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General Monitors IR400 User Manual

General Monitors IR400
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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

Table of Contents

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General Monitors IR400 Specifications

General IconGeneral
Sensor TypeInfrared (IR)
Operating Temperature-40°C to +75°C (-40°F to +167°F)
Operating Humidity0 to 99% RH (non-condensing)
Detection PrincipleNon-dispersive infrared (NDIR)
Target GasHydrocarbons
Response Time (T90)3 seconds
Power Supply18-32 VDC
Output Signal4-20 mA
ApprovalsATEX, IECEx, CSA
Ingress ProtectionIP66
Detection Range0-100% LEL
Operating Voltage18-32 VDC
Output4-20 mA
HousingStainless steel

Summary

Quick-Start Guide

Mounting and Orientation

Describes how to mount the Model IR400 horizontally to reduce dirt buildup on windows.

Wiring Connections

Power Connections

Instructions for connecting the +24 VDC power supply to the IR400.

Applying Power

Details on system startup, stabilization, and initial checks after applying power.

1.0 Introduction

Protection for Life

General Monitors' mission to provide safety solutions and handle products safely.

Special Cautions and Warnings

Highlights warnings to prevent injury and equipment damage.

Installation, Operation, and Maintenance

Pre-power up checks, system operation verification, and periodic testing.

2.0 Product Description

Features and Benefits

3.0 Installation

Receipt of Equipment

Instructions for checking and verifying shipped equipment.

Detector Location Considerations

Guidelines for selecting an optimal location for detector placement.

3.1 Attaching the IR400 to a Junction Box, IR4000S, or IR4000M

3.2 Mounting Instructions

Mounting an IR400 with an Attached Enclosure

Shows dimensions for mounting the IR400 with an attached junction box.

To Mount the IR400

Details on horizontal mounting, gas passage orientation, and bolt hole usage.

Cabling Safety Notices

Safety notices for wiring, EU cable requirements, and termination in non-hazardous areas.

Applying Sealants to Conduit Entries

Warnings and cautions for sealing conduit entries in hazardous locations.

3.3 Wiring Connections

Power Connections

Instructions for connecting the +24 VDC power supply to the IR400.

Signal Outputs and Interfaces

Covers 4-20mA output, Modbus, HART, and Magnetic Switch interfaces.

3.4 Applying Power

4.0 Operation and Configuration

Zeroing, Gas Check Tests, and Calibration

Procedures for zeroing, gas checks, and calibration to ensure accurate measurement.

Detector Response Time

Explains how detector response time is determined and tested.

Gas Check Mode

Steps to perform a gas check test to verify detector functionality.

HazardWatch Mode

Compatibility and configuration for HazardWatch System calibration.

IR400 Stand-alone Operation and Configuration

Operating and configuring the IR400 as a stand-alone unit using the junction box switch.

Zero Only Calibration

Procedure for performing a zero-only calibration using the unit's zero switch.

Full Span Calibration

Steps for performing a full span calibration after zero calibration.

5.0 Maintenance

Developing a Maintenance Schedule

Recommendations for establishing and following a periodic maintenance schedule.

Gas Checks, Zeroing and Recalibration

Guidance on performing gas checks, zeroing, and recalibration procedures.

5.3 Cleaning and Lubricating the IR400 and IR4000 Units

Cleaning the IR400 and IR4000 Units

Procedure for cleaning the IR400 optical windows using a soft cloth and cleaning solution.

Lubricating IR400 and IR4000 Units

Instructions for lubricating neoprene rubber gaskets (O-rings) on the enclosure.

Storage

Guidelines for storing the IR400 Gas Detector and IR4000 Monitor System.

6.0 Troubleshooting

7.0 Modbus Interface

8.0 Customer Support

9.0 Appendix

Warranty

Details the two-year warranty for the Model IR400 against defects.

Principle of Operation

Explains the Beer-Lambert Law and the NDIR absorption principle used by the IR400.

9.3 Specifications

System Specifications

Lists key system specifications including detector type, range, response time, and approvals.

