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SISI NUBI FIELDS DEVELOPMENT PROJECT PHASE 1

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FIRE & GAS DETECTORS ESD PB MAC


OPERATING AND MAINTENANCE MANUALS
5956-06

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SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 3 of 125

TABLE OF CONTENTS

1. IR POINT GAS DETECTOR CH4 IR2100 4

2. IR OPEN PATH GAS DETECTOR IR5000 44

3. INTRINSICALLY SAFE HEAT DETECTOR DT1101A-EX & SMOKE DETECTOR DO1101A-EX 102

4. INTRINSICALLY SAFE REMOTE INDICATOR DJ1192EX 116

5. INTRINSICALLY SAFE BARRIER MTL5061 119

6. PULL HANDLE 81300 121

7. NPT ADAPTERS 125

8. RESISTOR 125

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 4 of 125

1. IR POINT GAS DETECTOR CH4 IR2100

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
Model IR2100
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 02/06

General Monitors reserves the right to change


published specifications and designs without
prior notice.

Part No. MANIR2100-EU


Revision H/02-06

5 / 125
Model IR2100

Warranty Statement
General Monitors warrants the Model IR2100 to be free from defects in workmanship
or material under normal use and service within two (2) years from the date of
shipment. General Monitors will repair or replace without charge any such defective
equipment found to be defective during the warranty period. Full determination of the
nature of, and responsibility for, defective equipment will be made by General
Monitors personnel. Defective or damaged equipment must be shipped prepaid to
General Monitors plant or representative from which shipment was made. In all cases
this warranty is limited to the cost of the equipment supplied by General Monitors. The
customer will assume all liability for the misuse of this equipment by its employees or
other personnel.
All warranties are contingent upon proper use in the application for which the product
was intended and do not cover products which have been modified or repaired without
General Monitors approval, or which have been subjected to neglect, accident,
improper installation or application, or on which the original identification marks have
been removed or altered. Except for the express warranty stated above, General
Monitors disclaims all warranties with regard to the products sold, including all implied
warranties of merchantability and fitness and the express warranty stated herein are
in lieu of all obligations or liabilities on the part of General Monitors for damages
including, but not limited to, consequential damages arising out of/or in connection
with the use or performance of the product.

Warnings
The Model IR2100 Point IR Detector contains components which can be damaged by
static electricity. Special care must be taken when wiring the system to ensure that
only the connection points are touched.

The Zero Switch must be supplied from apparatus which provides protection against
short circuit currents of up to 4000A.

Note on Methane EU Gas: Users should be aware that these instruments may have
100% LEL of 4.4% by Volume. Methane Calibration level is
2.2% by Volume. See Section 2.4 for Unit part#s

ii

6 / 125
Model IR2100

E C Declaration of Conformity in accordance with EC Directives


We at General Monitors Ireland Ltd., Ballybrit Business Park, Galway, Republic of Ireland, hereby
declare that the equipment described below, both in its basic design and construction, and in the
version or versions marketed by us, conforms to the relevant safety and health related requirements of
the appropriate EC Directives, only as follows:

a) Conforms with the protection requirements of Council Directive 89/336/EEC, + Amd


92/31/68/EEC relating to Electromagnetic Compatibility, by the application of:

A Technical Construction File No. GM 97003 and Competent Body Report No. 4473/1L6/1

and

b) Conforms with the protection requirements of IEC 1010-1: 1990 + Amd 1:1992 +Amd 2: 1995
relating to safety by the application of:

A Technical Construction File No. GM 97003 and Competent Body Certificate No. 4146/1198/9684
issued by:

ERA Technology Ltd. Cleeve Road, Leatherhead Surrey KT22 7SA, England. Tel: +44 1372 367000

This declaration shall cease to be valid if modifications are made to the equipment without our approval.

Models: IR2100/IR7000 Point IR Detector

It is ensured through internal measures and our ISO9001: 2000 certifications, that series production
units conform at all times to the requirements of these current EC Directives and relevant standards.

Note: The Following Information applies to ATEX.


This equipment has been assured for use as a safety related device under the terms of Directive
94/9/EC EHSR 1.5.
General Monitors Ireland Ltd. in order to comply with ATEX, will provide this Instruction Manual in a
European Language required to operate the product upon request. Should this be necessary, General
Monitors Ireland Ltd. should be notified of this request to allow adequate time to process the request.

ATEX Certificate Markings.

II 2 G Demko 01.ATEX.130840
Model: IR2100

0518 EExd IIB + H2 T5


-40 C to +75C

Responsible Person: Date: 14-03-02

Denis Connolly
General Manager European Operations

The signatory acts on behalf of company management, and with full power of attorney

iii

7 / 125
Model IR2100

Table of Contents
Page
Warranty Statement ................................................................................................... ii
Warnings ................................................................................................... ii
Table of Contents .................................................................................................. iv
Table of Figures ................................................................................................... v

1.0 Introduction ................................................................................................... 1


1.1 General Description ................................................................................... 1
1.2 Features & Benefits.................................................................................... 2
1.3 Applications................................................................................................ 2

2.0 Specifications ................................................................................................... 3


2.1 System Specifications ................................................................................ 3
2.2 Mechanical Specifications .......................................................................... 3
2.3 Electrical Specifications.............................................................................. 4
2.4 Environmental Specifications ..................................................................... 5

3.0 Detector Assembly............................................................................................. 6


3.1 Signal Processing ...................................................................................... 6
3.2 Control Electronics ..................................................................................... 6

4.0 Installation ................................................................................................... 7


4.1 Receipt of Equipment ................................................................................. 7
4.2 Detector Location Considerations .............................................................. 7
4.3 Mounting and Orientation ........................................................................... 8
4.4 Wiring Connections .................................................................................... 8
4.5 Applying Power ........................................................................................ 11

5.0 Operation ................................................................................................. 12


5.1 Zeroing of IR2100 .................................................................................... 12
5.2 Maintenance ............................................................................................ 13
5.3 Communications ...................................................................................... 14

6.0 Appendix A ................................................................................................. 15


6.1 Engineering Documentation ..................................................................... 15
6.2 Spare Parts and Accessories ................................................................... 18

7.0 Supplement Modbus Communications


8.0 Customer Support
iv

8 / 125
Model IR2100

Table of Figures
Figure 1 Model IR2100 Picture...........................................................................................1

Figure 2 Wiring Chart .........................................................................................................8

Figure 3 IR2100 with Junction Box Wiring Detail.............................................................9

Figure 4 Cable Termination in the non-hazardous area ................................................... 11

Figure 5 Switch LED Sequence Chart.............................................................................. 13

Figure 6 Outline and Dimensional Drawing ................................................................ 15

Figure 7 EExe Junction Box and IR2100 Assembly ........................................................ 16

Figure 8 EExe Duct Mount Junction Box and IR2100 Assembly ...................................... 17

9 / 125
Model IR2100

1.0 Introduction
1.1 General Description

The Model IR2100 Infrared Point Detector is a microprocessor based hydrocarbon gas
detector. The General Monitors Model IR2100 is calibrated at the factory and needs no
routine field calibration. The sensitivity of the Model IR2100 can be checked by applying a
test film when the unit is placed in the Calibration Check mode. It is also relatively
maintenance free, requiring only a periodic cleaning of the windows to assure dependable
performance.

