing Sensorusing existing Junction Boxand Cable (where suitable).New Junction Box.New Installations.When used for calibrationand diagnostics purposesthe Hand-Held InterrogatorSHC-1 allows digitalcommunication with theOptima. It is connected tothe Optima via the ISSocket on the TerminationUnit DVC100 or via theSHC Protection Device forother junction boxes.15

MAN0551.P65 Issue 06 - 03/042108M05012. INSTALLATION VARIATIONS2.2 UL AND CSA UNITS ONLYUL and CSA Installationsusing Explosion ProofJunction Box.Note: The Junction Box must be suitable for the hazardouslocation in which the Optima is installed, check withthe Junction Box manufacturers literature as tosuitability of the box.TopDX100OptimaFieldCable / ConduitHandheldInterrogator Socket16

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATIONWARNINGThe Code of Practice regarding selection, installationand maintenance of electrical apparatus for use inpotentially explosive atmospheres must be complied withat all times.Notes:1. The flying leads of the Searchpoint Optima Plusmust be mechanically protected and terminatedwithin a suitable terminal or junction facility.2. When the detector is terminated in a hazardousarea a suitable UL listed enclosure must be used(where appropriate).3.1 UNPACKINGCarefully unpack the equipment, observing any instructionsthat may be printed on or contained in the packaging, andcheck the contents for transit damage.3.2 SITING AND ORIENTATIONSearchpoint Optima Plusmust be mountedhorizontally, as this greatlyreduces the risk of obscurationdue to build up of dirt andmoisture on the optical surfaces.Ensure the area immediatelysurrounding the sensor is freefrom objects that could hinderthe free flow of air around it.17

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATIONFor monitoring lighter than air gases, Searchpoint OptimaPlus should be mounted above the area requiring protection.For monitoring heavier than air gases it should be mountedbelow the area to be protected.When monitoring for heavier than air gases, try to mount thesensor at least 30cm off the floor, this slows down any buildupof general site debris on the detector.Whether Searchpoint Optima Plus is installed in a shelteredor an exposed location, it will require some form ofprotection around the optics. The standard weatherprotection combined with the sunshade/deluge protectionprovides a high degree of protection of the detector, suitablefor many outdoor environments. Detectors operating in veryexposed locations where torrential rain or driven sea-spray isroutinely encountered can benefit from the additionalprotection provided by the Storm Baffle (2108D0280).In areas where a high pressure jet may be used at closerange to wash down the surrounding location, it is advisableto fit some means of extra peripheral shielding, eg. StormBaffle or a shield plate.Accessories and attachments that can be used to improveease-of-use, performance and reliability in particularinstallations are described in Section 3.4.3.3 INSTALLATION GUIDENote: Installation of Searchpoint Optima Plus does notrequire the unit to be opened. There are no userserviceable parts inside the unit. Do not attempt toopen or dismantle the unit.(1) Ensure that the correct attachments and accessoriesfor the application have been fitted (see Section 3.4).18

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATION(5) Using a multimeter, check that the voltages on the+24V, and 4-20mA connections with respect to 0V areless than +32V DC and that there is no 110V or 230VAC around.(6) Wire up the unit's electrical connections in accordancewith Section 4, taking note of the generalrecommendations upon electrical installation.(7) Ensure that all cable entries are either used or pluggedin strict accordance with the relevant certificationrequirements and local codes of practice.(8) Verify the correct installation and operation of the unitusing the SHC-1 handheld interrogator. If a DVC100 orDX100 junction box has been used, testing can beperformed without the need for a hot work permit.Alternatively, if a basic junction box has been used,electrical connections can be made to the terminalsinside the box using the SHC adaptor. This willordinarily require a hot work permit.CAUTION1. Searchpoint Optima Plus is certified and specifiedfor operation in ambient temperatures from -40°C to+65°C. Operation of the unit outside of thistemperature range invalidates the certification andthe warranty. The unit records a non-erasable faultlog entry if it is operated at temperatures outside ofit's certified range.If the ambient temperature that the unit could beexposed to is likely to go outside of the certifiedrange it is recommended that the unit be locatedelsewhere. The use of sampling systems can behighly effective, especially in applications where hightemperatures are involved.20

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATION2. Searchpoint Optima Plus is specified for operation inenvironments where the rate of change of unittemperature is less than 3°C / minute. Exceedingthis rate of change of temperature will cause the unitto report a fault and may cause permanent damage.If the conditions experienced by the unit are likely tocause it to exceed this rate of change it isrecommended that additional preventative measuresare taken. The use of sampling systems is highlyeffective; whilst shielding the unit from the prevailingair flow can also be of benefit.3. Searchpoint Optima Plus is specified for operation inenvironments where the vibration levels from 2 to60Hz are below 1mm peak to peak (testing inaccordance with BS5445). If the vibration levels onthe installation exceed this, the unit's reliability andintegrity of operation will be degraded. Do not installunits in locations where the vibration exceeds thislevel.4. All optical gas detectors are eventually affected bythe build up of contaminants / condensation upontheir optical surfaces, normally resulting in faults orwarnings. In order to minimise the faults andwarnings caused by this it is recommended thatdetectors are located as far away as is possible fromsources of airborne contaminants and steam /condensation. Alternatively, the fitting of shields orthe Storm Baffle (2108D0280) should be considered.Sources of contamination / condensation that havecaused particular problems where appropriatemeasures were not taken include generator / turbineexhausts, steam lines / vents, drilling operation (oilmistand mud spray) and unfiltered HVACinstallations.21

MAN0551.P65 Issue 06 - 03/042108M05013.4 ATTACHMENTS AND OPTIONS3.4.1 General3. INSTALLATIONThere are a number of attachments and accessories availablefor use with Searchpoint Optima Plus. When specifyingOptima Plus for a particular application, it is recommendedthat the user contacts ZAL or their representatives todetermine the attachments and accessories required. Covers,barriers and baffles provide protection from a wide variety ofenvironmental conditions. Gassing covers, cells and flowhousings provide the means of applying gas to the detector.Mounting plates and remote gassing kits enable the detectorto be installed in ducts or in places where obtaining routineaccess is difficult.3.4.2 Standard Weather Protection (2108D0276)Provides the best compromisebetween response time andprotection. Suitable for indoor,outdoor and duct mountingapplications.3.4.3 Sunshade/Deluge Protection (2108D0275)Supplied as standardfor all outsideapplications. Providesadditional protectionagainst heavy rainfall,wash downs and directsunlight.22

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATIONThe Sunshade/Delugeprotection should beclamped around thebase of the StandardBaffle WeatherHousing with the longeroverhang extendingbeyond the StandardBaffle. Ensure theclamp does not coverthe gas venting slot ofthe Standard Baffle.3.4.4 Storm Baffle (2108D0280, Not Illustrated)The storm baffle provides increased protection against avariety of environmental conditions and effects. It isparticularly effective against torrential rain and driven seasprayand is recommended for exposed installations inmaritime locations or areas where monsoon or tropical rainconditions are experienced. The storm baffle can be beneficialin installations where steam drifting over the detector fromnearby plant is a problem. The storm baffle can also be usefulin some duct applications where the inlets are not filtered andwhere high flow rates result in dirt build-up or excessivecooling / condensation effects.3.4.5 Dust Barrier (2108D0259, Not Illustrated)Fits under the standard baffle weather housing to prevent theingress of dust or oil mist which could contaminate the opticalsurfaces. It also protects the optics in very wet or exposedlocations.23

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATIONCAUTIONThe Gassing Cover is designed for field testing andcalibration operations. If the cover is left fitted it willprevent ambient gas from reaching the detector'smeasurement chamber. Ensure that operators are awarethat gassing covers must not be left on detectors.Gassing covers are coloured red to reduce the likelihoodof this mistake.3.4.8 Flow Housing (2108D0282)For use in sampling systemapplications.The Flow Housing is fabricated fromsolvent resistant AnodisedAluminium.The nozzles on the Flow Housingare stainless steel with an outsidediameter of 6mm.It is advised that sample gases and vapours are sucked(negative pressure) rather than blown (positive pressure)through this housing and that sample flow rates do notexceed 2 litres per minute.The commissioning and calibration of an Optima equippedwith a flow housing is described in Sections 5 and 6.25

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATION3.4.9 Remote Gassing Cell (2108B0240)The Remote Gassing Cell (RGC) enables high %V/Vconcentration gas to be applied remotely forperforming functional response checks (bump tests). Itis useful for units installed in ducts or in areas whereobtaining access is difficult. The RGC window can beremoved for cleaning.Note:During production, Optima Plus units are calibratedwith gas in the main measurement chamber, not in theRGC. The RGC is not recommended for calibration orhigh accuracy calibration testing purposes. (The onlyexception to this is where units are being used tomeasure high %V/V gases using the RGC as a flowcell. In this instance, the units are production calibratedwith gas in the RGC.)In order to avoid pressurisation effects, the flow rate should bekept below 0.3 litres / minute.The RGC option is normally factory fitted.26

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATION3.4.10 Junction Box Adaptor Plate (04200-A-1040)The Junction Box Adaptor Plate provides a means ofincreasing the spacing between the junction box's glandentries and the mounting surface. This enables low glandclearance junction boxes to be used without the Optima Plusfouling on the wall / mounting surface. Junction boxes whichcan be accommodated include the Hawke PL612 and PJB1.27

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATION3.4.11 Duct Mounting Kit (04200-A-1015)This kit enables Optima Plus to be conveniently mountedinside a duct. Electrical connections are made to the detectorvia a junction box which is mounted outside of the duct. Usingthis kit, test gas can be non-invasively applied to the detectorvia the gassing points provided.Note 1: Dimensionsshown in mm.Note 2: The cutout inthe duct should be230mm x 230mm.28