Mechanical Specifications

Details the physical dimensions, weight, and enclosure type of the IR400.

Electrical Specifications

Outlines input power, analog signal range, and area classification.

Analog Current Output

Shows analog output values for different modes and fault conditions.

Recommended Cable Lengths

Provides guidance on maximum cable lengths for power and signal connections.

9.4 Environmental Specifications

9.5 Communications

RS-485 Interface

Details the IR400's RS-485 serial interface for communication.

Modbus RTU

Information on the Modbus RTU protocol for device communication.

HART

Refers to HART Field Device Specification for HART commands.

9.6 Engineering Documentation

9.7 Ordering Information

System Components

Lists system components and their corresponding part numbers.

Spare Parts and Accessories

Instructions on how to order spare parts and accessories.

Recommended Spare Parts for One (1) Year

Lists recommended spare parts for one year of operation.

Accessories

Lists available accessories for the IR400, such as junction boxes and splash guards.

ADDENDUM - Product Disposal Considerations

1.0 Introduction

Scope

Specifies device features and HART Protocol implementation details.

Purpose

Complements the instruction manual with HART communications perspective.

Who should use this document?

Identifies target audience as HART application developers and integrators.

2.0 Device Identification

3.0 Product Overview

4.0 Product Interfaces

Process Interface

Describes interfaces between devices and the measured process.

Sensor Input Channels

Section for sensor input channel details.

Host Interface

Details the HART interface using the 4-20mA current loop.

Local Interfaces, Jumpers, and Switches

Refers to the Installation Manual for connection details on local interfaces.

5.0 Device Variables

6.0 Dynamic Variables

7.0 Status Information

8.0 Universal Commands

9.0 Common Practice Commands

Supported Commands

Lists implemented common-practice commands.

10.0 Device Specific Commands

Command #131: Do Abort

Sends the unit to Run mode.

Command #136: Set Alarm Level

Command to set the alarm level.

Command #137: Set Warn Level

Command to set the warning level.

Command #142: Reset Event Happened Flag

Command to reset the event happened flag.

Command #143: Read Event Logging Counters

Reads the 5 event logging counters.

Command #144: Clear Event Logging Counters

Resets the 5 event logging counters to zero.

Command #145: Read Warning Event Log

Reads the Warning Event Log by event log number.

Command #146: Read Alarm Event Log

Reads the Alarm Event Log by event log number.

Command #147: Read Fault Event Log

Reads the Fault Event Log by event log number.

Command #148: Read Maintenance Event Log

Reads the Maintenance Event Log by event log number.

Command #149: Set Clock

Sets the internal real-time clock.

Command #150: Read Clock

Reads the internal real-time clock setting.

Command #151: Set Run Time Meter

Sets the internal run time meter.

Command #152: Read Run Time Meter

Reads the internal run time meter.

Command #154: Set Event Index

Sets the index of logged event to read.

Command #155: Get Event Index

Reads the event logged index.

Command #156: Read Calibration Event Log

Reads Calibration Event Log by event log number.

Command #163: Get Fast Changing Information

Retrieves fast changing device information.

Command #164: Get Slow Changing Information

Retrieves slow changing device information.

Command #165: Get Set Up Information

Retrieves device setup configuration parameters.

Command #170: Set Current Range

Sets the current range to one of two possible selections.

Command #185: Set Gas ID or sensor type

Sets the Gas ID or sensor type for the detector.

Command #186: Set Cal IO type

Sets the Calibration Input/Output type.

Command #187: Set Solenoid State

Sets the solenoid state (off, on, disabled).

Command #188: Read Solenoid State

Reads the current solenoid state.

Command #190: Set Calibration Level

Sets the calibration level in % of FS.

Command #191: Do Zero

Sends the unit to Zero mode.

Command #192: Do Calibration

Sends the unit to Calibration mode.

Command #193: Do Zero/Calibration

Sends the unit to Zero/Calibration mode.

Command #195: Do Gas Check

Sends the unit to Gas Check mode.