The Model IR2100 Infrared Point Detector continuously monitors combustible gases below
the Lower Explosion Level (LEL) range* and provides a 4 to 20mA analogue signal
proportional to the 0-100% LEL concentration it detects along with a digital RS485 output,
allowing unit to be addressable via Modbus Protocol.

Sensor data and status information for the Model IR2100 can be transmitted to a variety of
General Monitors readout units.

The Model IR2100 Infrared Point Detector operates from a nominal + 24VDC CE marked
supply which must be supplied by the customer.

The Model IR2100 may be mounted in a stand alone Junction Box, or Junction Box to
ducting via Duct Mounting Plate. A Zero Switch maybe fitted into this Junction Box. The
IR2100 may also be connected to the following:
Field Mounted Display TA102A S4100E

The Model IR2100 is available in a number of versions, designed to optimise detection of


customer specified gas.

* - or in Methane % by volume range, in which case all references to 0 to 100% LEL should
be read as 0 to 100% by volume.

Figure 1

10 / 125
Model IR2100

1.2 Features & Benefits

This is a partial list of features and benefits for the Model IR2100 Infrared Point Detector:

No routine calibration required


Fail to safe operation
4-20 mA output
Modbus communications link RS485
Heated optics to eliminate condensation
Dirty optics indication
Reading not affected by air velocity
Immune to typical poisons (e.g. silicones, halides, lead, sulfur)
Works in oxygen deficient environments
Able to operate in constant hydrocarbon environment without adverse effects
IP66/Type 4X rating
Interfaces directly with General Monitors 02A Series TA102A Trip Amplifiers

1.3 Applications
This is a partial list of applications suitable for the Model IR2100 Infrared Point Detector:

Drilling and Production Platforms


Fuel Loading Facilities
Compressor Station
Oil Well Logging
Liquefied Natural Gas/Liquefied Petroleum Gas
Gas Processing and Storage Facilities
Wastewater Treatment
Gas Turbines
Solvent Vapours
Refineries
Chemical Plants

11 / 125
Model IR2100

2.0 Specifications
2.1 System Specifications

Detector Type: Infrared Absorption Type


Detector Life: Greater than 5 years
Measuring Range: 0 to 100% LEL*
Zero Drift: <2% per year
Accuracy @ 25C: 3% FS 50% FS, 5% 50% LEL
Warranty: Two years

Readout Module: TA102A Single Channel, Zero Two Series, Rev E S/W and up.

Malfunctions Monitored
Re-calibration Error
EPROM Checksum Error
Optics Failure/Blockage
Low Supply Voltage
EEPROM Checksum Error
Heater Failure
Time to Re-Zero unit
Open Analogue Output Loop
Reference or Active Lamp Failure

Response Time
With 100% LEL* Methane Applied
T50 7 seconds & T90 10 seconds
* - also read as 0 to 100% by volume

Approvals
CSA (Class 1, Division I, Groups B, C & D),
CSA Certified to C22.2 No. 152-M1984*
ATEX (EExd IIB + H2 T5) & CE Marking

Design also conforms to the following performance standards:


FM 6310, 6320

* - 0 to 100% by volume unit does not conform to this standard.

2.2 Mechanical Specifications


Length: 262mm (10.30) 259mm (10.20)
Diameter: 72.6mm (2.86) 74mm (2.9)
Weight: 2.7kg (SS) (6lbs)
1.35 (Al) (3lbs)
Enclosure: Aluminium or Stainless Steel 316 IP66
Aluminium or
Stainless Steel; Explosion proof, IP66; TYPE 4X
Mounting: NPT or J-Box (optional)

12 / 125
Model IR2100

2.3 Electrical Specifications

Electrical Classification:
Class I, Division 1, Groups B, C and D
EExd, IIB+H2 T5

Power:
24 VDC @ 0.4 amp (nominal)
20 to 36 VDC range
NOTE: PSU noise and ripple voltage 1V pk/pk max.
Customer supplied PSU must meet requirements
IEC 1010-1 limiting current to 8A under Fault
conditions, in order to comply with CE Marking
requirements.

Analogue Signal Output (600 ohms max @ 24VDC)


Range 0 to 22 mA
Fault 0 mA
(Gas Check & Zero) 1.5 mA
Dirty Optics 2 mA
Zero Reading 4 mA 0.2 mA
0 to 100% LEL* 4 to 20 mA prop.
Overrange 20 to 22 mA
Modbus Output: Link up to 128 units
* - also read as 0 - 100% by volume

Recommended Cable Lengths:

Power - The maximum distance between the IR2100 and the Power Source varies
according to the wire size. (10 ohm loop resistance at 24 VDC)

Cable Cable Run Run


(mm2) AWG Metres Feet
0.25 22 85 285
0.75 20 135 450
1.00 18 220 720
1.5 16 345 1145
2.5 14 555 1830

Analogue Output Signal - The maximum total distance between the IR2100 and a device
with a 300 ohm input impedance varies according to the wire size.

Cable Cable Run Run


(mm2) AWG Metres Feet
0.25 22 243 800
0.75 20 365 1200
1.00 18 579 1900
1.50 16 792 2600
2.50 14 1371 4500

13 / 125
Model IR2100

2.4 Environmental Specifications

Operating Temperature Range (Approved) -40F to +167F (-40C to +75C)


Pentane, Hexane, Benzene only * -40F to +140F (-40C to +60C)

Operating Humidity Range


5 to 100% Relative Humidity (non-condensing)

Storage Temperature Range -58F to +167F (-50C to +75C)


Pentane, Hexane, Benzene only * -40F to +140F (-40C to +60C)

*For higher temperature range, consult factory

EMC Protection:
Complies with EN50082/2:1995) 10V/m max.

Note: Compliance with EMC Directive 89/336/EEC is only valid for environments
corresponding with the test standards EN50081-1:1992 and EN50082-2:1995

The following Units have 100% LEL of 4.4% by Volume:

31300-25 Point IR Aluminium Methane

31300-26 Point IR SST Methane

31300-27 Point IR Russian Aluminium Methane

31300-28 Point IR Russian SST Methane

14 / 125
Model IR2100

3.0 Detector Assembly


3.1 Signal Processing

Most gases absorb infrared radiation in specific wavelengths or bands that are
characteristic of the chemical structure of molecules in the gas. All hydrocarbon gases
absorb infrared radiation, but to differing degrees. Gases, to be infrared active, must have
an electric dipole moment.