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATION3.5 DUCT MOUNTING KIT ASSEMBLY &INSTALLATIONJunctionBoxJunctionBoxBracketGassingPointsSearchpointOptimaDuctMountingPlateNotes: 1. In order to make use of the gassing pointsprovided, the Optima unit must be fitted with theRemote Gassing Cell (2108B0240).2. In offshore HVAC ducts or ducts without inletfiltering, the use of the Storm Baffle (2108D0280)is recommended.3. CSA approval only applies for flow rates less than5 m/s and does not cover the use of the StormBaffle.The duct mounting kit is assembled and installed onto a ductas below:-(1) Cut a square 230mm * 230mm hole in the duct wall.Drill the holes required to attach the mounting plate tothe duct wall.29

MAN0551.P65 Issue 06 - 03/042108M05013. INSTALLATION(2) Place the Optima unit on the side of the mounting platewhere the threaded bushes protrude and feed the wiresthrough the central hole.(3) Locate the unit's boss in the central hole and feed theunit's wires through the chosen cable entry on thejunction box.(4) Screw the unit into the junction box until the assemblyis secure with the mounting plate trapped between thebox and the Optima.(5) Cut off the seals on the ends of the gassing cell inlettubes.(6) Attach the gassing tubing to the ends of the gassingcell inlet tubes.(7) Fasten the mounting plate to the wall of the duct,ensuring that the seal is compressed.(8) Wire up the unit in accordance with the electricalconnection details in Section 4.(9) Ensure that all cable entries are either used orplugged in strict accordance with the relevantcertification requirements and local codes of practice.30

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONSCAUTIONThe reliability and performance of instrumentationinstalled at industrial and petrochemical facilities can bestrongly influenced by the design and quality of theelectrical installation. It is strongly recommended thatbefore designing an electrical installation for SearchpointOptima Plus the electrical installation design authorityreads Section 4.1.4.1 GENERALSearchpoint Optima Plus complies with the European EMCrequirements set out in standards EN50081 and EN50082. Inorder to maintain compliance with these standards it isessential that the electrical installation of Searchpoint OptimaPlus is engineered appropriately.Electrical installation standards and practices vary fordifferent countries, companies and hazardous area approvals.It is the responsibility of the electrical installation designauthority to determine the applicable standards / practicesand ensure compliance with them. When designing electricalinstallations for Searchpoint Optima Plus it is recommendedthat the design authority considers the following:-a. Ideally, the cases of units should not be connected toelectrically noisy (dirty) metalwork or conductors.Preferably, the case (internally connected to the unit’sgreen / yellow GND wire) should be connected to a lownoise instrument (clean) earth.31

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONSb. Preferably, the field cable screen should be connectedto the unit’s green / yellow GND wire, providing a single,continuous earth screen connected to a low noiseinstrument (clean) earth. This connection must not beallowed to complete an earth loop or connectinstrument earth to safety earth.c. If armoured cable is being used it is necessary toprevent safety (dirty) earth from becoming connected toinstrument (clean) earth via the continuity plate in thefield junction box. This is most easily achieved by theuse of insulating cable glands for the field cable entry.d. For UL / CSA certified installations it is not practical toisolate the unit’s case from safety (dirty) earth. The unitand its junction box should be earthed in a manner thatcomplies with the certification requirements.e. Any earth / ground bonding arrangement employedshould ensure that the maximum peak voltage betweenthe unit’s case earth and any field cable conductor isless than 350V. This includes conditions wheretransient surge voltages are generated by lightning orthe switching of heavy electrical plant. Surge voltages inexcess of 350V can cause permanent damage to theunit’s RFI filters and such damage is not covered bywarranty.f. Earthing / grounding arrangements that employ multipleprotective earths or earth grids significantly increase thelikelihood of large transient surge voltages beinggenerated between a unit’s case earth and the fieldcable conductors.g. If it is suspected that the earth / ground bondingarrangement employed will not prevent voltagesbetween the unit’s case earth and any field cableconductor from exceeding 350V it is strongly32

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONSrecommended that surge suppression devices beinstalled close to the unit. Suitable, certified surgesuppression devices include MTL’s TP-48-I-NDI andPepperl & Fuchs’ FN-LB-1. Two of these devices aresufficient to provide protection of the +24V, 0V, 4-20mAand RS485 (A) connections to a unit.h. In general, correctly engineered star earthingarrangements minimise earth current crosstalk andnoise, improving the reliability and performance ofinstrumentation.i. Low noise instrument (clean) earth should only beconnected to safety earth (usually dirty) at a singlepoint on a site / installation. This connection should bemade in such a manner that it does not introduce noiseonto the instrument earth.j. The entire length of the field cabling connected to a unitshould be screened / shielded. This screen / shieldshould be connected to a low noise instrument (clean)earth at a single end. (The screen / shield can beconnected to the unit’s earth in the junction box,provided that this is isolated from all other earths /grounds.)k. For installations where the field cable conductors runthrough conduit or armour connected to safety (dirty)earth, the conduit or armour should not be consideredas a sufficient screen / shield. A separate cable screen/ shield, connected to a low noise instrument earthshould be employed.l. The screens / shields of field cabling should not beconnected in a manner that creates earth loops or thatwill result in the screens / shields carrying largecurrents from heavy plant or equipment.33

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONSm. The use of a single, screened / shielded cable for eachfield device ensures good screening / shielding andreduces crosstalk. Cabling arrangements that use asingle cable to connect a number of field devicescompromise screening and increase the potential forcrosstalk. Such arrangements should only be employedif the electrical installation design authority is confidentthat this will not adversely affect the reliability orperformance of the system.n. Any electrical interference induced onto the conductorsof a 4-20mA loop by the installation must be kept belowthe levels necessary to comply with the generalrequirements of EN50054 or other applicable gasdetector performance requirements / standards. Inpractice, this means that peak noise currents inducedon the current loop should be no greater than +/-0.25mA. If peak noise currents larger than this areinduced on the current loop it is possible that spuriousgas readings, alarms and faults will be reported by thecontrol system monitoring the current loop.o. The 0V rail of a control card / control system is oftenconnected directly to one side of the 4-20mA input’scurrent sensing resistor. In such instances, anyelectrical noise on the 0V rail can be considered to bedirectly connected to the 4-20mA input. In order toreduce the likelihood of such noise adversely affectingthe performance of a gas detection system it isdesirable to keep noise on the 0V rail to a minimum.Safety earth / ground frequently carries a high level ofelectrical noise and it is therefore advisable not toconnect the 0V rail to safety earth / ground. If the 0Vrail cannot be isolated from earth it is advisable to eitherconnect it to a low noise instrument (clean) earth orthrough a path that presents a high impedance to noiseon the earth.34

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONSp. For installations in Europe, all electrical equipmentconnected to the system should comply with EN50081and EN50082 or EN50270. For non-Europeaninstallations, electrical equipment connected to thesystem should comply with applicable national orinternational EMC standards.q. Searchpoint Optima Plus is designed to operatecorrectly with supply voltages down to 18V. Whensupplied with 18V, the maximum current drawn by asingle Searchpoint Optima Plus unit will be 250mA.The field cabling conductors should have sufficientcross sectional area to ensure that when a unit isdrawing 250mA the voltage reaching it does not fallbelow 18V. For a control room voltage of 24V, themaximum round loop cable resistance must thereforebe 24 Ohms. Round loop cable resistances greaterthan those necessary to ensure that units alwaysreceive at least 18V may result in unreliableoperation.r. Ideally, the 24V supply reaching units should be freefrom large transients, fluctuations or high frequencynoise. Transients or fluctuations which take thesupply voltage outside of the 18-32V range may resultin units switching off and re-booting.s. In order to reduce the likelihood of radio frequencyinterference affecting the operation of units it isrecommended that neither units nor their cabling areinstalled in close proximity to the antennae of highpowered radio, radar or satellite communicationequipment.35

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONS4.2 ANALOGUE CONNECTIONThe unit’s analogue 4-20mA output is non-isolated and sharesthe 0V return (black wire) connection with the DC supply tothe unit. The 4-20mA output is factory configured for currentsource or current sink. The configuration is identified by alabel on the white 4-20mA output wire. The connections to theunit are shown in the following figures.Note: If using Searchpoint Optima Plus to replace an existingcatalytic sensor, a Current to Bridge converter must beused.4.3 DIGITAL CONNECTIONSearchpoint Optima Plus has a built-in RS485 digitalcommunications link. For DVC100 / DX100 type TerminationUnits, this link can be connected to using the IS socket. Forother junction boxes, this link can be connected to using theSHC Protection Device between the junction box terminalsand the SHC-1 Handheld Interrogator.36

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONSThe RS485 communications link is connected to the unit’sorange (RS485(A)) and blue (RS485(B)) wires. If not used,these wires must be separately terminated in a suitableterminal or junction facility.4.4 +24V POWER CONNECTIONThe +24V DC power supply feed should be connected to theunit via the red (+24V) and black (0V return) wires.4.5 EARTH CONNECTIONAn earth connection can be made to the unit in a number ofways. When deciding how to earth the unit, considerationshould be given to the recommendations in section 4.1.Physically, the earth connection can be made either via theunit’s green/yellow earth wire, a metal nut between the unitand the junction box’s earth continuity plate or a wireconnected to the unit’s external earthing point.37

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONSMinimum Configuration for Retrofit Application(Optional Current to Bridge Converter)38

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONSConfiguration for Junction Box DVC100 with IS Socket and Hand-Held Interrogator39

MAN0551.P65 Issue 06 - 03/042108M05014. ELECTRICAL CONNECTIONSStandard Configuration for Retrofit Application(With SHC Protection Device and Hand-Held Interrogator Option.)40

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONING5.1 GENERALWARNINGS1. Alarm level signals may be intentionally generatedduring the commissioning procedure. Ensure thatappropriate steps are taken to prevent the unintendedsounding of alarms or executive actions. It isrecommended that the control card corresponding tothe detector is isolated or inhibited during the majorityof the commissioning procedure.2. In order to commission units installed with basicjunction boxes (i.e. not DVC100 or DX100), it will benecessary to open the junction boxes under power.This will require the appropriate safe operatingprocedures to be employed.3. The Optima Plus commissioning procedure is bestperformed using an SHC-1 Handheld Interrogator anda digital multimeter. Use of the SHC-1 interrogator incombination with a multimeter enables morecomprehensive checks and testing (Section 5.2). Ifhowever, an SHC-1 interrogator is not available, basiccommissioning can be performed using just amultimeter (Section 5.3).IMPORTANTSearchpoint Optima Plus is supplied calibrated and readyfor use. It does not require calibration duringcommissioning. Reference is made in this section to aGas Response Test. This is not a full calibration of thesensor where zero and span values are set, but aresponse test using a known concentration of gas tovalidate the calibration of the sensor.41

