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Summary of Contents for Crowcon IR PLUS
- Page 1 USER MANUAL IR PLUS Infrared Hydrocarbon Detector with Intelligent Heated Optics November 2024 M07031/ENG...
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Page 2: Table Of Contents
INSTALLATION Warning Location Storage Mounting Cabling directly to the IR Plus 2.5.1 Terminal Designation 2.5.2 Installing IR Plus using a mounting bracket Installing using a Spigot Gland and Auxiliary Junction Box Cabling Requirement Connections and Settings OPERATION Warning Commissioning Procedure... - Page 3 9.6.3 Cabling Requirement 9.6.4 How to fit IR Plus to a junction box 9.6.5 Field Cable Termination Exe Junction Box Pipe Mount 9.7.1 Kit Contents 9.7.2 Specification PC Communications Kit 9.8.1 Using the PC Communication Kit WARRANTY CONTACTS IR Plus User Manual | 3 ©2024 Crowcon Detection Instruments Ltd.
- Page 4 The display enables both local and remote monitoring of readings from the IR Plus. It can be directly attached to the IR Plus or connected via an Intrinsically Safe (IS) Barrier module using temporary or permanent cabling. Figure 2 illustrates the available options.
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Page 5: Safety Information
The IR Plus detector must be installed, operated and maintained in strict accordance with these instructions, warnings, label infor- mation, and within the limitations stated. • The rear nut on IR Plus must be kept tightly closed during operation. Do not attempt to remove the rear nut until power to the detector is isolated - otherwise ignition of a flammable atmosphere can occur. Before removing the nut for maintenance or servicing, check that the surrounding atmosphere is free of flammable gases or vapours. Do not open until several minutes after the power has been removed. -
Page 6: Introduction
NOTE: The IR Plus body is supplied with either two cable entries; M20 or ¾” NPT. One of the cable entries to the IR Plus product will be sealed using a certified plug. The IR Plus must be installed with both cable entries sealed: one with a cable gland, the other with a certified IP66 rated stopping plug or cable gland. - Page 7 Fixed Display Module 10. Fixed Display or IS Barrier Connecting lead (E07987) 11. IS Barrier Module 12. Remote Display or access box lead (E07988/E08005) 13. Remote Display mounting bracket (M03833) 14. Remote Display (C011161 or C011162) 7 | IR Plus User Manual ©2024 Crowcon Detection Instruments Ltd.
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Page 8: Installation
• Detectors supplied without a display are certified Ex db and cannot be retro- fitted for use with a Fixed Display. LOCATION The IR Plus 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, such as methane, detectors should be mounted at high level. To detect heavier- than-air gases, such as flammable vapours, detectors should be mounted at low level. Consider also the likely temperature of... -
Page 9: Cabling Directly To The Ir Plus
The 6-pin connector on the left of the PCB is for servicing and/or connection of a Fixed Display or IS Barrier module 2.5.2 INSTALLING IR PLUS USING A MOUNTING BRACKET IR Plus can be mounted directly using the built-in mounting lugs on IR Plus or wall mounting brackets (C011404) or pipe mounting brackets (C011405). 9 | IR Plus User Manual ©2024 Crowcon Detection Instruments... -
Page 10: Installing Using A Spigot Gland And Auxiliary Junction Box
Once the IR Plus is securely fixed in place, remove the IR Plus rear nut to enable access to the cable terminals. P repare the field cable – Crowcon recommends 1.5 mm2 Steel Wire Armoured (SWA) cable. Other cable types may be used provided they are compatible with Ex d certified glands. Fit a suitably certified Ex d cable gland, pass the cable conductors through the body of the IR Plus and screw in the cable gland. Secure the gland and ensure the cable armour is grounded to the cable gland and the IR Plus body. NB. Don’t forget to re-fit the rear nut after installing the cable. The retaining plate (item 7 on Figure 2) must be securely fitted to prevent any risk of the rear nut (or Fixed Display or IS Barrier module accessory) vibrating loose. -
Page 11: Cabling Requirement
The maximum recommended cable length is 3.4 km (see Table 1). IR Plus requires a dc supply of 12-30Vdc. Ensure there is a minimum of 12V at the IR Plus from the control panel, taking into account the voltage drop due to cable resistance at a peak power of 5.5W. -
Page 12: Operation
Check that: a. The cable connections are correct b. The supply voltage is set at the control card as 18 to 30 V. The voltage measured at the IR Plus PCBA terminals or within the Exe auxiliary junction box (if used) must be between 12 V and 30 V. -
Page 13: Routine Maintenance
Warranty will be voided if evidence of PCB removal is found. In the event of the IR Plus mirror becoming damaged or corroded, a replacement of the mirror is advised. Follow the below instructions;... -
Page 14: Specification
IR Plus with Fixed Display II 2 G Ex db ia IIC T4 Gb (-40°C to +70°C) IR Plus with IS Barrier module (for remote display): II 2 GD Ex db ia IIC T4 Gb (-40°C to +70°C) Ex tb ia IIIC T135°C Db (-40°C to +40°C) IR Plus User Manual | 14 ©2024 Crowcon Detection Instruments... -
Page 15: Accessories And Spare Parts
Enables mounting to a wall. C011410 Mesh Filter Stainless steel mesh filter with 100 micron pore-size. Fits within standard weather-cap to protect optical components in very dusty environments. This accessory increases the response time of IR Plus. C011405 Pipe Mounting Kit Enables mounting to a 2" (50 mm) pipe. C011406 Junction Box Mounting Kit Enables mounting of IR Plus and junction box to a 2" (50... - Page 16 S012295 M20 316SS Exd Junction ATEX/IECEx certified 316SS Exd junction box with 2 cable entries. Fitted with 5-way terminal block suitable for 2.5mm2 cables. Enables IR Plus to be connected on an RS- 485 Modbus network. (requires spigot gland) C03579 Spanner Essential for Fixed IR Display Module and IS Barrier Module installation. Simplifies tightening of the threaded...
