MSA General Monitors IR4000S 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 08-17
General Monitors reserves the right to change
published specifications and designs without
prior notice.
MANIR4000S
Part No. MANIR4000S
Revision H/08-17
Model IR4000S
Single-Point Monitor

Model IR4000S
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Model IR4000S
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Table of Contents
QUICK-START GUIDE.................................................................................................................1
Cabling and Wiring .................................................................................................................................1
Applying Power.......................................................................................................................................4
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
2.1 IR4000S Monitor........................................................................................................................6
2.2 Features and Benefits ...............................................................................................................6
3.0 INSTALLATION......................................................................................................................7
3.1 Unpacking the Equipment .........................................................................................................7
3.2 Mounting....................................................................................................................................8
3.3 Cabling and Wiring..................................................................................................................10
3.4 Applying Power and Starting Operation..................................................................................15
4.0 OPERATION AND CONFIGURATION.................................................................................17
4.1 Overview..................................................................................................................................17
4.2 Gas Checking the IR400 .........................................................................................................19
4.3 Zeroing the IR400....................................................................................................................19
4.4 Calibrating the IR400...............................................................................................................20
4.5 Setup .......................................................................................................................................21
4.6 Resetting the Relays (rSt ) ......................................................................................................22
5.0 MAINTENANCE....................................................................................................................23
5.1 Developing a Maintenance Schedule......................................................................................23
5.2 Zeroing and Recalibration .......................................................................................................23
5.3 Lubricating Threads and Seals................................................................................................23
5.4 Maintaining the X/P Integrity....................................................................................................23
5.5 Storage....................................................................................................................................24
6.0 TROUBLESHOOTING..........................................................................................................25
6.1 No Display on Power Up .........................................................................................................25
6.2 IR4000S Fault Codes and Remedies......................................................................................25
7.0 MODBUS INTERFACE.........................................................................................................28
8.0 CUSTOMER SUPPORT.......................................................................................................29
9.0 APPENDIX............................................................................................................................30
9.1 Warranty..................................................................................................................................30
9.2 Specifications...........................................................................................................................31
9.3 Ordering Information................................................................................................................34

Model IR4000S
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Table of Figures
Figure 1: IR4000S Outline and Mounting Dimensions, in inches [mm]........................................................1
Figure 2: IR4000S Terminal Block Connectors.............................................................................................3
Figure 3: IR4000S Single-Point Monitor .......................................................................................................6
Figure 6. IR4000S with IR400 Mounting Dimensions in inches [mm]..........................................................8
Figure 4: IR4000S Outline and Mounting Dimensions, in inches [mm]........................................................9
Figure 5: IR4000S Terminal Block Connectors...........................................................................................11
Figure 6: Push Type Terminal.....................................................................................................................12
Figure 7: Screw Type Terminal Block Operation........................................................................................12
Figure 8: Connecting IR400 Signal Wires to the TB1 Block.......................................................................13
Figure 9: Relay Protection for DC and AC Loads.......................................................................................14
Figure 10: Front Panel Display and Indicators............................................................................................17
Figure 11: IR4000S Menu Structure...........................................................................................................18
Table of Tables
Table 1: IR400/IR4000S Installation Overview.............................................................................................7
Table 2: TB3 Relay Contacts Energized/De-Energized Settings................................................................14
Table 3: 24VDC Cable Lengths..................................................................................................................32
Table 4: Analog Output Cable Lengths.......................................................................................................32

Model IR4000S
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Quick-Start Guide
Special tools:
5mm Allen wrench for cover (included with unit)
0.1” flat-head screwdriver for wiring (included with unit)
Adjustable wrench for conduit or cable gland connections (not included).
Mounting:
Allow convenient access to the front panel display and magnet switch input.
Leave sufficient room to attach cabling. Keep cable run distances below specified limits.
Although the Model IR4000S is RFI-resistant, where possible, mount it away from heavy
power cabling, radio transmitters, or similar equipment.
Where possible, locate the IR4000S away from excessive heat and vibration and as free
as possible from wind, dust, water, and direct sunlight.
MODEL IR4000M P/N 32580
CONFIG
MAN
S/N
0518
0539
CALIBRATION PROCEDURE
1. HAVE DETECTOR IN CLEAN AIR
2. APPLY MA GNET, AND WAIT FOR " AC"
ON DISPLAY
3. REMOVE MAGNET, WHEN d# IS
DISPLAYED, APPLY MAGNET TO
SELECT DETECTOR #
4. REMOVE MAGNET, FLASHING "AC"
IS DISPLAYED
5. WHEN "AC" IS STEADY, APPLY GAS
6. WHEN GAS IS DETECTED, "CP"IS
DISPLAYED
7. WHEN CALIBRATION IS COMPLETE,
"CC" IS DISPLAYED
8. REMOVE GAS
ALARM LED
WARN LED
YEAR OF CONSTRUCTION
Figure 1: IR4000S Outline and Mounting Dimensions, in inches [mm]
NOTE: Nameplate is for reference purposes only and may not contain up-to-date
information.