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONING5.2 COMMISSIONING PROCEDURE USINGSHC-1 AND MULTIMETER5.2.1 Electrical Commissioning and Tests(SHC-1 & Multimeter)The procedure for verifying the electrical installation of the unitis described below:-(1) Before applying power to the unit, ensure that the fieldwiring is correct and all electrical connections are inaccordance with Section 4.(2) Check that the unit’s 4-20mA output configuration iscorrect for the type of control card that it is connectedto. (Source output for sink input, sink output for sourceinput. Unit’s output configuration is on label attached towhite wire.)(3) Apply power to the control card connected to the unitbeing commissioned. Wait for 1 minute to allow the unitto initialise and stabilise. Using a multimeter set on dcvolts, measure the voltage across the red (+24V) andblack (0V return) connections. Nominally, this voltageshould be +24V. Voltages in the range +18V to +32Vare acceptable.(4) Using either the IS socket on the DVC100 / DX100junction boxes, or the SOAR Protection Device,connect the SHC-1 Handheld Interrogator to the unit’sRS485 comms link. (See Section 4.2 for SHCProtection Device connections.)(5) Select the DIAGNOSTICS option on the interrogatormenu and instruct the unit to display any ACTIVEWARNINGS or ACTIVE FAULTS. (Diagnosis of FAULT /WARNING codes is described in Section 8.)42

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONINGa. If there are any ACTIVE FAULTS, the cause(s) ofthese must be identified and remedied before theunit will become fully operational.b. If there are any ACTIVE WARNINGS, the unit canoperate correctly despite the warning(s). However,for reliable long term operation it is stronglyrecommended that problems causing warnings arefixed before a unit is fully commissioned.5.2.2 Gas Response Testing (SHC-1 & Multimeter)The procedure for testing gas response as part of thecommissioning process is described below:-(1) Select the DISPLAY mode on the SHC-1 HandheldInterrogator. Check that the displayed gas reading is0.0% LEL. If the displayed gas reading is not 0.0%LEL, check that their is no background gasconcentration present, the optics are clean and freefrom condensation and that the unit has been givensufficient time to stabilise in it’s intended operatingenvironment. (For best results, it is recommended thata unit is left powered up for one hour before performingzero or span calibration / test activities.)(2) Using the SHC-1 interrogator, put the detector intoINHIBIT (this will prevent gas readings from beingsignalled on the 4-20mA output).(3) Making use of either the gassing cover, or the remotegassing cell (where fitted), perform a functional gastest. The procedure for performing functional gas testsis detailed in Section 5.5. For a nominal 50% LEL testgas concentration, the displayed reading should bebetween 45% LEL and 55% LEL. (If necessary, testgas concentrations between 20%LEL and 95%LEL canbe used with the same +/- 5% LEL test tolerance.)43

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONINGProvided the displayed gas reading falls within the +/-5%LEL test tolerance range, the functional gas test hasbeen completed satisfactorily.44CAUTIONIf the displayed gas reading is not as expected, do notproceed to re-calibrate the unit immediately. Instead,double check the unit’s zero, the test gas and the gassingtechnique. (IR gas detectors do not exhibit significant spandrift and in most instances, any problem will be with thezero or the test gas / technique.) Only consider recalibratinga unit when certain that the zero, test gas andtechnique are correct and that the unit’s gas response issignificantly out. The calibration technique is detailed inSection 6.3.5.2.3 System Level Testing (SHC-1 & Multimeter)Confirmation of correct operation of the complete gas detectionsystem can be done using either test gas at the requiredconcentrations (Option B) or by FORCEing the unit’s 4-20mAoutput under control of the SHC-1 interrogator (Option A):-CAUTIONWhen performing system level tests, ensure that anyresulting alarms or executive actions will not give rise tounintended emergency drills or loss of production / shutdown.Note: It is assumed that the control system has been set upfor currents of 4mA and 20mA to read 0.0% LEL and100% LEL respectively. If necessary, the FORCE 4-20mA option can be used for setting up the control card.Be aware that a 10 minute timeout applies to FORCE’d4-20mA outputs.

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONINGOption A) System Test Using FORCE’d 4-20mA(1) The easiest way of performing system level functionaltests is to use the SHC-1 interrogator to FORCE the 4-20mA output to currents that are just above therelevant alarm thresholds.(2) The FORCE 4-20mA option is available from theCALIBRATE menu. Using this option, FORCE the 4-20mA output to a current just above the A1 alarmthreshold. For example, with an A1 of 20% LEL, acurrent of 7.5mA should suffice. Verify that the systemreports and responds as intended to this A1 signal.(3) FORCE the 4-20mA output to a current just above theA2 alarm threshold. With an A2 of 60% LEL, a currentof 14mA should suffice. Verify that the system reportsand responds correctly to this A2 signal.(4) RELEASE the 4-20mA output. Confirm that the systemreturns to normal, with no active alarms or faults.Option B) System Test Using GasIf system level functional tests must be performed using gas,test gas concentrations at least 5% LEL (ideally 10% LEL)above each alarm threshold are required in order to allow forsystem tolerances.(1) Using either the gassing cover or the remote gassingcell, apply test gas to the detector at the concentrationrequired to reliably exceed the A1 alarm threshold. Forexample, with an A1 alarm threshold of 20% LEL, theminimum nominal test gas concentration should be25% LEL (ideally 30% LEL). Verify that the systemresponds as intended to an A1 signal generated in thismanner.45

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONING(2) Apply test gas at the concentration required to reliablyexceed the A2 alarm threshold. With an A2 alarmthreshold of 60% LEL, the minimum nominal test gasconcentration should be 65% LEL (ideally 70%LEL).Verify that the system responds correctly to an A2signal generated in this manner.5.2.4 Final Commissioning (SHC-1 & Multimeter)The commissioning process is finished off as describedbelow:-(1) Remove or disconnect any gas testing equipment fromthe unit.(2) Ensure that any test gas used is fully vented from themeasurement chamber or gassing cell. Verify that thedisplayed gas reading returns to zero. (If the remotegassing cell has been used, ensure that once vented,it’s inlet tubes are sealed with the protective capsprovided (or a suitable alternative).)(3) If required, remove the detector from INHIBIT.(4) Select DIAGNOSTIC mode and verify that the unit hasno ACTIVE FAULTs or ACTIVE WARNINGs.(5) Disconnect the SHC-1 interrogator. Replace thejunction box lid (where removed).(6) When all of the relevant steps above are completedsatisfactorily, the unit has been commissioned and isready for operational use.46

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONING5.3 COMMISSIONING PROCEDURE WITHMULTIMETER ONLY5.3.1 Electrical Commissioning and Tests(Multimeter) OnlyThe procedure for verifying the electrical installation of the unitis described below:-(1) Before applying power to the unit, ensure that the fieldwiring is correct and in accordance with Section 4.(2) Check that the unit’s 4-20mA output configuration iscorrect for the type of control card that the unit isconnected to. (Source output for sink input, sink outputfor source input. The unit’s output configuration is on alabel attached to the white wire.)(3) Apply power to the control card connected to the unitbeing commissioned. Wait for 1 minute to allow theunit to initialise and stabilise. Using the multimeter seton dc volts, measure the voltage across the red (+24V)and black (0V return) connections. Nominally, thisvoltage should be +24V. Voltages in the range +18V to+32V are acceptable.(4) Remove power from the unit.(5) Insert the multimeter set to read current (mA) in serieswith the 4-20mA loop as follows:-a. Current Sink OutputRemove the unit’s white 4-20mA output wire fromthe terminal for the 4-20mA loop connection.Connect the multimeter’s negative probe to thewhite 4-20mA wire. Connect the multimeter’s47

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONINGpositive probe to either the +24V terminal or the 4-20mA loop terminal.b. Current Source OutputRemove the unit’s white 4-20mA output wire from theterminal for the 4-20mA loop connection. Connectthe multimeter’s positive probe to the white 4-20mAwire. Connect the multimeter’s negative probe toeither the 0V terminal or the 4-20mA loop terminal.(6) Apply power to the unit and monitor it’s 4-20mA outputto confirm that it executes the correct power-upsequence as below:-a. Output current of 0.0mA (0.0 to 0.5mA) for a periodof approximately seven seconds.b. Output current of 2mA (INHIBIT current, 1.8 to2.2mA) for a period of up to one minute whilst theunit initialises and stabilises.c. Output current of 4mA (ACTIVE zero gas current,3.8mA to 4.2mA), which indicates that the unit isoperational and reading 0.0% LEL gas.Note: If the unit is powered up in a non-zero gasconcentration, it will output a signalcorresponding to the gas concentration.48

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONING5.3.2 Gas Response Testing (Multimeter) OnlyCAUTIONWithout the SHC-1 interrogator it is not possible toINHIBIT the gas detector. To avoid unintended executiveactions or alarms, it is recommended to either isolate thedetector itself or inhibit / isolate the corresponding controlcard.Functional gas testing can be performed using the multimeterto monitor the 4-20mA output:-(1) Isolate the detector by disconnecting the 4-20mAoutput from the loop terminal and connecting themultimeter to measure the 4-20mA current to either the+24V (for current sink) or 0V (for current source).Alternatively, if the control card has been isolated /inhibited, connect the multimeter in series with the 4-20mA loop.(2) Making use of either the gassing cover, or the remotegassing cell (where fitted), perform a functional gas testas detailed in Section 5.5.CAUTIONIf the 4-20mA current is not as expected, double checkthe unit’s zero, the test gas and the gassing technique.(IR gas detectors do not exhibit significant span drift andin most instances the problem is with the zero or the testgas / technique.) Only consider re-calibrating a unit whencertain that the zero, test gas and technique are correctand that the unit’s gas response is significantly out. Thecalibration procedure is detailed in Section 6.3.49

