Crowcon Xgard Bright Manual

Installation, Operation and Maintenance Instructions
M070068
Issue 1
January 2019
Xgard Bright
Gas Detectors with Display and Relays

Contents
1. Introduction.............................................................................. 1
1.1 Product overview.............................................................. 1
1.2 Safety information............................................................ 1
1.3 Storage instructions.......................................................... 2
1.4 Certification labels........................................................... 3
1.5 Product dimensions .......................................................... 4
1.6 Exploded view .................................................................. 5
2. Installation................................................................................ 6
2.1 Location ........................................................................... 6
2.2 Mounting......................................................................... 7
2.3 Cabling requirement......................................................... 7
2.4 Electrical connections ....................................................... 8
2.5 Earthing requirements ...................................................... 9
2.6 Cable glands .................................................................. 10
2.7 Fitting accessories........................................................... 13
3. Operation ............................................................................... 14
3.1 Operation panel ............................................................. 14
3.2 Key Operation ................................................................ 14
3.3 Start up.......................................................................... 15
3.4 Menu functions.............................................................. 16
3.5 Zero ............................................................................... 17
3.6 Calibrate ....................................................................... 17
3.7 Routine maintenance ..................................................... 18
3.8 Sensor replacement........................................................ 18
4. Specifications.......................................................................... 20
5. Warranty ................................................................................ 21

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English
1. Introduction
1.1 Product overview
XGard Bright is a versatile gas detector for monitoring a wide range of
flammable and toxic gases and oxygen levels. XGard Bright incorporates a
bright OLED (organic light emitting diode) display and a magnetic wand for
easy menu operation.
XGard Bright provides analogue 4-20mA and RS-485 Modbus signals as
standard, with optional HART interface. Relays are also fitted for activating local
alarms or sending digital signals to control systems.
XGard Bright may be fitted with electrochemical type toxic or oxygen sensors,
pellistor-type flammable gas sensors or infrared (IR) hydrocarbon or carbon
dioxide gas sensors. Please refer to the product identification label to determine
the type of sensor fitted.
Pellistor sensors are designed to detect flammable gases and vapours in
concentrations not exceeding the Lower Explosive Limit (LEL) of the target gas
for which the detector is calibrated.
XGard Bright is ATEX and IECEx Ex db IIC T6 Gb flameproof certified for use in
Zone 1 or 2 hazardous areas
1.2 Safety information
Safety information relevant to Ex requirements:
• WARNING – POTENTIAL ELECTROSTATIC CHARGING HAZARD. The painted
aluminium enclosure constitutes a potential electrostatic hazard and the
equipment must only be cleaned using a damp cloth.
• The cable gland must be installed before use and must comply with the
requirements of standards EN60019-0 and EN60079-1 with minimum IP66
ingress protection.
• Unused cable entries must be sealed using an ATEX/IECEx Exd certified
stopping plug with minimum IP66 ingress protection.
• Only cables of types specific in these instructions can be used.
• External earthing should be considered and installed according to these
instructions before use.
• WARNING – DO NOT OPEN WHEN AN EXPLOSIVE ATMOSPHERE IS
PRESENT.
• The lid on XGard Bright must be kept tightly closed until power to the

Introduction
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detector is isolated otherwise ignition of a flammable atmosphere can
occur. Before removing the cover for maintenance, ensure the surrounding
atmosphere is free of flammable gases or vapours.
General safety information
• XGard Bright gas detectors must be installed, operated and maintained in
strict accordance with these instructions, warnings, label information, and
within the limitations stated.
• XGard Bright detectors are designed to detect gases or vapours in air, and
not inert or oxygen deficient atmospheres. XGard Bright oxygen detectors
can measure in oxygen deficient atmospheres.
• Electrochemical cells used in toxic and oxygen versions of XGard Bright
contain small volumes of corrosive electrolyte. Care should be observed
when replacing cells to ensure that the electrolyte does not come into
contact with skin or eyes.
• Maintenance and calibration operations must only be performed by
qualified service personnel.
• Only genuine Crowcon replacement parts must be used, substitute
components may invalidate the certification and warranty of the detector.
• XGard Bright detectors must be protected from extreme vibration, and
direct sunlight in hot environments as this may cause the temperature of
the detector to rise above its specified limits and cause premature failure. A
sunshade is available for XGard Bright.
• This equipment must not be used in a Carbon Disulphide atmosphere.
1.3 Storage instructions
Some types of sensor available with XGard Bright have limited life when left
un-powered and/or may be adversely affected by temperature extremes or
environmental contamination. Ideal storage conditions are 20˚C and 60%RH.
Do not expose sensors to contaminants such as silicones, lead compounds and
strong solvents such as isopropanol. It is strongly recommended detectors are
installed and powered within 3 months of purchase.