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Page 17: Spares
Detector in start-up Wait 10 seconds. Fast flash on and off or Supply voltage too low or too high. Ensure the IR Plus supply voltage is correctly set. Ensure irregular flash pattern. measurement is made directly at the detector terminals. Permanently on. Fault, host or i-module error. -
Page 18: Analogue Output
LINEAR BUS CONNECTION In a bus-connected topology all IR Plus are wired to a linear arrangement, usually with the control panel at one end. A classic situation is a tunnel installation, with IR Plus installed at regular intervals (see Figure 8). -
Page 19: Cabling Requirement
Contact Crowcon for advice in specific cases. Alternatively, follow the steps outlined below and the sample calculation shown in the next section. The voltage must not fall below 12V, so start the calculation by setting the voltage at the last IR Plus in the line at that value. Each IR Plus may draw up to 0.45A. Calculate the cable voltage loss of the first ‘hop’ between detectors by taking the ‘aggregate current’ to be 0.45A, and multiply this by the cable resistance of the ‘hop’ between the last and the last but one IR Plus. -
Page 20: Functional Safety Manual
8. FUNCTIONAL SAFETY MANUAL INTRODUCTION The following sections provide detail on the certification of IR Plus in accordance with the IEC 61508 and EN 50402 Functional Safety standards. Information is given on the features considered in the safety case, maintenance requirements and data to enable IR Plus to be integrated into Safety Instrumented System (SIS). IR PLUS SAFETY FUNCTION To measure the concentration of flammable gas and indicate the measurement by means of a 4-20mA output. Failures in respect of the safety function will be detected by the hardware and associated firmware. They will be revealed as an output signal of less than 3.6mA or more than 21mA updated once per second. -
Page 21: Hardware Configuration
The product shall be stored over a maximum ambient temperature range of -40°C to +80 °C. The product shall be operated over a maximum ambient Relative Humidity range of 0% to +100% condensing for temperature changes of up to 30 °C/hour. The product has an Ingress Protection rating of IP66 according to the definitions within standard EN60529. 21 | IR Plus User Manual ©2024 Crowcon Detection Instruments Ltd. -
Page 22: Hardware Fault Tolerance
The IR Plus is of Class SC2. 8.12 CLASSIFICATION The IR Plus is a type B component. 8.13 PROOF TEST Proof Test must be performed at least once per year, depending on operating conditions. More frequent Proof Testing should be considered when operating under: - •... -
Page 23: Powerdown And Restart
Table 4 - Example Proof Test Record Sheet 9. ACCESSORIES INTRODUCTION Crowcon IR detectors protect facilities against flammable gas hazards. The following section contains instructions for the use of the IR Plus accessories. Section 5 lists the Accessories and spare parts for IR Plus. See Section 4 Specification. WALL MOUNT The Wall Mount kit is used to enable the IR Plus detector to be mounted to a wall or other flat surface. -
Page 24: Specification
Figure 9: IR Plus Wall Mount Use the screws supplied to fix the bracket to the body of the detector. The wall mount may be fitted to IR Plus supplied with or without a Fixed Display or IS Barrier. 9.2.2 SPECIFICATION Material: AISI 316 Stainless Steel Sheet (SS) PIPE MOUNT The Wall Mount kit is used to enable the IR Plus detector to be mounted to a wall or other flat surface. 9.3.1 KIT CONTENTS Mounting Brackets & screws. Figure 10: IR Plus Pipe Mount Use the screws supplied to fix the bracket to the body of the detector. The pipe mount may be fitted to IR Plus supplied with or without a Fixed Display or IS Barrier module. -
Page 25: Sunshade
Sunshade & Rivets Figure 11: IR Plus Sunshade (fitted to the pipe mount) Use the rivets supplied to fix the bracket to the body of the detector. Attach the sunshade to the bracket using remaining screws. The sunshade may be fitted to IR Plus supplied with or without a Fixed Display or IS Barrier module. The sunshade is designed to fit to the pipe mounting bracket only as illustrated above. DUCT MOUNTING KIT The duct mounting kit is designed to be used with IR Plus for monitoring potentially hazardous gases within ventilation ducts. The air flow rate within the duct must be between 0.5 metres and 20 metres per second. 9.5.1 KIT CONTENTS Mounting Plate and Flange Detector... -
