General Monitors IR5500 User manual

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 08-16
General Monitors reserves the right to change
published specifications and designs without prior
notice.
MANIR5500
Part No. MANIR5500
Revision M/08-16
MODEL IR5500
Infrared Open Path Detector for
Hydrocarbon Gas Applications

Model IR5500
i
This page intentionally left blank

Model IR5500
ii
TABLE OF CONTENTS
MODEL IR5500..................................................................................................................................I
INFRARED OPEN PATH DETECTOR FOR HYDROCARBON GAS APPLICATIONS...............I
QUICK START GUIDE.................................................................................................................V
System Mounting.................................................................................................................................... v
Conduit Sealing ......................................................................................................................................vi
Terminal Connections............................................................................................................................vii
1.0INTRODUCTION.....................................................................................................................1
1.1Protection for Life ...................................................................................................................... 1
1.2Features and Benefits ............................................................................................................... 2
1.3Applications ............................................................................................................................... 2
1.4System Integrity Verification ...................................................................................................... 3
2.0PRODUCT DESCRIPTION.....................................................................................................4
2.1General Description................................................................................................................... 4
2.1.1Infrared Detection Principles ........................................................................................ 4
2.1.2IR5500 Detection Method............................................................................................. 4
2.1.3Measurement Scale...................................................................................................... 5
2.1.4Typical System Gas Cloud Measurements .................................................................. 6
2.1.5Control Electronics ....................................................................................................... 6
3.0INSTALLATION......................................................................................................................8
3.1Receipt of Equipment ................................................................................................................ 8
3.2Location Considerations ............................................................................................................ 8
3.3System Mounting....................................................................................................................... 9
3.4Installation................................................................................................................................ 10
3.5Conduit Sealing ....................................................................................................................... 11
3.6Terminal Connections.............................................................................................................. 11
3.6.1Terminal Block Operation ........................................................................................... 14
3.6.2Terminal Functions ..................................................................................................... 15
3.7Applying Power and Alignment................................................................................................ 16
3.7.1Start-Up Checklist....................................................................................................... 16
3.7.2Startup ........................................................................................................................ 16
3.7.3Alignment and Adjustment.......................................................................................... 17
3.7.4Response Test ........................................................................................................... 18
3.7.5Visible Light Filter ....................................................................................................... 18
3.8Operational Cautions............................................................................................................... 19
3.8.1Rapid and Massive Liquid Propane Releases............................................................ 19
3.8.2Solutions to Guard against These Situations ............................................................. 19
4.0OPERATION.........................................................................................................................21
4.1Using the IR5500 Menus ......................................................................................................... 21
4.2Menu Options .......................................................................................................................... 23
4.3Test “---”................................................................................................................................... 23