The Model IR2100 is based on measuring absorption of infrared radiation passing through
a volume of gas. Absorption of the radiation follows the Beer-Lambert Law, which states
the transmittance T of radiation through an absorbing medium decreases exponentially by
the product of the extinction coefficient A, the concentration C and the path length L :

T = exp (-ACL)

The Model IR2100 uses a single beam,dual source, single detector measurement
absorption method. One source is optimised to a wavelength where absorption of a
specific gas (or gases) occurs (the active wavelength). The reference source is optimised
to a wavelength that is adjacent to the active wavelength but not absorbed by the gas (or
gases). By comparing the signals from these two sources the concentration of the gas can
be measured using the differential absorption technique.

This method of gas detection comes under what is commonly known as the non-dispersive
infrared (NDIR) absorption principle. The reference wavelength is chosen suitable to
compensate for any interference that can otherwise occur from atmospheric variation (e.g.
humidity, dust, snow, fog, steam, temperature, etc.).

3.2 Control Electronics

The Model IR2100 operates from a customer supplied, CE Marked nominal +24VDC
(nominal) input, which is fed to an on board power-supply that produces all of the
necessary voltages within the unit.

The microprocessor constantly monitors the infrared wavelengths and performs


mathematical operations on these values in conjunction with values obtained during the
factory set-up process.

The microprocessor generates output information and feeds it to the digital to analogue
converter to produce a 4 to 20 milliampere (mA) signal that is
proportional to the 0 to 100% LEL concentration of gas at the sensor. The microprocessor
program also monitors other conditions such as the supply voltage and the optical path
integrity.
The Model IR2100 also provides a two-wire RS485 addressable communications link
conforming to the Modbus Protocol that is used to monitor the IR2100s status and settings
in order to simplify installation and maintenance and can be used to monitor the units
status, or change the detection gas requirements.

Bridge Output Version

The Model IR2100 can be configured to simulate a Wheat stone bridge output instead of
the 4-20 mA signal, which enables the unit to be retrofitted to an existing General
Monitors smart sensor. Contact the Factory for details.

15 / 125
Model IR2100

4.0 Installation
4.1 Receipt of Equipment

All equipment shipped by General Monitors is packaged in shock absorbing containers,


which provide considerable protection against physical damage. The contents should be
carefully removed and checked against the packing list. If any damage has occurred or
there is any discrepancy in the order, please notify General Monitors as soon as possible.
All subsequent correspondence with General Monitors must specify the equipment part
number and the serial number.

Each Model IR2100 is completely tested by the factory, however, a complete system
checkout is suggested upon initial installation and start-up to ensure system integrity.

Note: The Model IR2100 is factory set against the particular gas ordered by the Customer.
Where no gas is specified, Methane (CH4) is the factory standard. The unit may be
changed to detect another gas via RS485 comms link or by returning to General Monitors
Representative or the Factory.The gasses the unit can be changed to are:
Methane, Propane, Ethane, Hexane, n-Butane, Pentane and Methane 100% Volume.

NOTE: The indications shown in the table for cross sensitivity to other gasses is only a
guide as General Monitors recommends the unit should be calibrated for the specific gas.

Calibration Gas %LEL Methane Propane Ethane Hexane n-Butane Pentane % Vol CH4
methane 50 LEL 50 99 188 40 88 72 317
propane 50 LEL 25 50 94 20 44 36 159

NOTE: If the Model IR2100 is to be installed at altitudes greater than 1000 ft


(308m), it must be re-calibrated on-site.
4.2 Detector Location Considerations

There are no standard rules for detector placement, since the optimum detector location
varies with the application. The customer must evaluate conditions at the facility to make
this determination. If practical, the Model IR2100 Infrared Point Detector should be easily
accessible for occasional integrity checks. The unit should be mounted horizontally so that
dirt and dust do not build up on the windows. Although the Model IR2100 Infrared Point
Detector is RFI resistant, it should not be mounted close to radio transmitters or similar
equipment.

NOTE - Hydrogen (H2) gas cannot be detected by the Model IR2100.

Some other factors to consider when selecting a detector location:


Emission temperature and vapour density of the gas. The Model IR2100 should be located
near the floor for gas vapours, which are heavier than air.
Locate the Model IR2100 where prevailing air currents contain the maximum concentration
of gas.
Locate the Model IR2100 as near as possible to the likely source of a gas leak.
Observe the temperature range of the Model IR2100 and locate the unit away from
concentrated sources of heat or light.
Mount the Model IR2100 away from sources of excessive vibration.
A hood should be placed over the Model IR2100 in outdoor applications to prevent sunlight
and heavy rain from striking the unit.

16 / 125
Model IR2100

The Model is not affected by typical environmental poisons (but see note below) and is
suitable for use in an O2 deficient area.
The baffle design also ensures that gas readings are immune to air velocity, wind etc.

Note: Acetic acid will cause damage to metal components, metal hardware, ceramics ICs
etc. If damage results from the use of a sealant that outgases acetic acid (RTV silicone),
the normal two year warranty will be void.

4.3 Mounting and Orientation

The Model IR2100 should be mounted horizontally (see Figure 3) 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 3. Apply the supplied thread
lubricant/sealant to all conduit entries before use to prevent binding.

4.4 Wiring Connections

To make the power and analogue connections to the Model IR2100 Infrared Point
Detector, see below:

WIRING CHART
WIRE COLOR SIGNAL
BLACK COM (0 Volts)
GREEN FG (Earth Terminal)
RED +24V
WHITE 4-20mA
BLUE CBUSS+
WHT/BLU CBUSS-
BROWN CAL
Figure 2
The Model IR2100 Infrared Point Detector operates on nominal power of 24VDC which
must be provided by the customer, and shall be CE marked, meeting safety requirements
of IEC 10101-1. Since the Model IR2100 Infrared Point Detector is designed to
continuously monitor for leaks of hydrocarbon gas, a power switch is not included to
prevent accidental system shut down.

NOTE: Power should remain disconnected until all other wiring connections are
made.

The maximum distance between the Model IR2100 and the power source is specified in
the Appendix (see Section 2.3)

Power Connections

To connect the +24VDC to the Model IR2100 use the red lead from the IR2100 and
connect to the +24VDC source. Connect the black lead from the IR2100 to the power
supply Common. Refer to the manual of the power source being used, for more detailed
instructions. This customer supplied power supply must comply with IEC 1010-1 for CE
Marking compliance.

17 / 125
Model IR2100

NOTE: If the Model IR2100 is being used with a +24V power supply and an industrial
analogue to digital (A/D) converter, then the negative supply (Common) of all three must
be connected.