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1.4 Certification labels
Diagram 1: Xgard Bright Certification Labels
ATEX and IECEx certification label
Gas name and range label
Warning label

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1.5 Product dimensions
All dimensions in millimetres
Diagram 2: Xgard Bright dimension view

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1.6 Exploded view
Diagram 3: Xgard Bright exploded view

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2. Installation
WARNING
This detector is designed for use in Zone 1 and Zone 2 hazardous
areas, and is certified Ex db IIC T6 Gb for operation up to 70°C
(158°F). Installation must be in accordance with the recognized
standards of the appropriate authority in the country concerned.
For further information please contact Crowcon. Prior to carrying
out any installation work ensure local regulations and site
procedures are followed.
2.1 Location
The detector should be mounted where the gas to be detected is most likely to
be present. The following points should be noted when locating gas detectors:
• To detect gases which are lighter than air, detectors should be mounted at
high level and Crowcon recommend the use of a collector cone (Part No.
C01051).
• To detect heavier than air gases, detectors should be mounted at low level.
• When locating detectors consider the possible damage caused by natural
events e.g. rain or flooding. For detectors mounted outdoors Crowcon
recommend the use of a Spray Deflector (Part No. C01052).
• Consider ease of access for functional testing and servicing.
• Consider how the escaping gas may behave due to natural or forced air
currents. Mount detectors in ventilation ducts if appropriate.
• Consider the process conditions. For example, butane is normally heavier
than air, but if released from a process which is at an elevated temperature
and/or pressure, the gas may rise rather than fall.
• Location of oxygen sensors requires knowledge of the gas that may
displace the oxygen. For example, carbon dioxide is denser than air and
therefore is likely to displace oxygen from low levels upwards.
• Sensors should be mounted at head height (1.5m nominally) to detect
gases of a similar density to air, assuming that ambient conditions and the
temperature of the target gas are nominally 20˚C.
The placement of sensors should be determined following advice of experts
having specialist knowledge of gas dispersion, the plant processing equipment
as well as safety and engineering issues. The agreement reached on the
locations of sensors should be recorded.

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2.2 Mounting
XGard Bright should be installed at the designated location with the sensor
pointing down. This ensures that dust or water will not collect on the sensor
and stop gas entering the cell. Care should be taken when installing the
detector to avoid damaging the painted surface of the enclosure.
2.3 Cabling requirement
Cabling to XGard Bright must be in accordance with the recognised
standards of the appropriate authority in the country concerned and meet the
electrical requirements of the detector.
Suitable explosion proof glands must be used. Alternative cabling techniques,
such as steel conduit, may be acceptable provided appropriate standards are met.
XGard Bright requires a dc supply of 10-30V, at up to 100mA. Ensure there is
a minimum of 10V at the detector, taking into account the voltage drop due
to cable resistance. For example, a nominal dc supply at the control panel of
24V has a guaranteed minimum supply of 18V. The maximum voltage drop is
therefore 8V. XGard Bright can demand up to 100mA and so the maximum
loop resistance allowed is 80Ohms.
NOTE: The maximum current consumed at the end point of a cable may vary
if sounders and beacons are attached and controlled by Xgard Bright. Under
these circumstances cable distances will vary from those in the table.
A 1.5mm2cable will typically allow cable runs up to 3.3km. Table 1 below
shows the maximum cable distances given typical cable parameters.
C.S.A. Resistance
(Ohms per km)
Max. Distance
(km)
mm2Awg Cable Loop
1.0 17 18.1 36.2 2.2
1.5 15 12.1 24.2 3.3
2.5 13 7.4 14.8 5.4
Table 1: maximum cable distances for typical cables
The acceptable cross sectional area of wire used is 0.5 to 2.5mm2(20 to
13awg). The maximum acceptable diameter of cable used is 15mm. The
table is provided for guidance only, actual cable parameters for each
application should be used to calculate maximum cable distances.