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONINGFor a nominal 50% LEL test gas concentration, the 4-20mAoutput current should be between 11mA and 13mA. If themeasured current falls within the correct range, the functionalgas test has been completed satisfactorily.Note: Zeroing and calibration activities require use of theSHC-1 interrogator.5.3.3 System Level Testing (Multimeter)If it is necessary to confirm the correct operation of thecomplete gas detection system during commissioning(without an SHC-1 interrogator), this can only be done usingtest gases at concentrations which are at least 5% LEL(ideally 10% LEL) above the relevant alarm thresholds.(1) Remove power from the unit. Reconnect the unit’s 4-20mA output to the appropriate loop terminal (themultimeter should still be in series to measure current).(2) Making use of either the gassing cover, or the remotegassing cell (where fitted), introduce gas at the requiredA1 test concentration into the unit. For example, withan A1 alarm threshold of 20% LEL, the minimum testgas concentration required is 25% LEL. Thecorresponding 4-20mA output current should bebetween 7.2mA and 8.8mA. Confirm that the correctcurrent and system responses are observed when theA1 test gas is introduced into the unit.(3) Introduce gas at the required A2 test concentration intothe unit. With an A2 alarm threshold of 60% LEL, theminimum test gas concentration required is 65% LEL.The corresponding 4-20mA output current should bebetween 13mA & 15mA. Confirm that the correctcurrent and system responses are observed when theA2 test gas is introduced into the unit.50

MAN0551.P65 Issue 06 - 03/042108M05015. COMMISSIONING5.3.4 Final Commissioning (Multimeter)The commissioning process is finished off as describedbelow:-(1) Remove or disconnect any gas testing equipment fromthe unit.(2) Ensure that any test gas used is fully vented from themeasurement chamber or gassing cell. (If the remotegassing cell has been used, ensure that once vented,it’s inlet tubes are sealed with the protective capsprovided (or a suitable alternative).)(3) Verify that after the initialisation and stabilisation period(approximately 1 minute), the 4-20mA output returns to4mA nominal (between 3.8mA and 4.2mA).(4) Remove power from the unit and disconnect themultimeter from the 4-20mA loop. Connect the white 4-20mA wire back directly to the loop terminal. Re-applypower to the unit.(5) Verify that the unit returns to ACTIVE status and thatthe gas reading displayed on the control card is 0.0%LEL.(6) Replace the junction box lid.(7) When all of the relevant steps above are completedsatisfactorily, the unit has been commissioned and isready for operational use.51

MAN0551.P65 Issue 06 - 03/042108M05015.4 CONTROL SYSTEM SETUPIf the controller is in need of setting up, ie. for a 4 to 20mAsignal to show an equivalent reading eg. 0 - 100% fsd, thismay be done in two ways:i) By using the Hand-Held Interrogator to FORCE therequired signal to the controller (see Section 6.4 of thismanual)or5. COMMISSIONINGii)With calibration gas applied to the sensor.In each of these cases, a known signal is sent to thecontroller, and the controller is set to show the equivalentsignal.5.5 FUNCTIONAL RESPONSE CHECKING ANDCALIBRATIONSearchpoint Optima Plus is supplied factory calibrated andwhen commissioning a unit, all that should be required toverify correct operation is a functional response check. Theprocedure for functional response checking is described inSection 7 Routine Checks.Where local regulations or working practices require gasdetectors to be calibrated when they are commissioned, thisshould be performed in accordance with the proceduredescribed in Section 6 Calibration.52

MAN0551.P65 Issue 06 - 03/042108M05016.1 GENERAL6. CALIBRATIONSearchpoint Optima Plus is supplied factory calibrated for aparticular hydrocarbon gas (approximately 100 different gascalibrations are currently available). Properly installed andmaintained, Optima Plus does not require routine calibration.This operational benefit is made possible by the inherentstability of the IR absorption process and the fullycompensated optical configuration used. In order to maintainconfidence in the continued correct operation of fieldedOptima Plus units it is recommended that a functional gastest is incorporated into the planned maintenance procedurefor the unit. In most applications and installations, a plannedmaintenance / service interval of 1 year is appropriate,although this will depend upon site conditions andrequirements.Where site operating procedures or regulations require routinecalibration of gas detectors, this is possible using the SHC-1Handheld Interrogator and the gassing cover. Care needs tobe taken in order to ensure that routine field calibrations donot reduce the calibration accuracy compared to the originalfactory calibration. (Factory calibration is performed in morecontrolled conditions than are readily achievable in the field.)Functional gas testing and calibration are made considerablyeasier by use of the SHC-1 Handheld Interrogator. If an SHC-1is not available, basic functional gas testing can be performedusing just a multimeter to monitor the 4-20mA of the unitbeing tested.CAUTIONSearchpoint Optima Plus is a robust, flammable gasdetector, it is not an analyser. Where the performance orfeatures of an analyser are required, an analyser shouldbe used.53

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION6.2 SHC-1 HANDHELD INTERROGATORThe SHC-1 Handheld Interrogator is a portable, IntrinsicallySafe (IS) device which can be used to calibrate, test andcommission all of ZA’s Searchpoint and Searchline opticalgas detection products. The SHC-1 interrogatorcommunicates with detectors via a digital RS485 link.Electrically, this link can be made either by using the ISsocket on the DVC100 / DX100 or by connecting the flyingleads on the SHC Protection Device (04230-A-1025) to theappropriate junction box terminals.WARNINGThe IS certification of the SHC-1 Handheld Interrogatoronly remains valid if it is used in conjunction with theDVC100 / DX100 or the SHC Protection Device. Do notattempt to connect the SHC-1 interrogator directly tounits, always use either the DVC100 / DX100 or the SHCProtection Device.Press ↵ and hold for threeseconds to switch on.Press ↵ and esc togetherand hold to switch off.Unit powers down automaticallyafter 10 minutesto prolong battery life.54

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION6.2.1 Connecting the SHC-1 Hand-HeldInterrogator6.2.1.1 DVC100 and DX100 Termination UnitsWhen either the DVC100 or DX100 termination units areused, the SHC-1 Handheld Interrogator can be directlyconnected to the IS socket on the bottom of the junction box.IS SOCKET6.2.1.2 Other Junction Boxes(Use of SHC Protection Device)WARNINGThe SHC Protection Device can only be used in a safearea. ie. When a local safe area is achieved using a hotwork permit or other appropriate gas free permit.Interrogator connections to units mounted on junction boxesother than the DVC100 / DX100 can be made using the SHCProtection Device. The procedure for using the SHCProtection Device is as follows:-(1) Remove the cover to the respective junction box.55

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION(2) Connect the brown lead of the SHC Protection Device tothe orange lead of the Optima communications link.(3) Connect the blue lead of the SHC Protection Device tothe blue lead of the Optima communications link.(4) Connect the Hand-Held Interrogator SHC-1 to the SHCProtection Device connector.Note: When transporting the SHC Protection Device in ahazardous area, the SHC Protection Device must bedisconnected from the Hand-Held Interrogator.6.2.2 Hand-Held Interrogator Operating ModesThe Hand-Held Interrogator version 3v10 is compatible withSearchpoint Optima, Searchpoint Optima Plus and SearchlineExcel. To work with a specific product the correct operatingmode has to be selected as follows:(1) Press ↵ to switch on the power.(2) The display will first show a title screen:Z - SHC 1 OptimaInterrogator 3v10The current operating mode is shown in the top right ofthe display.(3) Press esc and the display will show:Z - SHC 1 Optima +Interrogator 3v1056

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION(4) Press esc again and the display will show:Z - SHC 1 ExcelInterrogator 3v10If esc is pressed again the operating mode will changeto Optima and the different modes can be steppedthrough again.(5) When the display shows Optima + as the operatingmode wait three seconds for the main menu to bedisplayed:MainDisplayNote: 1. The current operating mode is remembered whenthe Hand-Held is switched off.2. The operating mode can also be changed byselecting the change mode option on the main menu.(6) Press and the display will show:MainCalibrate(7) Press and the display will show:MainDiagnostics(8) Press and the display will show:MainGas Tables57

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION(9) Press and the display will show:MainConfigure(10) Press and the display will show:MainChange Mode(11) Press and the display will show:MainPower Off58

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATIONZ- SHC1 Optima +Interrogator 3v0MainDisplayMainCalibrateMainDiagnosticsMainGas TablesMainPower OffCalibrateDisplayDiagnosticActive FaultsGas TablesShow GasCalibrateCal SensorDiagnosticActive WarnsGas TablesShow LibraryMainConfigureCalibrateForce 4-20DiagnosticSelf TestGas TablesSelect GasMainChange ModeCalibrateNormal 4-20DiagnosticSoft ResetThis diagram shows all the Hand-held InterrogatorSoftware features. Use of the and keys to displaythe individual menu options. The options areselected by pressing ↵ and exited by press esc.SHC-1 Hand-held Calibrator Menu Structure59

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION6.2.3 Other Hand-Held Features6.2.3.1 DisplaySelecting this option from the main menu displays:Optima + Methanexx.x % LELThe display shows the gas type, the gas reading and in thebottom right a status indicator:Rotating bar indicates a healthy active unit.F indicates an active fault condition.W indicates an active warning.A indicates an active alarmO indicates an active overrange.Pressingor ↵ changes the display to show:Optima + S/W3v0The version of software currently installed within theSearchpoint Optima Plus unit.Pressing , or ↵ will return the display to showing thecurrent gas reading.Pressing esc exits the display option to the main menu.60

