General Monitors IR400 User manual

Model IR400
Infrared Point Detector for
Hydrocarbon Gas Applications
The information and technical data disclosed in
this document may be used and disseminated
only for the purposes and to the extent
specifically authorized in writing by General
Monitors.
Instruction Manual 05-11
General Monitors reserves the right to change
published specifications and designs without
prior notice.
Part No. MANIR400-EU
Revision D/05-11

Model IR400
iii
Table of Contents
TABLE OF FIGURES ...................................................................................................................V
TABLE OF TABLES.....................................................................................................................V
QUICK-START GUIDE................................................................................................................. 2
1.0 INTRODUCTION .................................................................................................................... 5
1.1 Protection for Life .......................................................................................................................5
1.2 Special Cautions and Warnings.................................................................................................5
1.3 Installation, Operation, and Maintenance ..................................................................................5
2.0 PRODUCT DESCRIPTION..................................................................................................... 6
3.0 INSTALLATION...................................................................................................................... 8
3.1 Attaching the IR400 to a Junction Box, IR4000S, or IR4000M..................................................9
3.2 Mounting Instructions...............................................................................................................10
3.3 Wiring Connections ..................................................................................................................13
3.4 Applying Power ........................................................................................................................15
4.0 OPERATION AND CONFIGURATION ................................................................................ 17
4.1 Zeroing, Gas Check Tests, and Calibration.............................................................................17
4.2 IR400 Stand-alone Operation and Configuration.....................................................................20
4.3 HazardWatch Mode .................................................................................................................23
4.4 Gas Check Mode .....................................................................................................................23
4.5 Detector Response Time .........................................................................................................23
5.0 MAINTENANCE ................................................................................................................... 25
5.1 Developing a Maintenance Schedule ......................................................................................25
5.2 Gas Checks, Zeroing and Recalibration ..................................................................................25
5.3 Cleaning and Lubricating the IR400 and IR4000 Units............................................................26
5.4 Storage.....................................................................................................................................26
6.0 TROUBLESHOOTING ......................................................................................................... 27
7.0 MODBUS INTERFACE ........................................................................................................ 29
8.0 CUSTOMER SUPPORT ....................................................................................................... 30

Model IR400
iv
9.0 APPENDIX............................................................................................................................ 31
9.1 Warranty...................................................................................................................................31
9.2 Principle of Operation...............................................................................................................32
9.3 Specifications ...........................................................................................................................33
9.4 Environmental Specifications...................................................................................................36
9.5 Communications ......................................................................................................................36
9.6 Engineering Documentation.....................................................................................................37
9.7 Ordering Information ................................................................................................................38
IR400 HART COMMUNICATION
IR400 MODBUS PROGRAMMING

Model IR400
v
Table of Figures
Figure 1a: IR400 with Junction Box........................................................................................................................ 2
Figure 1b: IR400 with European Junction Box ....................................................................................................... 2
Figure 2: Wiring Diagram from IR400 to Control Equipment.................................................................................. 4
Figure 3: Model IR400 ............................................................................................................................................ 6
Figure 4a: Model IR400 with a junction box ........................................................................................................... 9
Figure 4b: Model IR400 with a European junction box........................................................................................... 9
Figure 5a. IR400 Mounting Dimensions .............................................................................................................. 10
Figure 5b IR400 Mounting Dimensions with a European Box............................................................................. 11
Figure 6a: IR400 with Junction Box...................................................................................................................... 15
Figure 6b: IR400 with European Junction Box ..................................................................................................... 15
Figure 7: Wiring Diagram from IR400 to Control Equipment................................................................................ 16
Figure 8. IR400 Zero Switch / LED During Zeroing and Calibration .................................................................... 21
Figure 9 IR400 Optical Window Locations .......................................................................................................... 26
Table of Tables
Table 1: Wiring Chart.............................................................................................................................................. 3
Table 2: Wiring Chart............................................................................................................................................ 13
Table 3: IR400 without HART Option ................................................................................................................... 19
Table 4: IR400 with HART Option ........................................................................................................................ 19
Table 5: GM Locations.......................................................................................................................................... 30
Table 6: Analog Current Output............................................................................................................................ 35
Table 7: Maximum Distance between IR400 and Power Source......................................................................... 35
Table 8: Maximum Distance between IR400 and 500-Ohm Input Impedance..................................................... 35