Model IR4000S
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Cabling and Wiring
WARNING: Seal conduit entries per Class I hazardous location requirements. Under NO
circumstances should equipment be connected or disconnected when under power.
Equipment damaged in this manner is not covered under warranty.
CAUTION: Do not use a sealant that contains acetic acid. Use precautions to avoid
equipment damage by static electricity.
The cable armor must be connected to safety earth in the safe area.
The cable screen (drain wire) must be connected to an instrument earth in the
safe area.
Three-wire shielded cable is recommended for power and signal connections.
The push terminal blocks accept 14 AWG to 24 AWG stranded or solid wire. The
screw terminal blocks accept 12 to 28 AWG.
Power to the IR4000S must remain OFF until all wiring is completed and the
start-up readiness checklist has been verified. Wire installation order:
1. Common (COM) and Field Ground (FG) wires
2. Modbus (MOD), Analog (mA), CAL and relay wires (RLY, ALARM,
WARN, and FAULT)
3. 24 VDC power
NOTE: Suitably rated cable glands must be used in order to maintain the IP66 ingress
protection and hazardous locations protection concepts of the IR4000S in
accordance with EN/IEC 60079-14

Model IR4000S
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Figure 2: IR4000S Terminal Block Connectors
TB 3 - Relay Terminal
Pin # DE-ENERGIZED ENERGIZED
1 ALARM-NC ALARM-NO
2 ALARM-C ALARM-C
3 ALARM-NO ALARM-NC
4 WARN-NC WARN-NO
5 WARN-C WARN-C
6 WARN-NO WARN-NC
7 FAULT-NC FAULT-NO
8 FAULT-C FAULT-C
9 FAULT-NO FAULT-NC
TB2 - HOST Terminal
Pin # SIGNAL
1 4-20 mA out
2 IR400 MOD -
3 IR400 MOD +
4 NOT USED
5 NOT USED
6 CAL/ARGC
7 RLY RST
8 COM
9 +24 V IN
TB1 - Detector Terminal
Pin # SIGNAL
1 4-20 mA IN
2 CAL IN
3 COM
4 FGND
5 IR400 MOD +
6 IR400 MOD -
7 COM
8 +24 V
9 +24 V
TB1
Detector TB2 Host TB3
Relay

Model IR4000S
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Applying Power
Before applying power for the first time, check the following:
Verify that the junction box lid is securely installed, unless the area has been
declassified.
Inhibit any external devices, such as Trip Amplifiers, PLC devices or DCS
systems.
Verify that the power supply is connected properly. The Model IR4000S and
IR400 are powered by +24 VDC (20 to 36 VDC voltage range). The IR4000S will
display a fault code of bF6 if the power supply voltage is at or below 18 VDC.
IR4000S display sequence on power-up:
000 and Alarm indicator
All display elements (8.8.8.) and both Alarm and Warn indicators
Software revision (example: r C)
bSU (base Start Up)
SU (IR400 Start Up)
Gas concentration in % LEL
Please consult the remainder of the manual for more information on calibration,
operation, and other product features.
NOTE: The IR4000S is compatible with point IR detectors Model IR400 and Model
IR2100. This manual refers to the connected detector as IR400 throughout but all
instructions also apply to the IR2100 unless otherwise noted.

Model IR4000S
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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.
Specific Condition of Use
Flamepath joints are not intended for repair.
A damp cloth must be used if cleaning to avoid buildup of electrostatic charges
for Group III installations.
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 check and calibration intervals should be independently established through a
documented procedure, including a calibration log maintained by plant personnel, or third
party testing services.

Model IR4000S
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2.0 Product Description
Figure 3: IR4000S Single-Point Monitor
NOTE: Nameplate is for reference purposes only and may not contain up-to-date
information.
2.1 IR4000S Monitor
The Model IR4000S Single-Point Monitor is a display and user interface for the Model
IR400 point IR gas detector. The monitor allows local calibration and displays gas
concentration. Relays are optional. The relays provide output for Alarm, Warn, and Fault
conditions.
2.2 Features and Benefits
The IR4000S system enhances the features and benefits of the IR400 in several
important ways:
Local interface provides ease of maintenance and accessibility
Bright display permits clear indication
Explosion-proof enclosure and magnetic interface allow installation and
calibration in hazardous locations
Optional 8 Amp relays expand system functions, potentially eliminating the need
for additional equipment such as a PLC