MAN0551.P65 Issue 06 - 03/042108M05016.2.3.2 CalibrateDisplayThe Display option on the Calibrate menu provides the sameinformation as the Display option on the Main menu exceptthe analogue output will be inhibited. This function is useful ifa response check is to be carried out and you do not wish thegas reading to be reported on the analogue output.Note: The rotating bar will not be shown on the gas readingdisplay when the analogue output is inhibited.Normal 4-206. CALIBRATIONThis action releases the analogue output. It should be used ifa communication error occurs while performing an operationwith the Hand-Held which Inhibited the analogue output.Note: The unit will release its analogue output automatically10 minutes after it was Inhibited if no digitalcommunication occurs.6.2.3.3 DiagnosticsActive Faults/Active WarningSelecting one of these actions displays any fault or warningconditions which are present in the unit. If more than onecondition is simultaneously present, these may be scrolledthrough by pressing the or keys.FAULT conditions prevent the unit from working as a gasdetector and are always signalled on the analogue output as0mA.61

MAN0551.P65 Issue 06 - 03/042108M0501WARNING conditions indicate that the unit is operating closeto the limits of its specified operating envelope. The unit maygo into fault in the near future. If a fault condition is presentin the unit while the active warnings are being displayed, thetop line of the display will show Fault Present. Correct theFault condition first.A list of fault and warning conditions and the actions whichshould be taken to correct the problem are given in section 8.Self Test6. CALIBRATIONThis action instructs the unit to complete a self test cycle. Ifa fault or warning condition was found in the unit, the Hand-Held display will show:Fault PresentDetails of the fault or warning can be viewed by selecting theActive Fault/Active Warning menu option.Soft ResetSelecting this option forces the unit to reboot. It is equivalentto switching the power to the unit off and then on.6.2.3.4 Gas TableThe Show Gas menu option displays the current gas type.The Show Library action displays the part number and issueof the data base within the unit which contains the details ofthe diferent gasses which can be detected.The Select Gas menu option allows the gas type of the unitto be changed. The gas types available on the standard unitare listed in Section 11.1.62

MAN0551.P65 Issue 06 - 03/042108M05016.2.3.5 Config6. CALIBRATIONThe Show Config option on the Config menu shows the valuesof a number of key paramaters in the Searchpoint OptimaPlus. These may be scrolled through by pressing the orkeys.6.2.3.6 Power OffEntering this menu and pressing ↵ turns off the Hand-heldInterrogator to preserve battery life.63

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION6.3 CALIBRATING THE CONTROLLERThis procedure allows the user to calibrate the controller byFORCE’ing a known current out of the unit’s 4-20mA output.Use of this technique enables calibration of the controller’s 0-100% fsd scale without the need for gas.It is recommended that calibration of the controller isperformed at two points, ideally 4mA (0.0% fsd) and 12mA(50% fsd). Provided that no background gas concentration ispresent, the unit’s 4mA (0.0% fsd) output can be used tocalibrate the control cards zero point. The span calibration ofthe controller can then be calibrated by FORCE’ing therequired current as follows:-(1) Connect the Hand-Held Interrogator to the unit.(2) Press ↵ to switch the power on, ensure the Hand-heldis in Optima + mode and wait five seconds. The displaywill show:MainDisplay(3) Press and the display will show:MainCalibrate(4) Press ↵ and the display will show:CalibrateDisplay64

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION(5) Press and the display will show:CalibrateCal Sensor(6) Press and the display will show:CalibrateForce 4-20This selects the FORCE'd 4-20mA routine which can beused to calibrate the controller.(7) Press ↵ and the display will show:O/P 4-20 current4.0 mA(8) Press or to change the displayed mA value in0.5mA steps:O/P 4-20 current12.0 mAChoose the desired value.(9) Press ↵ and the display will show:Fixed: nn.nn mAPress enterwhere nn.nn is the current measured by the OptimaPlus diagnostic function. The analogue output is nowset to the selected value set in step (8). Specifiedaccuracy is ±1% FS (±0.2mA).65

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION(10) Calibrate the controller to display the correct readingfor the current being FORCE'd on the 4-20mA output.(11) Press ↵ and the display will show:Press Enter ToRelease 4 - 20Note: The unit will return to normal operation after 10 minutesif no key is pressed.(12) Press ↵ and the display will show for 3 seconds:4 - 20 ReleasedThe analogue output has now returned to normaloperation.(13) Wait and the display will show:CalibrateForce 4-20Returns to the Calibrate Menu.(14) Press esc twice to return to the Main Menu:MainDisplay(15) The Hand-Held Interrogator may be switched off bypressing esc and ↵ together.66

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION6.4 CALIBRATING THE SENSORCAUTIONS1. Searchpoint Optima Plus is supplied factorycalibrated for a particular hydrocarbon gas and shouldnot require routine gas calibration. In general, thisfactory calibration will be more accurate than whatcan be achieved in the field. Only perform gascalibration if this is required by local regulations or ifthere is clear evidence of a significant calibrationerror. In most instances, the zeroing and functionaltesting procedure described in Section 7 should besufficient to maintain a unit’s performance without theneed for gas re-calibration.2. Ensure that the correct calibration gas andconcentration are used. The concentration ofcalibration gas should be known to be accurate towithin +/-2.5% of the value declared on the cylinder /bottle.3. It is important to present the calibration gas correctlyto the detector. Only use Searchpoint Optima Plusgassing accessories as directed.4. Searchpoint Optima, in common with other IR gasdetectors, measures the total number of target gasmolecules in it’s beam and hence readings aredirectly related to the gas pressure in themeasurement path. Avoid pressurising calibration gasinside the unit’s measurement path by keeping gasflow rates below the maximum recommended levelsand ensuring that gas can freely vent to atmosphericpressure. The maximum recommended flow rates are0.3 l / min for the remote gassing cell, 2 l / min for thegassing cover and 2 l / min for the flow housing.67

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION5. Do not attempt to perform calibration during periodsof exceptionally low or high atmospheric pressure.(Normally associated with unusual or extremeweather conditions. Calibration is not recommendedduring storms, very strong winds or highlychangeable weather conditions.)6. Ordinarily, during production Optima Plus units arecalibrated with gas in the main measurementchamber, which is where they will detect gas inoperational service. The response in the RGC is notproduction calibrated. The RGC is not recommendedfor calibration or for high accuracy calibration testing.(The only exception to this is where units are beingused to measure high %V/V gases using the RGC asa flow cell. In this instance, the units are productioncalibrated with gas in the RGC.)7. Always allow unit’s to stabilise in the operatingenvironment for at least 30 minutes (ideally 1 hour)before performing gas calibration.Equipment Required:Gassing CoverInstrument Air (if a zero in ambient air cannot be guaranteed)Calibration Span Gas (i.e. 2.5% V/V methane for 50% LELoutput or 2.2% V/V for 50% UEG)SHC-1 Handheld Interrogator68

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATIONTo calibrate the sensor, proceed as follows:(1) Connect the Hand-Held SHC-1, press ↵ to switch onthe power, check the Hand-held is in Optima + mode,wait five seconds and the display will show:MainDisplay(2) Press and the display will show:MainCalibrate(3) Press ↵ and the display will show:CalibrateDisplay(4) Press and the display will show:CalibrateCal Sensor(5) Press ↵ and the display will show:Inhibiting 4 - 20Please WaitThis sets the analogue output to the inhibit level(default 2mA) for the duration of the calibrationsequence.(6) Remove weather protection and dust barrier. Check thatthe optics are clean and dry. Clean / dry optics ifnecessary. Refit the dust barrier and weatherprotection.69

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION(7) Wait and the display will show:Ensure Zero GasPress EnterNote: If at this stage the zero reading in ambient air cannotbe guaranteed, fit the gassing cover over the weatherprotection and apply instrument air at one litre/minutefor 30 seconds.(8) Press ↵ and the display will show:Processing DataPlease waitAfter 10s the display will show:Zero CalibratedThe new baseline (zero) is now set.(9) Wait and the display will show:(10) Either:Cal Span, EnterExit Cal, ESCa. press esc to end the calibration sequence withoutcarrying out a span calibration, orb. press ↵ and the display will show:Press Enter ToSelect Gas Conc.70

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATIONThis means set the gas concentration (ie. 50% LEL: for2.5% methane or 50% UEG: for 2.2% methane).(11) Press ↵ and the display will show:Span Gas50.0 % LEL(12) Press or to change the displayed gas value in1% steps to the value being applied.(13) Press ↵ and the display will show:Press Enter whenStable: xx.x(14) Fit the gassing cover over the weather protection of theSearchpoint Optima.(15) Apply span calibration gas at a rate of one litre/minuteand wait for reading to stabilise. This will takeapproximately 30 seconds to 1 minute, depending uponflow rate.Press Enter whenStable: xx.x(16) Press ↵ and the display will show:Processing DataPlease wait . . . .After 10s the display will show:Span Calibrated71

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION(17) Wait and the display will show:Remove gas, PressEnter: xx.x(18) Remove the gassing cover from the weather protection.Ensure the reading has returned to 00.0% LEL.(19) Press ↵ and the display will show:Press Enter ToRelease 4 - 20Releases the analog output from 2mA (inhibit signal)to normal operation (4mA).(20) Press ↵ and the display will show for 3 seconds:4 - 20 releasedThe analogue output has now returned to normaloperation.(21) Wait and the display will show:CalibrateCal SensorReturns to the Calibrate Menu.(22) Press esc twice to return to the Main Menu:MainDisplay72

MAN0551.P65 Issue 06 - 03/042108M05016. CALIBRATION(23) The Hand-Held Interrogator may be switched off bypressing esc and ↵ together.Gassing Cover Fitted Over Weather Protection73