Model IR400
2
Quick-Start Guide
Mounting and Orientation
The Model IR400 should be mounted horizontally (Figure 1a/Figure 1b) to reduce the likelihood
of dirt and dust build-up on the windows. For optimum performance, the splashguards should
be located on the top and bottom as shown in Figure 1a/Figure 1b. Apply the supplied thread
lubricant/sealant to all conduit entries before use to prevent binding.
Figure 1a: IR400 with Junction Box
Figure 1b: IR400 with European Junction Box

Model IR400
3
Wiring Connections
TERMINAL WIRE COLOR SIGNAL
1 BLACK COM
2 GREEN FIELD GROUND (FG)
3 RED +24 V
4 WHITE 4-20 mA
5 BLUE MOD1+
6 WHT/BLU MOD1 -
7 BROWN CAL
8 - MOD2+ (no connection for IR400)
9 - MOD2 - (no connection for IR400)
10 - No Connection
Table 1: Wiring Chart
•NOTE: Power should remain disconnected until all other wiring connections are made.
Power Connections
To supply power to the IR400, connect the red lead from the IR400 to the +24 VDC terminal on
the power supply. Connect the black lead from the IR400 to the power supply Common. Refer
to the manual of the power source being used, for more detailed instructions.
•NOTE: If the Model IR400 is being used with a +24 VDC power supply and an
industrial analog to digital (A/D) converter, then the negative supply (Common) of all
three must be connected.
Applying Power
Before applying power to the system for the first time, all wiring connections should be checked
for correctness. Upon initial power-up or after a fault condition has been corrected, the unit will
enter a start-up mode for 2 minutes before normal operation. IR400 Ethylene start-up can take
up to 10 minutes. As a unit warms up, output may briefly be negative.
After power is applied, the IR400 should be allowed to stabilize for approximately 60 minutes
while the unit attains the proper operating temperature. After stabilization, it is recommended
that the IR400 be zeroed, per the procedure in section 4.1 (step 1 only). A gas check should
then be performed to ensure that the unit is operating properly. Use the General Monitors Gas
Check Kit (P/N 32548) to perform this check.

Model IR400
4
Figure 2: Wiring Diagram from IR400 to Control Equipment
The instrument is now ready to operate. Please further consult this manual for more information
on the instrument’s many features.

Model IR400
5
1.0 Introduction
1.1 Protection for Life
General Monitors’ mission is to benefit society by providing solutions through industry-leading
safety products, services and systems that save lives and protect capital resources from the
dangers of hazardous flames, gases and vapors.
The safety products you have purchased should be handled carefully and installed, calibrated
and maintained in accordance with this instruction manual. Remember, these products are for
your safety.
1.2 Special Cautions and Warnings
This instruction manual includes numerous cautions and warnings that are included to prevent
injury to personnel and prevent damage to equipment.
WARNING: TOXIC, COMBUSTIBLE, AND FLAMMABLE GASES AND VAPORS ARE VERY
DANGEROUS. USE EXTREME CAUTION WHEN THESE HAZARDS ARE PRESENT.
1.3 Installation, Operation, and Maintenance
Before power up, verify wiring, terminal connections and stability of mounting for all integral
safety equipment.
Proper system operation should be verified by performing a full, functional test of all component
devices of the safety system, ensuring that the proper levels of alarming occur.
Fault/malfunction circuit operation should be verified.
Periodic testing/calibrating should be performed per the manufacturer’s recommendations and
instructions.
When testing produces results outside of the manufacturer’s specifications, re-calibration or
repair/replacement of the suspect device(s) should be performed as necessary. Calibration
intervals should be independently established through a documented procedure, including a
calibration log maintained by plant personnel, or third party testing services.

Model IR400
6
2.0 Product Description
General Description
The Model IR400 infrared (IR) point detector is a microprocessor-based combustible gas
detector, is calibrated at the factory and needs no routine field calibration. Applying a test gas
to the unit can check the sensitivity of the IR400. It is also relatively maintenance free, requiring
only a periodic cleaning of the windows and re-zeroing to ensure dependable performance.
The IR400 continuously monitors combustible gases in the lower explosive limit (LEL) range
and provides a 4 to 20 mA analog signal proportional to the 0 to 100% LEL concentration. Gas
calibration is available to LEL values defined by ISO 10156/NFPA 325 and IEC 61779-1. A
Modbus communications interface is also provided for informational / programming purposes.
Sensor data and status information from the IR400 can be transmitted to a variety of General
Monitors’ readout units.
The IR400 operates from an unregulated +24 volt DC supply, which can be supplied by the
customer, or is supplied by General Monitors’ Model DC130 readout units.
Figure 3: Model IR400