Model IR5500
iii
4.4Setup “SE” ............................................................................................................................... 23
4.5Flash Input “in”......................................................................................................................... 33
4.6Alignment/Adjustment “Pct” or “AJ” ......................................................................................... 35
4.7Log – Fault Log and Zero ........................................................................................................ 37
4.8Finish “Fi”................................................................................................................................. 39
4.9Maintenance ............................................................................................................................ 39
4.10Display and Fault Codes ......................................................................................................... 39
4.11LEL and ppm Negative Drift Faults ......................................................................................... 39
5.0TROUBLESHOOTING..........................................................................................................41
5.1Fault Codes ............................................................................................................................. 41
5.1.1F0 Excess Negative Drift............................................................................................ 42
5.1.2F1 Close to Low IR ..................................................................................................... 42
5.1.3F3 Beam Block ........................................................................................................... 43
5.1.4F4 IR Flash Timing ..................................................................................................... 43
5.1.5F5 Setup Menu ........................................................................................................... 43
5.1.6F6 Low Voltage Input at the Receiver ........................................................................ 43
5.1.7F7 Code Checksum.................................................................................................... 43
5.1.8F8 Fault during Zeroing .............................................................................................. 43
5.1.9F9 Gas Left................................................................................................................. 43
5.1.10F10 Reset Short ......................................................................................................... 43
5.1.11F11 Receiver Overheating.......................................................................................... 44
5.1.12F12 IR Flash Intensity Variation ................................................................................. 44
5.1.13F13 Non-Volatile Memory (NVM) Checksum ............................................................. 44
5.1.14F14 Analog Output for LEL-m .................................................................................... 44
5.1.15F15 Receiver Heater .................................................................................................. 44
5.1.16F16 High IR ................................................................................................................ 45
5.1.17F18 Dirty Lens ............................................................................................................ 45
5.1.18F19 Magnet ................................................................................................................ 45
5.1.19F20 Low Alignment Signal.......................................................................................... 45
5.1.20F21 Zeroing ................................................................................................................ 45
5.1.21F22 RAM Checksum .................................................................................................. 45
5.1.22F23 Hardware Revision .............................................................................................. 45
5.1.23F24 Receiver Temperature Sensor ............................................................................ 46
5.1.24F25 Analog Output for ppm-m .................................................................................... 46
5.1.25tF6 Low Voltage Input at the Source .......................................................................... 46
5.1.26tF7 Source Heater ...................................................................................................... 46
5.1.27tF8 Source Overheating ............................................................................................. 46
5.2Other Troubleshooting Tips ..................................................................................................... 46
5.2.1Source does not flash................................................................................................. 46
5.2.2Receiver does not display startup sequence when power is applied......................... 47
5.2.3Receiver displays ]-[ during alignment ....................................................................... 47
5.2.4Receiver displays F1 or F3 after alignment................................................................ 47
5.2.5Receiver does not respond to the magnet ................................................................. 47
5.2.6Receiver signal level number went to 0 with no “A” on the display ............................ 47
5.2.7Receiver displays information other than described .................................................. 47
5.2.8Source or Receiver will not move............................................................................... 47
6.0CUSTOMER SUPPORT.......................................................................................................48

Model IR5500
iv
7.0APPENDIX............................................................................................................................49
7.1Warranty .................................................................................................................................. 49
7.2Specifications........................................................................................................................... 50
7.2.1System Specifications ................................................................................................ 50
7.2.2Electrical Specification................................................................................................ 51
7.2.3Mechanical Specification ............................................................................................ 51
7.2.4Environmental Specification ....................................................................................... 52
7.2.5Approvals.................................................................................................................... 52
7.2.6Cable Requirements................................................................................................... 52
7.3Spare Parts and Accessories .................................................................................................. 53
7.3.1Spare Parts................................................................................................................. 53
7.3.2Accessories ................................................................................................................ 53
7.4Engineering Documentation .................................................................................................... 54
8.0APPENDIX A........................................................................................................................55
8.1Split-Range Analog Output Option .......................................................................................... 55
8.2Alignment Using Legacy AJ Value .......................................................................................... 56
Table of Figures
Figure 1: IR5500 Open Path Gas Detector.................................................................................. 1
Figure 2: Indoor Gas Cloud.......................................................................................................... 5
Figure 3: Outdoor Gas Cloud....................................................................................................... 5
Figure 4: Outline and Dimensional Drawing with Mounting Options............................................ 9
Figure 5: Installation onto Mounting Arm ................................................................................... 10
Table of Tables
Table 1: Readings of Methane Gas Clouds 0-5000 ppm•m Range .............................................. 6
Table 2: Readings of Methane Gas Clouds 0-5 LEL•m Range..................................................... 6
Table 3: Receiver Wiring Terminal Locations ............................................................................. 14
Table 4: Locations....................................................................................................................... 48
Table 5: Distances from Power Supply to Source and Receiver ................................................ 52
Table 6: Distances from Receiver to Analog Output Load.......................................................... 53

Model IR5500
Quick Start Guide
v
Quick Start Guide
System Mounting
The Model IR5500 units are shipped with either mounting assembly shown below. After
the mounting location has been established, mount the support arm/base. Attach a pan-tilt
assembly to each unit. Apply lithium grease on each taper joint before attaching a unit to
a support arm/base. Add the supplied bolt and washers; do not tighten until unit is fully
adjusted. If the bolt has been tightened and further adjustment is necessary, loosen the
bolt two turns and use a screwdriver between the pan-tilt assembly and arm to release the
taper.
Arm Assembl
y
with Fine Ad
j
ustments Basic Arm Assembly
Base Assembl
y
with Fine Ad
j
ustments