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MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKS(2) Connect the SHC-1 interrogator to the unit.(3) INHIBIT the unit by selecting the DISPLAY option in theCALIBRATE menu.(4) Unscrew the two retaining nuts and remove theStandard Weather Protection. Inspect the StandardWeather Protection for damage or build up of debris /contaminants. If required, clean or replace weatherprotection.(5) Inspect the Dust Barrier and clean or replace if required.(6) Remove the Dust Barrier and inspect the optics.(7) Clean any dust or contaminants from the optics usingmild detergent or window cleaner and a soft cloth orcotton bud.Note: If a remote gassing cell is fitted, the cell window can beunscrewed and removed for cleaning purposes wherenecessary. When replacing, ensure that the cell windowis fully screwed home (the effective thickness of thegassing cell is reliant upon this).CAUTIONS1. Do not attempt to clean the optics using abrasive orcorrosive materials.2. Do not attempt to clean the unit using a sand-blasteror similar equipment.3. Do not use concentrated organic solvents to clean theunit. These substances contain hydrocarbons whichmay give rise to gas readings when they evaporate.76

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKS(8) Refit or replace the Dust Barrier and Standard WeatherProtection.(9) Verify that there are no ACTIVE FAULTs or WARNINGsby checking that the ‘/’ line is present on the right sideof the CALIBRATE / DISPLAY screen. If there areFAULTs or WARNINGs, the ‘/’ will be replaced witheither an F or a W.(10) If ACTIVE FAULTs or WARNINGs are present,investigate these by using the DIAGNOSTIC menuoptions. Wherever possible, correct any ACTIVE FAULTsor WARNINGs before proceeding to the next stage.Having completed the above steps, you are now ready toperform a functional response check. Functional responsechecks can either be performed using the Gassing Cover and%LEL concentration gas or using the Remote Gassing Cell andhigh %V/V gas. The procedures for performing functionalresponse checks are described in the following sections.7.2.1 Response Check Using Gassing Cover and%LEL Concentration GasNote: For best results when performing functional responsechecks it is important to re-ZERO a unit before theresponse check.(1) For best results, allow the sensor to remain under powerfor one hour prior to performing response check. Thisallows the unit's temperature to stabilise in the operatingenvironment.77

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKS(2) Fit the Gassing Cover over the weather housing,ensuring the gas entry slot at the base of the standardweather protection is covered.(3) Ensure that there is a suitable zero gas inside theunit’s main measurement chamber and the remotegassing cell (if fitted). Suitable zero gases includefume/vapour-free atmospheric air, instrument air andnitrogen. (In most outdoor or well ventilatedinstallations, atmospheric air will suffice for zeroing.Instrument air or nitrogen should only be necessary forpoorly ventilated installations or where a significanthydrocarbon background is present or expected.)(4) Select the CALIBRATE / CAL SENSOR menu optionand re-zero the unit. (Do not re-calibrate the unit’s spangas response.)(5) Select the CALIBRATE / DISPLAY menu option.(6) Using the Gassing Cover, apply test gas to the unit.Allow approximately 30 seconds to 1 minute for the gasconcentration in the measurement chamber to stabilise.78

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKS(7) Monitor the DISPLAY’ed gas reading and confirm that itis within +/-5% LEL of the anticipated reading. If thereading is within +/- 5% LEL of what is anticipated, theunit is definitely operating correctly. Do not consider recalibratingunits with apparent “calibration errors” lessthan +/- 5% LEL. Be aware that field calibration andresponse checking techniques are not sufficientlyaccurate to determine whether such small “errors” aregenuine, or to correct them.(8) If the DISPLAY’ed gas reading is within +/-10% fsd ofthe anticipated reading, it is possible that there mightbe a calibration error but it is still more likely that theerror will be due to the prevailing conditions or test gas/ technique. Before considering re-calibration, doublecheckthe following:-a. The optics are clean and un-contaminated.b. The unit has been correctly zeroed in a genuinezero gas background.c. The correct test gas and concentration are beingused for the range being tested.d. The tolerance on the test gas concentration issignificantly less than the apparent reading error.e. There is adequate test gas in the cylinder.(Cylinders that are nearly empty tend to read on thelow side.)f. The test gas in the measurement chamber / remotegassing cell is not being pressurised due to highflow rates or blockages / restrictions.g. The atmospheric pressure is not unusually high orlow.h. The unit has had sufficient time to stabilise in it’soperating environment. (At least 30 minutes, ideally1 hour after any significant change or power-up.)i. An approved, ZA supplied gas testing accessory isbeing used. (Either the gassing cover, calibrationcap or the remote gassing cell.)79

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKSIf after checking the above, the error remains, considerre-calibrating the unit in accordance with the proceduredetailed in Section 6.4.(9) Errors in the DISPLAY’ed gas reading larger than +/-10% fsd are rare. Where encountered, they are morelikely to be associated with the considerations listed in(16) for double-checking than errors in the actual unit'scalibration. Ensure that all of the considerations arefully checked before re-calibrating. If the apparentcalibration error is larger than +/-15% fsd, contact ZA ortheir representatives for advice before attempting recalibration.(10) Before releasing the detector from INHIBIT, ensure thatany test gas inside the unit’s measurement chamberhas been fully removed. This can be achieved either byblowing instrument air / nitrogen through the GassingCover, or by removing the Gassing Cover and allowingthe test gas to escape (this takes around 30 seconds).(11) Release the detector from INHIBIT by selecting theMAIN DISPLAY menu option.(12) Remove the unit from INHIBIT by selecting the MAINDISPLAY menu option.(13) Provided that on the MAIN DISPLAY, the unit is reading0.0% LEL and the ‘/’ line is rotating, the unit isoperating normally and all tests and maintenanceactivities have been completed.If the ‘/’ line has been replaced by a W, there is anACTIVE WARNING in the unit, which should beinvestigated and where possible cleared before leavingthe unit for operational use.80

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKSIf the ‘/’ line is not rotating or has been replaced by an F,there is an ACTIVE FAULT. The unit will not operate withan ACTIVE FAULT. Use the DIAGNOSTICS menu optionto identify the cause of the FAULT and remedy wherepossible.(14) Disconnect the SHC-1 interrogator from the unit.(15) The functional response check has been completed7.2.2 Response Check Using Remote Gassing Cell& High %VV GasNote:1. This only applies if the optional Remote GassingCell has been selected and fitted.2. The Remote Gassing Cell is designed to facilitatefunctional response checking of units installed inpositions where obtaining access is difficult. TheRGC is not recommended for calibration or for highaccuracy calibration testing. During production,Optima Plus units are calibrated with gas in themain measurement chamber, which is where theywill detect gas in operational service. The responsein the RGC is not production calibrated. (The onlyexception to this is where units are being used tomeasure high %V/V gases using the RGC as a flowcell. In this instance, the units are productioncalibrated with gas in the RGC.)3. The functional response check limits recommendedfor this procedure include reasonable allowances forthe effects of atmospheric pressure, test gastolerances and test repeatability. These functionalresponse check limits are representative of whatthe user should expect to achieve under typical fieldconditions.81

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKS4. This procedure assumes the Searchpoint OptimaPlus has been calibrated for 0 - 100% LELmethane.CAUTIONS1. In order to avoid pressurisation, gas should flowthrough the remote gassing cell at no more than0.3 litre/min.2. Ensure that the exhaust pipe is not blocked sincethis may pressurise the flow through the cell and maycause permanent damage to the unit.3. Never blow air from the lungs directly into the remotegassing cell since the presence of any foreignsubstances within the cell will adversely affect theoperation of the unit.4. Always use a Flow Filter on the inlet of the remotegassing cell when a remote gassing pipe ispermanently installed.5. For other gases, contact Zellweger Analytics Limited.82

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKSEquipment Required:Flow Through Cell Gassing Kit, consisting of:Lengths of plastic tube with In Line Particle Filter.Cylinder of 50% v/v Methane.Cylinder of nitrogen (zero gas).Exhaust Pipe (at least one metre of plastic tube).Multimeter.(1) Remove the dust caps from the two pipes / tubesleading to the Remote Gassing Cell Nozzles. (Whilstthe RGC is not being used for response checking, thepipes / tubes leading to the RGC should be sealed toprevent dirt / moisture ingress into the RGC. It isassumed that the dust caps supplied fitted to thegassing cell nozzles will be used for this purpose.)(2) Connect the outlet from the zero gas cylinder to thepipe / tube leading to the RGC.(3) Ensure that the exhaust pipe / tube coming from theRGC is clear and that it vents well away from theSearchpoint Optima. (If concentrated %V/V gas leaving83

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKSthe exhaust pipe / tube gets into the mainmeasurement chamber it will significantly affect thereadings obtained when using the RGC.)(4) Flush the RGC with zero gas for at least 30 seconds.(5) Select the CALIBRATE / CAL SENSOR menu optionand re-ZERO the unit. (Do not re-calibrate the unit’sspan gas response.)(6) Disconnect the zero gas and connect the highconcentration %V/V span test gas to the pipe / tubeleading to the RGC.(7) Apply 50%V/V methane to the RGC at a flow rate of 0.3litres / minute.(8) Allow approximately 30 seconds to 1 minute for the gasconcentration in the RGC to stabilise.(9) Monitor the DISPLAY’ed gas reading and confirm that itis within +/-10% LEL of the anticipated reading(57.5%LEL +/- 10%LEL for 50%V/V methane in theRGC.). If the reading is within +/- 10% LEL of what isanticipated, the unit is operating correctly. Do notconsider re-calibrating units with apparent errors lessthan +/- 10% LEL. Be aware that field calibration andresponse checking techniques using the RGC are notsufficiently accurate to determine whether such errorsare genuine, or to correct them.(10) If the DISPLAY’ed gas reading differs from theanticipated reading by more than +/- 10% LEL, it ispossible that there might be a calibration error but it isstill more likely that any errors will be due to theprevailing conditions, test gas or gassing technique.Before considering re-calibration, double-check thefollowing:-84