Figure 3

An internal diode protects the system in the event of inadvertent supply reversal.

4- 20mA Output
A 4 to 20mA output signal is provided by the Model IR2100 and can be sent to a General
Monitors read-out/relay display module or any industrial device that can accept a 4 to
20mA signal, for computer based multi-point monitoring. The Analogue
Output connection provides a signal for use in displaying current LEL readings, special
operation or fault conditions. The maximum distance between the Model IR2100 and the
device connected to the Analogue Output Signal is specified in the Appendix.

Connect the white lead from the IR2100, to the signal in terminal of the input unit (display
module)
Connect the black lead from the IR2100, to the device Common. The Common connection
serves both the Analogue Signal and the Power connections.

The Green lead from the IR2100 can be connected to Earth stud, (or Safety Earth) on
Junction Box, which is in turn connected to cable armour.

To connect the RS485 output, the blue lead from the IR2100 is connected to the RS485
BUSS+ terminal and the blue/white lead is connected to the RS485 BUSS-terminal on the
customers RS485 capable device.

18 / 125
Model IR2100

Cable Termination in the non-hazardous area

The interconnecting cables must have an overall screen and armour. Cables to BS5308
Part 2 or equivalent are suitable. Note that the terms screen and shield are equivalent for
the purpose of this manual. The cable armour must be terminated in a suitable cable gland
at the detector to ensure a positive electrical connection. The Green wire from Model
IR2100 should be connected to Earth stud on continuity plate of GM housing or to internal
Earthing point if using a non-GM Junction Box.

General Monitors do not recommend the use of cable shoes or crimps on any junction box
or housing wiring terminals. Poor crimping can cause bad connection when unit
experiences temperature variations. We therefore would recommend the following:

The cable armour 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.

The power supply OV return must be connected to an instrument earth in the safe
area.

The interconnecting cables should be segregated from power and other noisy
cables. Avoid proximity to cables associated with radio transmitters, welders, switch
mode power supplies, inverters, battery chargers, ignition systems, generators, high
power switching process equipment. Avoid running instrument cable trenches close
to lightning conductor earthing pits.

Complete all cable insulation testing before connecting the cable at either end.

10

19 / 125
Model IR2100

Figure 4

WARNING
Under no circumstances should equipment be connected or disconnected when
under power. This is contrary to hazardous area regulations and may lead to
serious damage to the equipment. Equipment damaged in this manner is not
covered under warranty.

4.5 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 120 seconds before returning to normal
operation (Analogue output will be 0 mA).
After power is applied, the Model IR2100 should be allowed to stabilize for approximately
60 minutes while the unit attains its proper operating temperature.
After stabilization, it is recommended that the Model IR2100 be zeroed, per the procedure
in Section 5.1 (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 31468) to perform this
check. If the unit does not respond properly, calibrate per the procedure in Section 4.1
(steps 1-4).

a) When connecting the Model IR2100 to a safety system, the +24V (Red) wire should be
the last wire connected and first wire disconnected when removing unit to protect the
system from shorting.

B) If the analogue (4-20 mA) output is not used, then the white signal wire must be
connected to ground to prevent a fault condition.

Note: Where customer requires unit to detect a different gas from that which unit has been
factory calibrated to, then the IR2100 must be re-calibrated by General Monitors personnel
or authorised representatives.

11

20 / 125
Model IR2100

5.0 Operation
5.1 Zeroing of IR2100

The Model IR2100 also provides a lead for the connection of a +24VDC powered EExd
approved magnetic switch. This switch is available in 316 Stainless Steel with an M20
thread. The switch can be fitted to a General Monitors supplied Junction Box.

Special conditions for safe use of General Monitors Ex. Approved Zero Switch

The Zero Switch, where used, must be mounted in a suitably certified enclosure or
enclosure wall, and its flying leads terminated at Ex e terminals, also within a
suitably certified enclosure.

The electrical supply to the Zero Switch must not exceed the following values:

Rated Input Voltage = 24V


Rated Input Current = 22mA

The Zero Switch must be supplied from apparatus which provides protection against short
circuit currents of up to 4000A.

The Brown lead from the IR2100 is connected to the powered side of the switch so that
Brown lead is grounded when switch is activated via magnet.

Alternatively, the Brown lead may be grounded for 10 to 15 seconds.

The Zeroing eliminates any background gas fluctuations. See below.

1. Apply the General Monitors magnet, which was included with the unit, to the Magnetic
switch Assembly for approximately three seconds. The LED in the switch will light to
show proper placement. Remove the magnet and the LED will flash on for one second
and off for one second to indicate that the unit is attaining a zero value.

2. When the unit has finished zeroing, the LED will turn on and flash off quickly once per
second for 30 seconds. If a complete gas check is required, apply the magnet and the
unit will enter gas check mode (if the magnet is not applied, the unit will return to
normal operation). The LED will flash off quickly once every half second while the unit
is waiting for gas to be applied.

3. Apply 50% LEL* calibration gas. When the unit is seeing gas, the LED will flash on for
a half second every one and one-half seconds.

4. Once gas check has been completed, the LED will turn on and flash off once every
second. Remove the gas and the unit will return to normal operation once the gas has
fallen below 5% LEL.

* or 50% and 5% by volume for those units specifically designed for monitoring 0 to
100% by volume.

Note on Methane EU Gas: Users should be aware that these instruments may have
100% LEL of 4.4% by Volume. Methane Calibration level is
2.2% by Volume. See Section 2.4 for Unit part#s

12

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Model IR2100

IR2100 Switch LED Sequence

Figure 5
5.2 Maintenance

Although the Model IR2100 is calibrated at the factory and fails-to-safe, periodic cleaning
and integrity tests are required to ensure proper operation. The windows should be
cleaned by gently wiping them with a soft, clean cloth, which has a cleaning solution (P/N
10272-1) applied. Integrity checks can be performed using the General Monitors Gas
Check Kit (P/N 31468).
General Monitors recommends that a maintenance logbook be kept for each unit in
operation. Since maintenance requirements will vary with each installation, this
maintenance record will help to develop an efficient schedule for periodic maintenance.

NOTE: Gassing into the screened splashguard will not provide a stable or accurate
reading.

Warning - Do not clean the windows while the unit is zeroing or in recalibration mode.

The unit must be re-zeroed after the windows have been cleaned.

If an optical fault still occurs after cleaning and re-zeroing is complete, the unit must be
returned to the factory for service. The reverse is also the case.

13

22 / 125
Model IR2100

5.3 Communications

The Model IR2100 has built-in serial communications in the form of a half- duplex RS- 485
digital serial interface designed to conform with EIA-485 specifications.
The format is in binary data transferred at 9600 baud with 1 start bit, 8 data bits, 1 stop bit
and no parity.

