Crowcon FGard IR3 User manual

Crowcon FGard IR3
Installation, Operating and Maintenance Instructions
Flame detector IR3 (FGard IR3) – FD-AC-07
Issue 1: February 21
IR3 Flame Detector

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Contents
1Introduction .................................................................................................................................................................................5
1.1 Detector Features ............................................................................................................................................................5
2Safety Instructions .....................................................................................................................................................................6
2.1 Specific conditions of use ..............................................................................................................................................6
2.2 Cautions..............................................................................................................................................................................6
2.3 Important Safety Notices................................................................................................................................................ 6
2.4 EN 54-part 10 Limitation of use ................................................................................................................................... 8
3Installation ....................................................................................................................................................................................8
3.1 Detector Enclosure ..........................................................................................................................................................8
3.2 Mounting & Orientation..................................................................................................................................................8
3.3 Wiring Procedure ...........................................................................................................................................................10
3.4 0-20mA Output...............................................................................................................................................................11
3.5 Relay Output....................................................................................................................................................................12
3.6 Internal Inter-connections............................................................................................................................................13
3.7 Installation Checklist ......................................................................................................................................................14
3.7.1 Mechanical.............................................................................................................................................................14
3.7.2 Electrical ..................................................................................................................................................................14
4System Design Guidelines.....................................................................................................................................................15
4.1 Power Supply...................................................................................................................................................................15
4.2 Cable Selection ...............................................................................................................................................................15
4.3 DC Power .........................................................................................................................................................................15
5Application Guidelines............................................................................................................................................................16
5.1 Positioning Requirements ............................................................................................................................................16
5.2 Detection Coverage.......................................................................................................................................................17
5.3 Exposure to Flare Radiation.........................................................................................................................................17
5.4 Optical Contamination...................................................................................................................................................17
5.5 Enclosed Areas ...............................................................................................................................................................17
5.6 Detector Sensitivity ........................................................................................................................................................17
5.7 Detector Alarm Delay....................................................................................................................................................17
6Maintenance and Commissioning.......................................................................................................................................19
6.1 Procedure.........................................................................................................................................................................19
6.2 Functional Testing ..........................................................................................................................................................21
7Fault Finding..............................................................................................................................................................................22
7.1 Removal of the Electronics...........................................................................................................................................22
7.2 Replacement of the Electronics..................................................................................................................................22

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7.3 Diagnostics ......................................................................................................................................................................22
7.4 LED Indication.................................................................................................................................................................23
7.5 Power Fault ......................................................................................................................................................................24
8Technical Specification...........................................................................................................................................................25
8.1 Detector Information .....................................................................................................................................................25
8.2 Electrical Specification ..................................................................................................................................................25
8.3 Mechanical Specification .............................................................................................................................................25
8.4 Environmental Specification.........................................................................................................................................25
8.5 Certification and Approvals .........................................................................................................................................26
8.6Operating Specification ................................................................................................................................................26
8.7 FGard IR3 Detector Ordering Information...............................................................................................................27
8.8 Detector Accessories and Spares .............................................................................................................................27
9Appendix A - Acronyms, Terms & Abbreviations ...........................................................................................................28
10 Appendix B - Help us to help you. .................................................................................................................................29
11 Appendix C - Field of View...............................................................................................................................................30
12 Appendix D - FM Approval Performance Report.......................................................................................................31
13 Appendix E – Marine Certification..................................................................................................................................33
14 Appendix F - IEC 61508 Failure Rate Data ..................................................................................................................34

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1Introduction
This safety and technical manual applies to the Crowcon IR3 Flame Detector (FGard IR3) hardware version 1.0
and above.
The Crowcon FGard IR3 is a (triple) IR flame detector. It uses three IR sensors, digital signal processing
hardware and firmware algorithms to interpret the radiant characteristics of flame.
FM Approvals ensures that our flame detection firmware and hardware is fit for purpose through rigorous
research and testing to a range of fire types and various potential false alarm stimuli. This testing proves that the
FGard IR3 has an unsurpassed false alarm immunity.
The FGard IR3 has been designed for use in standalone operation.
1.1 Detector Features
•The FGard IR3 has a 90° cone of vision with a range of 60 metres to a 0.1m2pan fire of n-heptane.
•Three detection sensitivity settings allowing the user to select the sensitivity that is most suitable for their
application.
•Superior false alarm immunity to common sources of unwanted alarms such as hot process and hot
work.
•Advanced optical verification test assuring readiness to perform when needed.
•Outputs include both relay contacts and 0-20mA.
•Separate termination chamber for ease of installation.
•Certified Flame Simulator FGard SIM verifies operation from distances of 3 to 8 metres.
•FGard IR3 can operate via a standard 3 or 4 wire termination.
•Microprocessor controlled heated optics increases resistance to moisture and ice.