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKSa. The optics are clean and un-contaminated.b. The unit has been correctly zeroed in a genuinezero gas background.c. The correct test gas and concentration are beingused for the range being tested.d. The tolerance on the test gas concentration issignificantly less than the apparent reading error.e. There is adequate test gas in the cylinder.(Cylinders that are nearly empty tend to read on thelow side.)f. The test gas in the measurement chamber / remotegassing cell is not being pressurised due to highflow rates or blockages / restrictions.g. The atmospheric pressure is not unusually high orlow.h. The unit has had sufficient time to stabilise in it’soperating environment. (At least 30 minutes, ideally1 hour after any significant change or power-up.)i. An approved, ZA supplied gas testing accessory isbeing used. (Either the gassing cover, calibrationcap or the remote gassing cell.)If after checking the above, the error remains, considerre-calibrating the unit in accordance with the proceduredetailed in Section 6.4.(11) Before releasing the detector from INHIBIT, ensure thatany test gas inside the unit’s RGC has been fullyremoved. This can be achieved by blowing instrumentair / nitrogen through the RGC for approximately 1minute.(12) Re-seal the pipes / tubes leading to the RGC using thedust caps provided (or a suitable alternative).(13) Release the detector from INHIBIT by selecting theMAIN DISPLAY menu option.85

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKSwish to perform all inspection and testing activities withoutremoving units or their mounting plates from the duct wall.The duct mounting kit makes it possible to interrogate andfunctionally gas test units in-situ, which covers mostrecommended maintenance and testing activities. However, itis not possible to inspect or clean a unit whilst it is inside theduct. The requirement to inspect and clean a unit variesdepending upon the conditions inside the duct:-a. Clean / Dry Ducts: Where the conditions inside a ductare clean and dry, the likelihood of contaminant orcondensation build-up on the dust barrier or optics isrelatively low. Provided that a unit is not reporting anyFAULTs or WARNINGs, it should not be necessary tophysically inspect it. Typical clean / dry ductinstallations include filtered, onshore HVAC inlets andoutlets from clean plant / building areas.b. Dirty / Damp Ducts: Where the conditions inside a ductare dirty or damp, the likelihood of contaminant orcondensation build-up on the dust barrier or optics issignificantly increased. It is therefore stronglyrecommended that units are temporarily de-mountedfrom the duct in order to perform inspection andcleaning. Typical dirty / damp duct installations includeoffshore HVAC inlets and un-filtered plant / buildinginlets.The procedure for testing and inspection of units installed inducts is essentially the same as that described inSection 7.2.87

MAN0551.P65 Issue 06 - 03/042108M05017. ROUTINE CHECKS7.4 REMOVAL AND REFITTING OF FLOWHOUSING7.4 1 Removal of Flow HousingBefore the inspection check can be carried out on aSearchpoint Optima Unit fitted with a Flow Housing, the FlowHousing must be removed as follows:(1) Disconnect any pipework attached to the flow housing.(2) Using a ½ inch A/F open ended spanner, remove thetwo black nuts which retain the flow housing. Keep theO-ring seals which are below the retaining nuts.(3) Slide the flow housing off the Optima. NB: This mayrequire some force due to the friction of the O ring.(4) The window and mirror can now be inspected andcleaned if necessary.7.4.2 Refitting of Flow HousingTo refit the flow housing, proceed as follows:(1) Check the window and mirror are free fromcontamination.(2) Ensure that the large sealing O ring, in the body of theflow housing, and the two small O rings, which gobelow the retaining nuts, are clean and in goodcondition. Replace if in doubt.(3) Slide the flow housing over the end of the SearchpointOptima and push until the flow housing is firmly seated.88

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MAN0551.P65 Issue 06 - 03/042108M05018.1 TROUBLESHOOTING8. FAULT FINDINGThe table below describes some possible faults and problems that can beencountered and their most likely causes and remedies. The user should beaware that there are often significant differences between what appears to bethe problem and the actual problem when fully diagnosed. Experience hasshown that a methodical, whole-system orientated approach is the mosteffective for solving problems with gas detection systems and installations.Fault / ProblemOutput is 0mACause:Remedy:Cause:Remedy:Cause:Remedy:Cause:Cause / RemedyUnit is in FAULT conditionConnect SHC-1 interrogator to unit and useDIAGNOSTIC menu options to ascertainreason for FAULT report.Electrical installation problem.(1) Check +24V power supply to unit.(2) Check cables and connections,especially 4-20mA loop connections.(3) Check that unit has correct 4-20mAoutput configuration for use with thecontroller.Optical surfaces are obscured by dirt /contaminants.Clean optical surfaces.Unit’s zero position has negative offset.Remedy:Check that optics are clean and dry. Rezerounit.91

MAN0551.P65 Issue 06 - 03/042108M05018. FAULT FINDINGFault / ProblemOutput is 0mAUnit fails torespond toSHC-1 HandheldInterrogatorCause:Remedy:Cause:Remedy:Cause:Remedy:Cause:Remedy:Cause:Remedy:Cause:Remedy:Cause / RemedyUnit has developed an electrical fault.Most electrical faults result from damagecaused by site / installation problems.Check for correct wiring, voltage spikes /transients, power surges and earthingproblems.Incorrect connection of interrogator’scommunication link.Check that the SHC-1 is correctly pluggedinto IS socket or that SHC ProtectionDevice leads are connected to the rightjunction box terminals.Incorrect software version in HandheldInterrogator.Optima Plus only works with version 3V0interrogator software and above. Checkinterrogator software version.No power applied to Optima Plus unit.Check +24V power supply to unit.Incorrect mode selected on interrogator.Select Optima + mode on interrogator.Battery failed in Handheld Interrogator.Check / replace interrogator battery.92

MAN0551.P65 Issue 06 - 03/042108M05018. FAULT FINDINGFault / ProblemUnit’s outputappears to bedrifting.Cause:Remedy:Cause:Remedy:Cause:Remedy:Cause / RemedyCorrect response to genuine, low levelfluctuations in gas concentration wherethe unit is installed.A commonly misinterpreted problem whichis resolved when the source of thefluctuating gas leak is finally identified. If aunit is transmitting a gas reading, doublecheckthe gas concentration at the exactpoint where the detector is installed usinga sensitive portable gas detector that hasbeen carefully zeroed. (Do not use astandard catalytic detector on a 0-100%LEL range, they are not sensitive enoughto reliably detect low % LELconcentrations.)Build-up of contaminants on optics,especially oil-mist, exhaust fumes, greaseand solvents.Check that dust barrier is fitted correctly,clean and intact. Closely inspect theoptics to be sure that nothing is buildingup on them. Clean and re-zero unit ifnecessary.Exposure of unit to extreme temperatures.Check unit’s FAULT / WARNING log tosee if it has records of Temp LimExceded. If temperature problems areconfirmed, either relocate or shield thedetector or consider use of a samplingsystem.94

MAN0551.P65 Issue 06 - 03/042108M05018. FAULT FINDINGFault / ProblemUnit’s outputappears unstableand erratic.(cont.)Cause:Remedy:Cause:Remedy:Cause / RemedyNote: These filtering and processingmeasures are not typically taken onstandard PLC inputs / systems andthis has led to problems when suchsystems are used for gas detectionapplications.)Unit has developed an electrical fault.Most electrical faults result from damagecaused by site / installation problems.Check for correct wiring, voltage spikes /transients, power surges and earthingproblems. Correct any electricalinstallation problems. Return unit to ZA forrepair.Unit is experiencing an intermittent fault oris fluctuating about the FAULT / WARNINGthreshold for a particular diagnostic test.(1) Check the unit’s FAULT / WARNINGlog to find clues as to what might becausing the intermittent orfluctuating fault condition.(2) Check that the optics are clean anddry and that no foreign objects aremoving in the measurementchamber.(3) If no cause for the intermittentbehaviour can be identified, returnthe unit to ZA for furtherinvestigation and / or repair.96

MAN0551.P65 Issue 06 - 03/042108M05018. FAULT FINDINGSHC-1Handheld TextW-See InstGuideBad 24V SupplyW-See InstGuideBad 4-20mALoopDescriptionWARNING:The 24V supply voltageis just outside of thespecified limits. (18V to32V)FAULT:The 24V supply voltageis well outside of thespecified limits.(34V)WARNING:The 4-20mA monitoringsystem has detected acurrent error greaterthan +/- 0.5mA.Remedial Action(s)(1) Check the 0V and 24Vconnections andcabling to the unit.(2) Verify that the roundtripresistance of thesupply cable is lessthan 25.5 ohms.(3) Check that the supplyvoltage at the controlleris at least 24V.(4) Take appropriatemeasures to ensurethat the supply voltagereaching unit isbetween 18V and 32V.See (1) to (4) above.(1) Check the 4-20mA loopconnections andcabling.(2) Check that the loopresistance is less than600 Ohms.98

MAN0551.P65 Issue 06 - 03/042108M05018. FAULT FINDINGSHC-1Handheld TextW-See OpsGuideLamp OutputDescriptionFAULT:The lamp output hasfallen below the minimumoperating limit.Remedial Action(s)Replace the Optima Plusunit with a spare and returnit to ZA for service or repair.W-See OpsGuideObscured OpticsWARNING:Foreign objects orcontaminants arepresent in the opticalpath.(1) Remove the weatherprotection and dustbarrier.(2) Clean the optics andremove any foreignobjects from themeasurement path.FAULT:The optical path hasbecome heavily obscuredby contaminants orforeign objects.See (1) & (2) above.W-See OpsGuideNeg Gas ReadingWARNING:There is a small negativeoffset on the unit’s zerogas reading.FAULT:There is a significantnegative offset on theunit’s zero gas reading.(1) The main cause ofnegative offsets ismoisture /condensation on theoptics. Check that theoptics are clean anddry. If the units is in anenvironment wherevery damp /condensing conditionsare prevalent, consideradditional protection.(Fitting of Storm Baffleor use of samplingsystem.)100

MAN0551.P65 Issue 06 - 03/042108M05018. FAULT FINDINGSHC-1Handheld TextW-See OpsGuideSignal QualityDescriptionRemedial Action(s)(3) Check that the unit isnot being exposed toexcessive vibration ortemperatures.(4) Check that the 24Vpower supply to the unitis relatively stable andfree from transients,interruptions andsurges.(5) Ensure that the unit isadequately protectedfrom thermal shock.(Rates of changegreater than 3 degreescentigrade per minutecan cause problems.)(6) Attempt to restart theunit by either switchingthe power off and onagain or selecting theDIAGNOSTIC >SOFTWARE RESEToption on the SHC-1.(7) If the above checks /actions do not resolvethe problem, the unithas probably developeda hardware fault. Returnthe unit to ZA for repair.102