General Monitors has available a Windows-based program that allows the user to
configure the IR2100 for use in their facility. The customer must provide access to the RS-
485 bus by way of a PLC or other controlling device (bus master) with communications
software programmed to provide the following information to the Model IR2100.

The bus master sends a command message to the Model IR2100, which is comprised of
5 bytes of data in the following for mat. The first byte is the address of the slave device
(IR2100). The second byte is the Command Word (see page 18). The third byte is the
Command Data. The last two bytes are a 16-bit checksum calculated by performing a 16-
bit addition of the first three bytes of the message and placing the result in the check sum
bytes.

A 1" in the most significant bit of the Command Word (byte 2), tells the Model IR2100 to
change its settings to those given in the Command Data (byte 3).
A 0" in the most significant bit of the Command Word (byte 2), tells the Model IR2100 to
return its current settings. In this case the Command Data (byte 3) will be all 0s.

The Model IR2100 then responds by sending back a 5-byte message in the following
format. The first byte is the address of the Model IR2100. The second byte is an echo of
the Command Word sent by the bus master. The third byte is
the data requested by the Command Word. The last two bytes are the 16- bit check sum.

NOTE: Users not using RS485 bus on installed IR2100s cannot change detection gas
without returning unit to GM Factory or local Representative.

14

23 / 125
Model IR2100

6.0 Appendix A
6.1 Engineering Documentation

Figure 6

15

24 / 125
Model IR2100

Figure 7

16

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Model IR2100

Figure 8

17

26 / 125
Model IR2100

6.2 Spare Parts and Accessories

To order spare parts and/or accessories, please contact your nearest General Monitors
Representative or General Monitors directly and give the following information:

1 Part Number

2 Description

3 Quantity

CAL check equipment:

IR2100 CAL check assembly

Manual, MANIR2100

Recommended Spare Parts for One (1) Year:

31037-1 Double Magnet Assembly

Accessories:

Junction Box - Housing used to accommodate field wiring terminals and zero switch.
ATEX (P/N 31421-4)

Flow Block (P/N 31420-1) - Used to connect the IR2100 to a gas sampling system.

Zero Switch (P/N 31414-1)

Duct Mount Plate - Used to facilitate mounting in ventilation systems.


(Part No. 31483-1)

Duct Mount Junction Box European Version (P/N 31424-1)

Splashguard Fitted as standard. Has facility to connect remote gas supply for testing
indoors.
Version with CAL cell for calibration in outside also available P/N 31467-1

Gas Check Kit (P/N 31468-Specify Gas) Gas bottle with regulator and cup.

Gas Check Chamber (P/N 31428-1) Used when checking the IR2100s response to a
Liquid.

Cleaning Solution (P/N 10272-1)

18

27 / 125
Modbus Communications

Safety Warning
Installation and maintenance must be carried out by suitably skilled and competent
personnel only.

Note: The Modbus protocol applies only to factory shipments of product from the end of
July 1998. Please contact GM factory for confirmation.

Modbus Table of Contents


1.0 Modbus ...................................................................................................... 1

2.0 Series Protocol........................................................................................... 1


2.1 Baud Rate ........................................................................................ 1
2.2 Data Format ..................................................................................... 1
2.3 Default ............................................................................................. 1

3.0 Modbus Read Status Protocol (Query/Response)...................................... 2


3.1 Modbus Read Query Message......................................................... 2
3.2 Modbus Read Response Message .................................................. 2

4.0 Modbus Write Command Protocol (Query Response)................................ 3


4.1 Modbus Write Query Message......................................................... 3
4.2 Modbus Write Response Message................................................... 3

5.0 Function Codes Supported......................................................................... 3

6.0 Exception Responses and Exception Codes.............................................. 4


6.1 Exception Response ........................................................................ 4
6.2 Exception Codes .............................................................................. 5

7.0 Command Register Locations .................................................................... 6

28 / 125
Modbus Communications

8.0 Command Register Details ........................................................................ 7


8.1 Analogue (00H)................................................................................. 7
8.2 Mode (01H) ....................................................................................... 8
8.3 Status/Error (02H)............................................................................. 8
8.4 Gas (03H) ......................................................................................... 9
8.5 Type Unit (04H)................................................................................. 9
8.6 Software Rev. (05H).......................................................................... 9
8.7 Gain (06H) ........................................................................................ 9
8.8 LED Disable (07H) .......................................................................... 10
8.9 Solenoid On/Off (08H)..................................................................... 10
8.10 Address (09H)................................................................................. 10
8.11 Adjusted Ratio (0AH) ...................................................................... 10
8.12 Baud Rate (0BH)............................................................................. 11
8.13 Data Format (0CH) ......................................................................... 11
8.14 Total Receive Errors (20H) ............................................................. 11
8.15 Bus Activity Rate (21H) ................................................................... 11
8.16 Function Code Errors (22H) ............................................................ 12
8.17 Starting Address Errors (23H) ......................................................... 12
8.18 Number of Register Errors (24H) .................................................... 12
8.19 RXD CRC Hi Errors (25H)............................................................... 12
8.20 RXD CRC Lo Errors (26H) .............................................................. 12
8.21 Overrun Errors (27H) ...................................................................... 12
8.22 Noise Flag Errors(28H) ................................................................... 12
8.23 Framing Errors (29H) ...................................................................... 12
8.24 Clean Comm Errors (30H) .............................................................. 12

ii

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Modbus Communications

Modbus RTU
Serial Communications Protocol for IR2100 Methane & IR2100
Ethylene Series

1.0 Modbus
Modbus on the IR2100 enables the operator to get gas and status information and also
remotely zero or gas check the unit.

2.0 Series Protocol


The unit can accommodate different communication speeds and data formats.

2.1 Baud Rate

The Baud rate is a selectable setting via the Modbus Communications Interface. The
selectable baud rates are 9600, 4800 or 2400 bits per second. (Factory default is 9600).

2.2 Data Format

The Data Format is a selectable setting via the Modbus Communications Interface. The
selectable data formats are as follows:

Data Bits Parity Stop Bit Format


8 None 1 8-N-1 (Default setting)
8 Even 1 8-E-1
8 Odd 1 9-O-1
8 None 2 8-N-2

2.3 Default

The unit is shipped with the following default baud rate and data format. The baud rate is
9600 baud. The format is 8 Data bits, no parity and 1 stop bit (8-N-1).

If you are unsure of the settings, the default settings can be recovered using the following
procedures:

1. Turn off power to the unit

2. While holding the magnet over the zero switch turn the power back on.
2a If you do not have the zero switch installed, ground the brown wire, and hold.