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2Safety Instructions
For the correct and effective use of this equipment, to maintain safety and avoid hazards it is essential that you
read and understand these instructions fully and act accordingly BEFORE installing, operating, or maintaining the
equipment.
PAY ATTENTION TO ALL SAFETY WARNINGS AND CAUTIONS
2.1 Specific conditions of use
This equipment is certified and intended for use in potentially hazardous areas. Install and use the equipment in
accordance with the latest regulations. The end user shall close any unused entries using suitably certified
blanking elements to maintain the housing’s type of protection.
For European (ATEX) installations IEC/EN60079-14 ‘Electrical Installations in Hazardous Areas’ and
ICE/EN60079-17 ‘Inspection and Maintenance in Hazardous Areas’ should be strictly observed. The IR3 type
flame detector; Crowcon FGard IR3, is to be installed in places where there is a low risk of mechanical damage.
For installations in North America the National Electrical Code (NEC) should be strictly observed. In other
countries the appropriate local or national regulations should be observed.
The equipment must be properly earthed to protect against electrical shock and minimise electrical interference.
Do not drill holes in any housing or enclosure as this will invalidate the explosion protection. Ensure that the
enclosure lid is fully tightened and locked into position before energising the equipment.
Do not open the enclosure in the presence of an explosive atmosphere.
All permits and proper site procedure and practices must be followed, and the equipment must be isolated from
the power supply before opening the enclosure in the field.
Operators must be properly trained and aware of what actions to take in the event of a fire being detected.
Cable to be used for installation is to be selected with a temperature rating of greater than 25 degrees Celsius
above the maximum ambient temperature. The metric cable entries are fitted with an internal stop. This will result
in threads of the cable gland being visible. Do not over tighten.
2.2 Cautions
Use only approved parts and accessories with this equipment.
Do not attempt to replace the window as the sapphire and the front cover are individually matched pairs to meet
the stringent requirement of the hazardous area certification.
The threaded portions of the detector are flame paths. These threads and the flame paths are not to be repaired.
To maintain safety standards, commissioning and regular maintenance should be performed by a qualified
person.
2.3 Important Safety Notices
Pay attention to the guidelines given throughout this document.
If in any doubt about the instructions listed within this manual, then please contact Crowcon. Crowcon takes no
responsibility for installation and/or use of its equipment if it is not in accordance with the appropriate issue
and/or amendment of the manual. Crowcon reserve the right to change or revise the information contained
herein without notice and without obligation to notify any person or organisation of such action.

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Only those parameters and configurations highlighted with the FM diamond ( ) have been tested and
approved by Factory Mutual.
Warning
Do not open the detector assembly in a hazardous area. The detector contains limited serviceable components
and should only be opened by trained personnel.
Caution
The wiring procedures in this manual are intended to ensure functionality of the device under normal conditions.
Due to the many variations in wiring codes and regulations, total compliance to these ordinances cannot be
guaranteed. Be certain that all wiring complies with all local ordinances. If in doubt, consult the authority having
jurisdiction before wiring the system. Installation must be done by trained personnel.
Caution
To prevent unwanted actuation or alarm, extinguishing devices must be inhibited/isolated prior to performance
testing or maintenance.
Detector Orientation
Detectors should be mounted with the earth stud directly below the lens.
Detector Positioning
Detectors should be positioned to provide the best unobstructed view of the area to be protected.
The following factors should also be taken into consideration:
Identify all high-risk fire ignition sources. Ensure that enough detectors are used to adequately cover the
hazardous area.
Locate and position the detector so that the fire hazard(s) are within both the field of view and detection range
of the device.
For best performance, the detector should be mounted on a rigid surface in a low vibration area.
Extremely dense fog or blizzard conditions could eventually block the vision of the detector.
For indoor applications, if dense smoke is expected to accumulate at the onset of a fire, mount the detector on a
side wall (approximately 1 to 2 metres) below the ceiling.
The FGard IR3 has three sensitivity settings, which may be changed via a Crowcon application.
The flame detector carries out continuous internal hardware diagnostic testing to ensure correct operation is
relayed to the control system.
The FGard IR3 is not designed to annunciate diagnostic failure of signal returns via external wiring. Control
systems and fire panels generally have fault monitoring for such an eventuality.

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2.4 EN 54-part 10 Limitation of use
The FGard IR3 is not approved for use in oxygen-enriched atmospheres.
As the FGard IR3 responds to flame, it cannot be used in locations where flare stacks are within its field of view
or a reflected view is present without triggering alarms.
As the FGard IR3 responds to CO2emissions of a flame the FGard IR3 cannot detect non-hydrocarbon fires,
such as those using pure hydrogen, silane, and sulphur as fuel.
The sensitivity of the FGard IR3 is reduced by obscurants such as smoke, fog, and other airborne particulates.
The FGard IR3 may be blinded by extremely dense obscurants.
Arc welding should not take place within 10m of the FGard IR3 when using the highest sensitivity setting.
3Installation
The FGard IR3 design has been developed to allow simple installation. The detector comprises two key
components, the detector enclosure, and the detector internal assembly. The detector assembly located in the
front of the enclosure should not be removed except by trained personnel. Unauthorised removal or disassembly
of the detector assembly will invalidate the warranty. Only the rear end cap can be removed for terminal access.
3.1 Detector Enclosure
The detector electronics are housed in an enclosure certified for use in hazardous areas. For the exact
certification and conditions of use see certification label on the device, or the example drawing below:
The enclosure comprises the front window cover including the window part number 3303.8004, the rear
enclosure cover part number 2301.6009, the enclosure body part number 2301.6007, certification rating label
(see above) part number 3303.6008.04, and the mounting bracket Part Number 2301.6012.
3.2 Mounting & Orientation
The mounting bracket allows the detector’s vertical orientation to be adjusted from 0 to 45° and allows a
horizontal rotation of +/-45° when mounted from above.
Figure 1: Detector Mounting Bracket

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Figure 2: Ceiling Mount
Figure 3: Wall Mount
Firm, vibration free mountings are essential for trouble free operation of optical systems and the detector should
be fixed to a rigid mounting. When mounting on a wall in this orientation allow for the cable gland and cable as
this may restrict the downward rotation of the detector.

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3.3 Wiring Procedure
The wiring terminals are in the rear section of the detector enclosure and are accessible by removal of the end
cap.
The front section of the enclosure should only be accessed by trained personnel.
The terminal schematic detailed below shows the view looking inside the detector following removal of the end
cap.
Figure 4: Terminal Schematic
The detector has two types of alarm output available simultaneously.
• 0-20mA (source non-isolated)
• Relay (Alarm & Fault)
Listed below are wiring options dependent on the functional requirements of the detector.