MAN0551.P65 Issue 06 - 03/042108M05018. FAULT FINDINGSHC-1Handheld TextW-See OpsGuideInternal FailureW-InformativeAlarmDescriptionFAULT (ONLY):An internal hardwarefault has beendiagnosed.WARNING (ONLY):The unit is or hasdetected a gas levelthat exceeds the alarmthreshold.Remedial Action(s)(1) Attempt to restart theunit by switching thepower off and on againor selecting theDIAGNOSTIC >SOFTWARE RESEToption on the SHC-1.(2) If the problem persists,return the unit to ZAfor repair /replacement.Provided for establishingwhether genuine alarmsignals have beengenerated by the unit.Minimum alarm threshold is10%.103

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MAN0551.P65 Issue 06 - 03/042108M050110. ACCESSORIES/REPLACEMENT PARTSPart Number04200-A-101504200-A-104004200-A-105004200-A-110004200-A-120104220-A-100004230-A-100104230-A-102504234-A-100000780-A-0100DescriptionSearchpoint Optima Duct Mounting KitJunction Box Adaptor PlateRemote Gassing Attachment KitFlow Through Cell Gassing Kit4 - 20mA to Bridge ConverterTermination Unit, DVC100Hand-Held Interrogator SHC-1SHC Protection DeviceHand-Held Interrogator SHC-1, UL Non-IncendiveHawke PL612 Junction Box108

MAN0551.P65 Issue 06 - 03/042108M050111. SPECIFICATIONOPERATIONAL ANDCERTIFIEDTEMPERATURE RANGE: -40°C to +65°CDRIFT OVER TIME ORTEMPERATURE RANGE: Baseline < +/- 2% LEL,50% FSD < +/- 4% LELOPERATING HUMIDITY: 0 to 99% RH (non-condensing)PRESSURE RANGE:PRESSURECOEFFICIENT:POWER SUPPLY:POWERCONSUMPTION:CURRENT DEMAND:STABILISATION TIME:900 to 1100 mbar(non-compensated)< 0.1% of reading per mbar18 to 32V (24V nominal)< 4.5W max< 235mA at 18V< 190 mA at 24V< 155mA at 32V1 hour, nominal.OUTPUTSANALOGUE:MAXIMUM 4-20mALOOP RESISTANCE:DIGITAL:4-20mA, non-isolated, currentsource or sink. (Defaultconfiguration is current source.)600 Ohms.RS485 (Two way, point to point.)110

MAN0551.P65 Issue 06 - 03/042108M050111. SPECIFICATIONOUTPUT SIGNALS:MEASURING RANGE:( 0-100% FSD)INHIBIT:WARNING:FAULT:OVER-RANGE:4-20mA1 to 3mA (Default 2mA)0 to 4mA (Default 4mA)0mA20 to 21.5mA (Default 21mA)CERTIFICATIONAPPROVALS:CENELEC (BASEEFA):(ATEX) II 2G EEx d IICT5 (T amb-40°C to +55°C)T4 (T amb-40°C to +65°C)UL: Class 1, Div 1, Groups B,C and D.-40°C to +65°CPERFORMANCEAPPROVALS:EMC COMPLIANCE:DMT (pending)EN50081-1: 1992 andEN50082-2: 1995ENVIRONMENTALPROTECTION: IP 66 / 67VIBRATION:2Hz to 60Hz, 1mm peak to peak.BS5445 Appendix D (modified levelsand frequency range).DIMENSIONS: Length: 165mmDiameter: 73mmWEIGHT:MATERIAL:1.6kg.316 stainless steel.111

MAN0551.P65 Issue 06 - 03/042108M050111. SPECIFICATION11.2 CROSS INTERFERENCE TO OTHERGASES AND VAPOURSSearchpoint Optima is despatched pre-calibrated and readyfor installation. The signal output configuration, gas and rangefor which the unit is calibrated are indicated on a labelattached to the main housing.THE FOLLOWING IS ONLY APPLICABLE WHENDETECTING HYDROCARBONS:A Searchpoint Optima Plus Unit calibrated for a particularhydrocarbon will have a response to most other hydrocarbongases. The cross-sensitivity figures below are approximateand are for guidance only:Concentration v/v:2.5% methane0.4% ethane0.3% propane0.2% butane0.3% pentane0.3% hexane0.3% heptane0.3% octane0.8% propylene2.7% ethyleneApproximate amount of gasrequired to give an outputequal to 50% LEL methane, onSearchpoint Optima calibratedfor 100% LEL (fsd) methane.112

MAN0551.P65 Issue 06 - 03/042108M050111. SPECIFICATION11.3 HAND-HELD INTERROGATOR SHC-1SPECIFICATIONCERTIFICATION:BASEEFA/CENELEC: EN 50014/50018.EEx ia IIC T4 amb -40 o C to +40 o C.OPERATINGTEMPERATURE RANGE: 0 o C to +40 o C.(DMT evaluated: -25°C to +55°C).STORAGETEMPERATURE RANGE:OPERATING HUMIDITY:-10°C to +40°C.0 to 99% RH.DIMENSIONS:` Long: 190mm.Depth: 40mm.Width: 80mm.WEIGHT:0.5kg.MATERIAL: Stainless Steel ANSI 316.SHCI ATEX CERTIFIEDLATER VERSIONS OF SHCI ARE ATEX CERTIFIED.CERTIFICATION: ALL OTHER SPECIFICATIONS AS ABOVE.BASEEFA 03 ATEX 0073II 2G EEx ia IIC T4TAMB. -40°C to +40°CEXPLOSIVEATMOSPHERES MARKAND ATEX CATEGORYCODESPRODUCT NAMECERTIFICATE NO.MANUFACTURER'STRADEMARKCE MARK ANDIDENTIFICATIONMARK OF ATEXNOTIFIED BODYCERTIFICATION CODESCERTIFIED AMBIENTTEMPERATUREYEAR OFMANUFACTUREAND SERIAL NO.MOD STATE113

MAN0551.P65 Issue 06 - 03/042108M050111. SPECIFICATION11.5 TERMINATION UNIT DVC100SPECIFICATIONCERTIFICATION:BASEEFA/CENELEC:EN 50014, EN50019, EN50020,EN50028EEx e m ia IIC T6 amb -40 o C to +65 o C.OPERATINGTEMPERATURE RANGE: -40 o C to +65 o C.(DMT evaluated: -25°C to +55°C).STORAGETEMPERATURE: -10°C to +40°C).OPERATING HUMIDITY:0 to 99% RH.(DMT evaluated: 5% to 90% RH).DIMENSIONS: Long: 156mm.Depth: 100mm.Width: 148mm.WEIGHT:MATERIAL:1.0kg.DMC reinforced polyester.EMC COMPLIANCE: EN 50081 and EN 50082,susceptibility to 20V/m (DMTevaluated up to 3V/m).115

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MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILSCENELECORATEX versionII 2G EEx ia IICT4-40°C to +40°CStandard Configuration117

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILSCENELECOR ATEX versionII 2G EEx ia IICT4-40°C to +40°CAlternative Connections118

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILSCENELECCertified Drawing BAS - Searchpoint Optima System DiagramNOTE: ATEX Version of SHC1 Certificate no. Baseefa 03ATEX0073, maybe used in place of SHC1 Certificate BAS no. 95C2005 in abovediagram.119

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILSULSearchpoint Optima PlusClass 1, Div 1, Groups B, C, and D.(-40°C to +65°C)Termination Unit DX100Class 1, Div 1, Groups B, C, and D.(-25°C to +40°C)TopDX100OptimaFieldCable / ConduitHandheldInterrogator Socket120

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILSULControlNumberTERMINATION UNIT TYPE DX100PART NUMBER 2104BXXXXCLASSIFIED AS TO FIRE, ELECTRICAL SHOCK& EXPLOSIVE HAZARDS ONLY.FOR USE IN CLASS 1, GROUPS B,C,D.PROVIDES INTRINSICALLY SAFE CIRCUIT WHEN93X0INSTALLED IN ACCORDANCE WITH CONTROLDRAWING 2104E0045.Vmax:32VDC SER.NO. NNNNNIMAX: 2AMod. StateAMB. TEMP. RANGE-25 O C TO +40 O C1234567WARNING:- SUBSTITUTION OF COMPONENTS MAYIMPAIR INTRINSIC SAFETY.Notes: 1. Apparatus which is unspecified except that it mustnot be supplied from, nor contain in normal orabnormal conditions a source of potential withrespect to earth in excess of 250V r.m.s. or 250Vd.c.2. Wiring from the hand-held calibrator (SHC-1) to thetermination unit (DX100) is not to exceed 15metres max.3. Install equipment including field wiring inaccordance with articles of the National ElectricalCode for Division 1 Hazardous Locations.121

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILSSUPPLY ENTRY(CONDUITHAZARDOUS (CLASSIFIED) LOCATION NON HAZARDOUS AREACONTROLEQUIPMENTTERMINATIONUNIT DX100UL FILENOTE 2SENSOR ENTRY(CONDUITCOMMUNICATIONSFIXED SOCKET I.S.OUTPUT TOSENSORANY SUITABLE ULLISTED ORHANDHELDCALIBRATOR TYPECLASSIFIED INFORMATION ONTHIS DRAWINGREPRODUCED FROM122

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILSCSA/FM123

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILS124

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILSCSA/FM125

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILS126

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILSCSA/FM127

MAN0551.P65 Issue 06 - 03/042108M050112. CERTIFICATION DETAILS128

MAN0551.P65 Issue 06 - 03/042108M050113. WARRANTYFor warranty information, consult the latest issue ofWA100 - General Statement of Limited Warranty129

MAN0551.P65 Issue 06 - 03/042108M0501NOTES130

MAN0551.P65 Issue 06 - 03/042108M0501NOTES131

MAN0551.P65 Issue 06 - 03/042108M0501NOTES132

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