3. Continue to hold the magnet over the switch (or ground the brown wire) for 10
seconds.

4. The baud rate will now be 9600, and the data format will be 8-N-1.

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Modbus Communications

3.0 Modbus Read Status Protocol


(Query/Response)
3.1 Modbus Read Query Message

Byte Modbus Range Referenced to IR2100

1st Slave address 1-247* (Decimal) ID (Address)


2nd Function Code 03 Read Holding Registers
3rd Starting Address Hi** Not used
4th Starting Address Lo** 00-FF (Hex) Commands
5th No. of Registers Hi 00 Not Used
6th No. of Registers Lo 01 No. of 16 Bit Registers
7th CRC Lo 00-FF (Hex) CRC Lo Byte
8th CRC Hi 00-FF (Hex) CRC Hi Byte

* Note: Address 0 is reserved for broadcast mode and will not be supported at this
time.

** Note: Start Address can be a maximum of 9999 Address Locations (0000-270E).

3.2 Modbus Read Response Message

Byte Modbus Range Referenced to IR2100


st
1 Slave Address 1-247* (Decimal) ID (Address)
2nd Function Code 03 Read Holding Registers
3rd Byte Count 02 No. of Data Bytes
th
4 Data Hi 00-FF (Hex) Hi Byte Status Data
5th Data Lo 00-FF (Hex) Lo Byte Status Data
6th CRC Lo 00-FF (Hex) CRC Lo Byte
th
7 CRC Hi 00-FF (Hex) CRC Hi Byte

* Note: Address 0 is reserved for broadcast mode and will not be supported at this
time.

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Modbus Communications

4.0 Modbus Write Command


Protocol (Query Response)
4.1 Modbus Write Query Message

Byte Modbus Range Referenced to IR2100

1st Slave address 1-247* (Decimal) ID (Address)


2nd Function Code 06 Preset Single Register
3rd Register Address Hi 00 Not Used
4th Register Address Lo 00-FF (Hex) Commands
5th Present Data Hi 00-FF (Hex) Hi Byte Command Data
6th Present Data Lo 00-FF (Hex) Lo Byte Command Data
7th CRC Lo 00-FF (Hex) CRC Lo Byte
8th CRC Hi 00-FF (Hex) CRC Hi Byte

* Note: Address 0 is reserved for broadcast mode and will not be supported at this time.

4.2 Modbus Write Response Message

Byte Modbus Range Referenced to IR2100

1st Slave address 1-247* (Decimal) ID (Address)


2nd Function Code 06 Preset Single Register
rd
3 Register Address Hi 00 Not Used
4th Register Address Lo 00-FF (Hex) Commands
5th Present Data Hi 00-FF (Hex) Hi Byte Command Data
th
6 Present Data Lo 00-FF (Hex) Lo Byte Command Data
7th CRC Lo 00-FF (Hex) CRC Lo Byte
8th CRC Hi 00-FF (Hex) CRC Hi Byte

* Note: Address 0 is reserved for broadcast mode and will not be supported at this time.

5.0 Function Codes Supported

Function Code 03, (Read Holding Registers) will be used to read status from the slave
unit. Function Code 06, (Preset Single Register) will be used to write a command to the
slave unit.

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Modbus Communications

6.0 Exception Responses and


Exception Codes
6.1 Exception Response

In a normal communications query and response, the master device sends a query and
the unit receives the query without a communications error and handles it normally within
the master devices allowable timeout. The unit then returns a normal response to the
master. Abnormal communications produce one of four possible events.

1. If the unit does not receive the query due to a communications error, then no
response is returned and the master device will eventually process a timeout
condition for the query.

2. If the unit receives the query, but detects a communication error (CRC, etc.), then no
response is returned and the master device will eventually process a timeout
condition for the query.

3. If the unit receives the query without a communications error, but cannot process the
response to the master within the masters timeout setting, then no response is
returned and the master device will eventually process a timeout condition from the
query. In order to prevent this condition from occurring the maximum
response time for the unit is 200 milliseconds. Therefore the Masters Timeout
Setting should be set to 200 milliseconds or greater.

4. If the unit receives the query without a communications error, but cannot process it
due to reading or writing to a non-existent command register, then the unit will return
an exception response message informing the master of the error.

The exception response message (ref. No. 4 above) has two fields that differentiate it
from a normal response:

Byte Modbus Range Referenced to IR2100

1st Slave address 1-247*(Decimal) ID (Address)


nd
2 Function Code 83 or 86 (Hex) MSB is set with Function
Code
3rd Exception Code 01-06 (Hex) Appropriate Exception Code
(See below)
4th CRC Lo 00-FF (Hex) CRC Lo Byte
5th CRC Hi 00-FF (Hex) CRC Hi Byte

* Note: Address 0 is reserved for broadcast mode and will not be supported at this time

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Modbus Communications

6.2 Exception Codes

Exception Code Field:


In normal response, the unit returns data and status in the data field, which was
requested in the query from the master. In an exception response, the unit returns an
exception code in the data field, which describes the condition that caused the exception.
Below is a list of exception codes that are supported:

Code Name Description

01 Illegal Function The function code received in the query is not an


allowable action.

02 Illegal Data Address The data address received in the query is not an
allowable address.

03 Illegal Data Value A value contained in the query data field is not an
allowable value.

04 Slave Device Failure An unrecoverable error occurred while the unit was
attempting to perform the requested action.

05 Acknowledge The request has been accepted and is being


processed, but a long duration of time will be
required to do so. This response is returned to
prevent a timeout error from occurring in the
master.

06 Device Busy The unit is engaged in processing a long-duration


program command. The master should retransmit
the message later when the slave is free.

34 / 125
Modbus Communications

7.0 Command Register Locations

Parameter Function Type Scale Access Register Master I/O


Address Address
Analogue 0-20mA Current Output Value 16 Bit Read 0000 40001

Mode Indicates and Controls mode Bit Read/Write 0001 40002

Status/Error Indicates Errors Bit Read 0002 40003

Gas Type of Gas Unit is sensing Value Dec Read/Write 0003 40004

Type Unit Identifies the unit in Decimal Value Read 0004 40005

Software Rev. Indicates the Software Rev. ASCII 2-Char Read 0005 40006

Gain Measure of Dirt on Windows Value 16-Bit Read 0006 40007

LED Disable Disables the LED Function Value Read/Write 0007 40008

Sol On/Off Turns the Solenoid On or Off Value Read/Write 0008 40009

Address Unit Address Value Read/Write 0009 40010

Adjusted Ratio Adjusted Ratio Value 15-Bit Read 000A 40011


Signed

Baud Rate Indicates present Baud Rate


(2400, 4800, 9600) Value (0-4) Read/Write 000B 40012

Data Format Indicates present Data Format


(8-N-1, 8-E-1, 8-0-1, 8-N-2) Value (0-3) Read/Write 000C 40013
Not used 000D to & including 0019