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2.4 Electrical connections
All electrical connections are made via the screw terminal block mounted on
the terminal PCB in the enclosure base. The terminals are marked ‘+’, ‘Sig’
and ‘-’ and correct polarity should be observed when connecting the detector
to control equipment.
XGard Bright is factory set as a ‘current sink’ device unless otherwise
specified when ordering. To reset to ‘current source’, open the enclosure base
and move the three links on the terminal PCB from the ‘SINK' position to the
‘SOURCE’ position.
Relays are fitted to indicate any Fault, Level 1 alarm or Level 2 alarm and are
marked accordingly. The Alarm relays are normally de-energised, the Fault
relay is normally energised (fail-safe). The volt-free contacts can be changed
from Normally Open (NO) to Normally Closed (NC) by moving the adjacent
link, where NO and NC refer to the de-energised state. The fault relay on
XGard Bright is normally energised (when the detector is healthy), therefore
the operation of the FAULT contacts is the reverse of that stated.
To limit radio frequency interference, the enclosure base and cable armour
should be grounded (earthed) at the control panel. Ensure the earth
connection is provided in a safe area only, so as to avoid earth loops.
Sounder terminals: provide a high-end output for directly triggering audible-
visual alarms. Alarms will be activated by a voltage equivalent to the XGard
Bright detectors supply (24Vdc nominally). Devices with a total maximum
current of 250mA may be connected.
Note: When connected with an audible-visual alarm the maximum
detector current need to be added up with the current that source into
the audible-visual alarm. The maximum 350mA current should be used
to calculate maximum cable distances.
RS-485 terminals: can be used to enable XGard Bright to communicate to
a Modbus Master device using the Modbus RTU protocol. This function can
be used in conjunction with the 4-20mA analogue signal to transmit data
to a central system, or used for multi-dropping detectors on an addressable
network. An ‘XGard Bright Modbus Instructions’ document is available
from Crowcon detailing all necessary connection, data format and address
information

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2.5 Earthing requirements
Earth terminals are provided on the outside of the XGard Bright enclosure
adjacent to the top-right cable entry, and internally adjacent to the left-hand
sounder out cable connector. For electrical safety it is essential that the XGard
Bright enclosure is bonded to earth, usually using the external earth lug, if
an earth cable is provided in the field cable the internal earth point can be
used. The grounding terminal connection must be tightened using a torque
screwdriver to 10Nm; secured using an M4 x 6mm screw, a plain washer and
a star/lock washer. Earthing cables must be 4mm2or greater in cross-sectional
area.
Diagram 4: Earthing Connections

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2.6 Cable glands
Instructions for installing appropriate certified glands with unarmoured and
armoured cable is given below.
Unarmoured cable
1. Backnut
2. Compression Spigot
3. Seal
4. Middle Nut
5. Inner Seal
6. Entry
Allow sufficient length of cable to the detector, fit shroud if required, pass the
cable through cable gland.
1. Screw the gland Entry into the XGard Bright M20 cable Entry. Using two
spanners or wrenches, hold the gland Entry in position to prevent rotation
and tighten the Middle Nut until resistance is felt between the Seal and
cable. Then turn the Middle Nut through a further half to one full turn to
complete the Inner Seal.
2. Hold the Middle Nut in position to prevent rotation and tighten the
Backnut until resistance is felt between the Seal and cable, then turn the
Middle Nut through a further half to one full turn to complete the Outer
Seal.

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Armoured cable
1. Backnut
2. Compression Spigot
3. Compression seal
4. Middle Nut
5. Reversible Armour Clamping Ring
6. Armour Spigot
7. Inner seal
8. Entry
1. Expose the armour/braid “A” by
stripping the cable's armoured / woven
layer and removing the cable filler.
2. Push the cable through the Armour
Spigot. Spread armour/braid over the
Armour Spigot until the end of the
armour/braid is up against the shoulder
of the armour cone. Position the Armour Clamping Ring.
3. Remove the Inner seal from the Entry.
Place the Entry over the Armour Spigot.
Move the Middle Nut to meet the Entry.
4. Hold the Entry in position with a
spanner/wrench to prevent rotation.
Hand tighten the middle Nut to the
Entry and turn a further half to one
full turn with a spanner/wrench.
5. Unscrew the Middle Nut and visually
inspect that the armour/braid has
been successfully clamped between
the Armour Spigot and the Armour
Clamping Ring. If armour/braid not
clamped, repeat assembly.
A=15mm

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6. Remove Entry and refit Inner Seal,
replace Entry and re-assemble Middle
Nut onto the entry component.
Tighten up the Middle Nut by hand
then using a wrench/spanner a further
1 to 4 turns until fully tight.
Notes:
1. These instructions are provided for general guidance only. It is essential
that the instructions provided by the cable gland manufacturer are strictly
adhered to.
2. Only cable glands ATEX and IECEx certified Exd Flameproof may be used
with XGard Bright.
3. Cable glands must have a minimum ingress protection rating of IP66.