Page 26: Installation
Figure 12: IR Plus Duct Mount Kit Figure 13: Duct Mount Illustration 9.5.2 INSTALLATION A standard 1m length of sampling tube is supplied. Cut the open end so the tube is the correct length: the gas entry window is half way across the duct. To avoid the adverse effects of turbulence, the duct mounting kit should be installed in the centre of a straight section of duct which has a length at least six times its width. If the section of duct is shorter, the adequacy of the flow should be tested with... -
Page 27: Testing And Commissioning
Secure the casting to the duct using suitable bolts. Remove and discard the detector’s weatherproof cover to reveal a suitable thread for attaching the IR Plus to the duct boss. Install the IR Plus by screwing it into the duct boss (about 3 turns). -
Page 28: Specification
Unused cable entries on the auxiliary junction box must be sealed using a certified blanking Plus detectors can be linked only in a bus configuration as described below. To Control Panel Figure 15: Multi-Drop Illustration If the IR Plus are to be multi-dropped into an addressable network, RS485 Modbus enabled IR Plus must be connected to auxiliary junction boxes as shown in Figure 15. 166.3 Figure 16: Auxiliary junction box showing dimensions in millimetres IR Plus User Manual | 28 ©2024 Crowcon Detection Instruments... -
Page 29: Installation
The auxiliary junction box should be installed at the designated location with the detector entry pointing down (Figure 16) 9.6.3 CABLING REQUIREMENT The spigot gland has five wires running through it to enable the user to connect one end to the detector and the other end to the junction box. Correct connection of wires at each end can easily be achieved through colour coding of the wires (Figure 17) 9.6.4 HOW TO FIT IR PLUS TO A JUNCTION BOX Carefully remove the outer section 1 of the spigot gland (see Figure 18). Screw the narrow end 2 of the spigot gland into the auxiliary junction box. R aise the detector to the auxiliary junction box and pass the wires through the assembly and into the auxiliary junction box. Secure the detector by screwing the collar tightly to the cable gland. Tighten grub screw 3. The main body of the detector can be swivelled horizontally at any angle, provided it is mechanically secure, does not interfere with other equipment and is accessible for maintenance. -
Page 30: Field Cable Termination
9.6.5 FIELD CABLE TERMINATION Field cables must be terminated to the auxiliary junction box using Ex d certified cable glands suitable for the type of cable used. EXE JUNCTION BOX PIPE MOUNT The Junction box mounting kit enables the mounting of an IR Plus and Exe Junction Box to be mounted to a pipe. An optional Sunshade is also compatible with the junction box mounting bracket as illustrated below. 9.7.1 KIT CONTENTS Brackets & screws. -
Page 31: Using The Pc Communication Kit
NOTE: Ensure communications switch on the IR Plus terminal PCBA is set to ‘SRV’ position. Launch the Detectors Pro. The computer will detect the communications module and the interface can be used to monitor and control the detector. -
Page 32: Warranty
Crowcon reserves the right to determine a reduced warranty period, or decline a warranty period for any sensor supplied for use in an environment or for an application known to carry risk of degradation or damage to the sensor. - Page 33 Crowcon product or refund of the purchase price. Limitation of Liability: Except where prohibited by law, Crowcon will not be liable for any loss or damage arising from the Crowcon product, whether direct, indirect, special, incidental or consequential, regardless of the legal theory asserted, including warranty, contract, negligence or strict liability.
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Page 34: Contacts
This document is not intended to form the basis of a contract. For more information: t: +44 (0)1235 557700 e: info@crowcon.com w: www.crowcon.com Locate your Regional Sales Representative at: www.crowcon.com/contact-us/where-to-buy © 2024 Crowcon Detection Instruments Ltd.
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