Total Receive
Errors Total # of Receive Errors Value 8-Bit Read 0020 40033

Bus Activity Bus Activity Rate in % of this


Rate Address Node vs. Other
Addressed Notes Dec (0-100%) Read 0021 40034

Function Code Total # of Function Code


Errors Errors Value 8-Bit Read 0022 40035

Starting Total # of Starting Address


Errors Errors Value 8-Bit Read 0023 40036

Number of
Register Errors Total # of Register Errors Value 8-Bit Read 0024 40037

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Modbus Communications

Parameter Function Type Scale Access Register Master I/O


Address Address

RXD CRC Hi Total # of RXD CRC Hi


Errors Errors Value 8-Bit Read 0025 40038

RXD CRC Lo Total # of RXD CRC Lo


Errors Errors Value 8-Bit Read 0026 40039

Overrun Errors Total # of Overrun Errors Value 8-Bit Read 0027 40040

Noise Flag Total # of Noise Flag Errors


Errors Value 8-Bit Read 0028 40041

Framing Errors Total # of f Framing Errors Value 8-Bit Read 0029 40042

Not used 002A 40043

Not used 002B 40044

Not used 002C 40045

Clear Comm
Errors Clear all Comm Errors Bit 1-Bit Write 002D 40046

8.0 Command Register Details


8.1 Analogue (00H)
A read returns a value which is proportional to the 0-20mA output current. The current is
based on a 16-bit value. The master scaling is 0-65535 Decimal which corresponds to
the scaling which is 0-21.7mA

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Modbus Communications

8.2 Mode (01H)


A read returns the present operating mode. A write command changes the mode to the
requested mode.

Exception: Returns an Exception Code 01 (Illegal Function) if an illegal write is


requested. A zero or cal command returns an Exception Code 01
(Acknowledge 05). The operation will take a long time to complete

When in zero mode (Bit-3) and a calibrate command is given, the unit will return an
Exception Code 06 (Device Busy) until it is ready to go to the calibrate mode (Bit-4).

Function Bit Position Access

Slope Mode 8 MSB Read


Initial Mode 7 Read
Calibration Complete 6 Read
Waiting for Gas 5 Read
Waiting for Calibration Request 4 Read
Zero Mode 3 Read/Write
Calibration Mode 2 Read/Write
Run Mode 1 LSB Read/Write

8.3 Status/Error (02H)


A read returns the errors that are occurring at the present time which are indicated by bit
position. (The error must exist for 10 seconds before it will be displayed) (See Product
Manual for explanation).

Byte Function Bit Position Access

High EEPROM 16MSB Read


Excess Negative 15 Read
RAM 14 Read
Checksum 13 Read
Heater 12 Read
Lamp Reference 11 Read
Lamp Active 10 Read
Loop 9 Read

Low Failed to Zero 8 Read


Failed to calibrate 7 Read
Low line voltage 6 Read
Sudden Change 5 Read
IR High 4 Read
IR Low 3 Read
Clean Window Lens 2 Read
IR is close to Low 1 Read

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Modbus Communications

8.4 Gas (03H)


A read returns the present gas type. A write command changes the unit to the requested
gas type. Since it is not calibrated for the new gas, the Fail to Calibrate error is set. The
only way to reset this failure is to calibrate to the new gas or return to the original gas.

Exception: If the gas is not a 0 to 8, the Exception Code 03 (Illegal Data Value) is
returned.

Exception: If the EEPROM cannot store the Gas type, an Exception Code 04 (Slave
device failure) is returned.

IR2100 Methane (Standard Unit) Series

Function Value(Decimal) Access

Methane 0 Read/Write
Propane 1 Read/Write
Butane 2 Read/Write
Hexane 3 Read/Write
100% by Volume 4 Read/Write
TBD 5 Read/Write
Ethane 6 Read/Write
Pentane 7 Read/Write
Other 8 Read/Write

8.5 Type Unit (04H)


A read returns the Decimal Value 2100. This identifies the IR2100 Methane Series
A read returns the Decimal Value 2200. This identifies the IR2100 Ethylene Series

8.6 Software Rev. (05H)


A read returns the software revision in 2 ASCII characters.

8.7 Gain (06H)


A read returns the value of the gain. The difference between the initial value and the
present value indicates the amount of blockage caused by dirt on the windows.

38 / 125
Modbus Communications

8.8 LED Disable (07H)


When the LED is disabled the LED driver is disabled from blinking error codes etc; it then
can be used to drive a solenoid, thus, the serial bus can activate the solenoid to apply cal
gas. A write command enables/disables the normal LED function. The solenoid function
cannot be used until the LED function is disabled.

Function Value (Decimal) Access

Disable Normal Function 1 Read/Write


Enable Normal Function 0 Read/Write

Exception: If a value other than 0 or 1 is used, then the Exception Code 01 (Illegal
Function) is returned. If an EEPROM error occurs, then the Exception
Code 04 (Slave Device Failure) is returned.

8.9 Solenoid On/Off (08H)


This feature is used for calibration check. In this situation the LED driver is used as a
Solenoid Driver. See LED Disable.

A write command turns the solenoid output On or Off. A read returns the status of the
solenoid output; if the LED is not disabled, a value of 30 will be returned.

Function Value (Decimal) Access

On 10 Read/Write
Off 20 Read/Write
Normal Operation 30 Read

Exception: If a value other than 10 or 20 is used, then the Exception Code 03 is


returned. If an EEPROM error occurs, then the Exception Code 04 (Slave
Device Failure) is returned.

8.10 Address (09H)


A read returns the address of the unit. A write changes the address to the requested
address. The range of the address is 1 to 247.

Exception: If the EEPROM write fails, and Exception Code 04 (Slave Device
Failure) is returned.

NOTE: By activating the magnetic switch input during power-up (10 seconds), the
Address will default to 1.

8.11 Adjusted Ratio (0AH)


A read returns the unprocessed input data from the unit indicating that it is receiving gas
during calibration. This data is assigned a 15-bit integer.

10

39 / 125
Modbus Communications

8.12 Baud Rate (0BH)


A read returns the baud rate of the IR2100. A write changes the baud rate to the
requested baud rate. After the baud rate has been changed to the addressed unit, the
Modbus communications will cease because the rate has been changed; therefore the
master will have to change its baud rate to the slaves new baud rate in order to restart
the communications.

Baud Rate Low Data Byte Access

9600 02 Read/Write
4800 01 Read/Write
2400 00 Read/Write

This function is indicated on the Low Data Byte and the High Data Byte is not used.

Exception: If the baud rate is not in range, an illegal data value (03) is returned.

Note: By activating the magnetic switch during power-up (10 seconds), the Baud Rate
will default to 9600.