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2.7 Fitting accessories
Collector cone (product code C01051)
Aids detection of lighter than air gases such as hydrogen or
methane. Includes a pipe spigot for application of bump test
gas
Spray deflector (product code C01052)
For outdoor installations and sensor protection from water
sprays.
Weatherproof cap (product code C01442)
For use offshore or very wet environments.
Flow adaptor (product code C01339)
For use in sampling applications.
Sun shield (product code C011063)
Prevents against excessive heat build-up due to direct
sunlight.
Calibration adaptor (product code C03005)
Enables application of calibration gas to the sensor.

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3. Operation
WARNING
Prior to carrying out any work ensure local regulations and site
procedures are followed. Never attempt to open the detector or
enclosure base when flammable gas is present. Ensure that the
associated control panel is inhibited so as to prevent false alarms.
3.1 Operation panel
The XGard Bright operation panel comprises an OLED screen, a three-colour
status LED and two magnetically operated Hall Effect switches. The screen
displays white characters on a black background and can be viewed clearly
even in bright sunlight. Reversed white screen saver will be activated in
normal detection condition while long time no operation.
Diagram 5: Xgard Bright operation panel
3.2 Key Operation
Key response has time dependency, two kinds of action would be generated
depend on how long time the key was hold.
• Short-time action event, magnet applied and removed in 2 seconds.
• Long-time action event, magnet applied and hold for more than 2 seconds,
a short beep will indicate 2 seconds is complete.
%lel
50

Operation
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3.3 Start up
When the XGard Bright is powered up, the unit will perform internal
diagnostic checks whilst the display will show a Crowcon logo. This procedure
will be displayed for about 10 seconds followed by displaying a warming up
status for about 120 seconds.
Diagram 6: Start up and Warming up
If the diagnostic checks were successful, the gas status screen will be
displayed. In normal operation the gas level will be indicated on the display.
Use the supplied magnetic wand to select the Scroll key to move between the
information screens shown below.
Diagram 7: Gas status screen
%lel
50 ppm 16 %vol 20.9 ma 4.00
oxygen
19.6
1419
20%vol
20.9
-0.0161
Gas name
PCB temperature
ADC value
Range
Gas value
Gain
SN: 0000000000000000
f: 2. 10 : 0.3 h: 151003
1 0 0 0
Volt: 23v dt: 20171206






1. Serial number
2. Firmware version, Hardware version
3. HART ID
4. Detector 485 Address, 485 packets
received, 485 packets address match,
Polling address
5. Detector supply voltage
6. Due time in format YYYYMMDD

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3.4 Menu functions
From the gas display screen, use the supplied magnetic wand to select the
Enter/Menu key to show password screen.
Enter the password: ‘0000’ to display the following menu. Select the Scroll key
to change the displayed number, and the Enter/Menu key to move to the next
integer. Hold the Enter/Menu key for two seconds to enter the menu.
Use Scroll key to move down the menu options list and to change the numbers
in any screen. Hold the scroll key for 2 seconds to move up the menu options.
1. Zero: to zero the sensor
2. Cal gas: to calibrate the sensor
3. To main menu: returns the display to the main gas screen
4. Set Alarm 1: to adjust the first alarm threshold
5. Set Alarm 2: to adjust the second alarm threshold
Note: if the Alarm 2 threshold is set lower than the Alarm 1 threshold
both will act as falling alarms.
6. Clr Loc Alarm: to de-activate the ‘Sounder Out’ output (used to silence
alarms even if the gas level remains above the alarm thresholds).
7. Chn/Eng: switch between Chinese and English display
8. Set 485 Addr: sets the node address of the detector for Modbus operation
9. Test Relay: adjust the analogue output signal: Dec/OK to decrease, Add/
Back to increase. The alarm relays will activate at the appropriate point.
a. Adj Loop mA: errors in the zero-level analogue output signal can be
adjusted by up to +/-2mA
Enter/Menu key Scroll key