11.0 Tables

IR400 – Device Specific Commands Summary

Summary table of IR400 Device Specific Commands.

IR400 – Operating Mode Values

Fault Event Log – Cause Description

12.0 Performance

Sampling Rates

Details the sampling rate of the IR400 detector.

Power-up

Describes the IR400 self-test procedure during power-up.

Command Response Delay

Lists the minimum, typical, and maximum response times for commands.

Annex A. Capability Checklist

Annex B. Default Configuration

1.0 MODBUS RTU

1.1 Serial Communications Protocol for IR400

Details the default Modbus setup and communication protocol.

1.1.1 Baud Rate

Information on selectable baud rates for Modbus communication.

1.1.2 Data Format

Lists selectable data formats for Modbus communication.

1.1.3 Modbus Read Status Protocol (Query/Response)

Describes the Modbus read query and response message structure.

1.2 Function Codes Supported

1.2.1 Exception Responses and Exception Codes

Details exception response messages and codes for abnormal communications.

1.3 IR400 Command Register Locations

1.4 IR400 Command Register Details

Analog

Details the Analog Output register and its scaling.

Operating Mode (Read/Write)

Describes the register for reporting and setting the IR400 operating mode.

Status Error (0x0002)

Explains the status error register and its bit map for error conditions.

Gas Selection (0x0003)

Details the register for reading/setting gas selection.

Model Type (0x0004)

Describes the register that returns the model type.

Software Rev (0x0005)

Explains the register for retrieving the software revision.

Gain (0x0006)

Describes the register for reading the detector gain value.

Calibration IO type (0x0007)

Details the register for setting the Calibration Input/Output type.

Solenoid On/Off (0x0008)

Explains the feature for Calibration and Gas check solenoid control.

Address (0x0009)

Describes the register for reading/changing the Modbus unit address.

Baud Rate (0x000B)

Details the register for reading/changing the Modbus baud rate.

Data Format (0x000C)

Explains the register for reading/changing the Modbus data format.

Priority Fault (0x000D)

Describes the register that returns the primary fault.

Hazard Watch Options (0x0016)

Details the register for enabling/disabling Hazard Watch mode.

Alarm Level (0x0018)

Sets/reads the minimum gas concentration level for alarm events.

Warn Level (0x0019)

Sets/reads the minimum gas concentration level for warn events.

HART Configuration (0x001A)

Configures HART interface and current range settings.

Communication Error Counters

Details registers for Total Receive, Function, Start Address, CRC Hi/Lo, Overrun, Framing, and Clear errors.

Beam Block Percentage (0x0054)

Returns optical path blockage percentage.

Gas ID (0x008D)

Reads the unique Gas ID number for the selected gas.

Reset Events (0x00B0)

Clears event counters or resets event happened flag.

Running Time in seconds hi word (0x00B1)

Reads/sets the hi word of device running time in seconds.

Running Time in seconds lo word (0x00B2)

Reads/sets the lo word of device running time in seconds.

Real-time Clock Registers

Covers Year/Month, Day/Hour, and Minute/Second for real-time clock.

Power Cycle Flag and Event Index

Details the flag for power cycle reset and the index for event logs.

Warning Event Time Registers

Registers for warning running time and clock time (Year/Month, Day/Hour, Minute/Second).

Alarm Event Time Registers

Registers for alarm running time and clock time (Year/Month, Day/Hour, Minute/Second).

Total Event Counters

Counters for Total Warning and Alarm events.

Fault Event Time Registers

Registers for fault running time and clock time (Year/Month, Day/Hour, Minute/Second).

Maintenance Event Time Registers

Registers for maintenance running time and clock time (Year/Month, Day/Hour, Minute/Second).

Total Fault and Maintenance Event Counters

Counters for Total Fault and Maintenance events.

Calibration Event Time Registers

Registers for calibration running time and clock time (Year/Month, Day/Hour, Minute/Second).

Calibration Code and Total Event Counter

Returns calibration code and total calibration events count.

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