Model IR5500
Quick Start Guide
vi
Conduit Sealing
Each conduit run from a hazardous to a non-hazardous location should be sealed so that
gas or flames cannot pass from one electrical installation to another through the conduit
system. A conduit seal must also be installed within 18 inches of the Source and Receiver
enclosure if installed in a Division 1 location. A conduit seal may not be required if installed
in a Division 2 location.
General Monitors requires the use of a drain loop or conduit seal in the conduit to prevent
moisture from entering the unit housing. For installation in a Division 2 location using
Division 2 wiring methods, a drain loop or conduit seal may not be required. Consult
Article 501 of the NEC for details.
WARNING: The conduit entries should be sealed per the NEC 501.15 or Canadian
Electrical Code Handbook (Part 1, Section 18-154) for Division 1
installations.
WARNING: Unused cable entry holes must be sealed with an approved explosion-proof
stopping plug.
CAUTION: Acetic acid will damage metal components, hardware, and other
components. If damage results from the use of a sealant that outgases
acetic acid such as a room temperature vulcanizing sealant (RTV), the two-
year warranty will be void.
CAUTION: Consult the manufacturer for dimensional information on the flameproof
joints for repair.

Model IR5500
Quick Start Guide
vii
Terminal Connections
To make the wiring connections to the Model IR5500, loosen the retaining screw on the
cover of each unit using the supplied hex wrench and unscrew the rear cover. All output
connections are made inside the housing (see figures on following page for terminal block
locations). Recommended stripping length is 4/10” (10 mm) for push terminals, ½” (11
mm) for screw terminals.
NOTE:Contact with printed circuit board (PCB) components should be avoided to
prevent damage by static electricity.

Model IR5500
Quick Start Guide
viii
9 10 11 12 13 14 15 16
+24V
COM
0-20mA L
COM
0-20mA P
COM
RST
COM
8 MOD1- Modbus1- Modbus2- MOD2- 17
7 MOD1+ Modbus1+ Modbus2+ MOD2+ 18
Normally
De-
energized
Normally
Energized Normally Energized
Normally
De-
energized
6 A2 Alarm NO Alarm NC Fault NO Fault NO FLT1 19
5 AC Alarm C Alarm C Fault C Fault C FLTC 20
4 A1 Alarm NC Alarm NO Fault NC Fault NC FLT2 21
3 W2 L Warn
LEL•m NO Warn LEL•m NC Warn ppm•m NC Warn ppm•m NO W2 P 22
2 WC L Warn
LEL•m C Warn LEL•m C Warn ppm•m C Warn ppm•m C WC P 23
1 W1 L Warn
LEL•m NC Warn LEL•m NO Warn ppm•m NO Warn ppm•m NC W1 P 24
Receiver Wiring Terminal Locations

Model IR5500
Quick Start Guide
ix
Terminal Block Operation
To connect wiring to the terminal block, insert a screwdriver into the orange tab and
press down, opening the terminal (see figure below). Insert the wire into the terminal
and release the orange tab, clamping the wire in the terminal. Check the clamp by
GENTLY tugging the wire to ensure it is locked in. Make sure that the terminal clamps
on to the wire, not the insulation.
Terminal Block Operation Diagram
The push terminal block is designed to accept 24 AWG to 16 AWG (0.2 mm
2
to 1.5 mm
2
)
stranded or solid-wire. The optional screw terminal block accepts 26 AWG to 14 AWG
(0.14 mm
2
to 2.5 mm
2
) wire.
Primary DC voltage power must be provided by the customer. Since the Model IR5500
Infrared Open Path System is designed to continuously monitor for leaks of combustible
gas, a power switch is not included to prevent accidental system shutdown. Power must
remain disconnected until all other wiring connections are made.