8.13 Data Format (0CH)


A read returns the data format of the unit. A write will change the data format to the
requested data format. After the data format has been changed, the addressed unit may
cease communicating or start producing comm errors because the data format has
changed; therefore the master will have to change its data format to the slaves new data
format in order to allow proper communications.

Data Parity Stop Format Low Data Byte Access

8 None 1 8-N-1 00 Read/Write


8 Even 1 8-E-1 01 Read/Write
8 Odd 1 8-O-1 02 Read/Write
8 None 2 8-N-2 03 Read/Write

This function is indicated on the Low Data Byte and the High Data Byte is not used.

NOTE: By activating the magnetic switch during power-up (10 seconds), the Data Format
will default to 8-N-1.

Exception: If the baud rate is not in range, an illegal data value (03) is returned.

8.14 Total Receive Errors (20H)


A read indicates the total Modbus Comm Receive Errors that occurred in the slave
device. The maximum count is 255 and then the counter will roll over to zero and begin
counting again. The total errors are an accumulation of the individual comm errors listed
over.

8.15 Bus Activity Rate (21H)


A read indicates the Bus Activity Rate in percent of the Slaves addressed node versus
other addressed nodes. Range of this value is in hex (0-64) which translates to decimal
(0-100%).

11

40 / 125
Modbus Communications

8.16 Function Code Errors (22H)


A read indicates the number of Function Code Errors that occurred in the slave device.
The maximum count is 255 and then the counter will roll over to zero and begin counting
again.

8.17 Starting Address Errors (23H)


The counter is incremented for each address that does not equal the device address. A
read indicates the number of Starting Address Errors that occurred in the slave device.
The maximum count is 255 and then the counter will roll over to zero and begin counting
again.

8.18 Number of Register Errors (24H)


A read indicates the Number of Register Errors that occurred in the slave device. The
maximum count is 255 and then the counter will roll over to zero and begin counting
again.

8.19 RXD CRC Hi Errors (25H)


A read indicates the number of RXD CRC Hi Byte Errors that occurred in the slave
device. The maximum count is 255 and then the counter will roll over to zero and begin
counting again.

8.20 RXD CRC Lo Errors (26H)


A read indicates the number of RXD CRC Lo Byte Errors that occurred in the slave
device. The maximum count is 255 and then the counter will roll over to zero and begin
counting again.

8.21 Overrun Errors (27H)


A read indicates the number of Overrun Errors that occurred in the slave device. The
maximum count is 255 and then the counter will roll over to zero and begin counting
again.

8.22 Noise Flag Errors(28H)


A read indicates the number of Noise Flag Errors that occurred in the slave device. The
maximum count is 255 and then the counter will roll over to zero and begin counting
again.

8.23 Framing Errors (29H)


A read indicates the number of Framing Errors that occurred in the slave device. The
maximum count is 255 and then the counter will roll over to zero and begin counting
again.

8.24 Clean Comm Errors (30H)


A read or write resets all the Modbus Com Error counters to zero.

12

41 / 125
Model IR2100

Customer Support

UNITED STATES

Corporate Office: Phone: +1-949-581-4464


26776 Simpatica Circle Fax: +1-949-581-1151
Lake Forest, CA 92630 Email: sales@generalmonitors.com

9776 Whithorn Drive Phone: +1-281-855-6000


Houston, TX 77095 Fax: +1-281-855-3290
Email: gmhou@generalmonitors.com

UNITED KINGDOM
Heather Close Phone: +44-1625-619-583
Lyme Green Business Park Fax: +44-1625-619-098
Macclesfield, Cheshire, Email: info@generalmonitors.co.uk
United Kingdom, SK11 0LR

IRELAND
Ballybrit Business Park Phone: +353-91-751175
Galway, Republic of Ireland Fax: +353-91-751317
Email: info@gmil.ie

SINGAPORE
No. 2 Kallang Pudding Rd. Phone: +656-748-3488
#09-16 Mactech Building Fax: +656-748-1911
Singapore 349307 Email: genmon@gmpacifica.com.sg

MIDDLE EAST
LOB12, #G20 Phone: +971-4-8815751
P.O. Box 61209 Fax: +971-4-8817927
Jebel Ali, Dubai Email: gmme@emirates.net.ae
United Arab Emirates

13

42 / 125
Model IR2100

Customer Satisfaction Questionnaire


Attention Field Operations:
We would appreciate your help in assessing and thus improving the quality of our Equipment and Service
and would therefore be grateful if you would complete the Questionnaire below and return it to:

General Monitors Ireland Ltd,


Ballybrit Business Park,
Galway,
Republic of Ireland.

Thank you for your assistance

Client

Client Order No. ______________________________________________________________________

General Monitors Sales Order No. ________________________________________________________

(Please tick appropriate box) Yes No

1. Was the equipment the correct option?

2. Are sensors correct type and range?

3. Is mechanical assembly good?


(everything proper fit and tight)

4. Did you receive the necessary accessories


to commission the equipment?

5. Has the equipment been commissioned?

6. Any problems encountered during commissioning?

7. Is the equipment functioning correctly at present?

If you have answered NO to any of the above, please provide further details overleaf. Thank you.

Completed by: _______________________________ Date: ______________________

14

43 / 125
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 44 of 125

2. IR OPEN PATH GAS DETECTOR IR5000

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
MODEL IR5000
Infrared Open Path 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 08/05

General Monitors reserves the right to change


published specifications and designs without prior
notice.

Part No. MANIR5000-EU


Revision N/08-05

45 / 125
Model IR5000

Table of Contents
Table of Contents ................................................................................................ i
Table of Figures .............................................................................................. iv
Table of Tables ............................................................................................... v
E C Declaration of Conformity in accordance with EC & ATEX Directives ......... vi

1.0 Warranty ............................................................................................. vii


1.1 Warning .............................................................................................vii
1.2 System Integrity Verification............................................................. viii
1.3 Commissioning Safety Systems....................................................... viii
1.4 Periodic Testing/Calibration of Field Devices.....................................ix
1.5 Periodic System Verification...............................................................ix

2.0 Quick Start Guide .......................................................................................... x


2.1 Receipt of Equipment ......................................................................... x
2.2 Location Considerations ..................................................................... x
2.3 IR5000 Detection Method...................................................................xi
2.3.1 Measurement Scale ..................................................................xi
2.4 System.............................................................................................. xiii
2.4.1 Gas cloud measurements .................................................... xiii
2.5 Control Electronics ........................................................................... xiii
2.6 System Mounting..............................................................................xiv
2.7 Conduit Sealing .................................................................................xv
2.8 Terminal Connections........................................................................xv
2.8.1 Terminal Block Operation.....................................................xv
2.8.2 The terminal connections for the Input Power .....................xvi
2.9 Relay Output Connections .............................................................. xvii
2.9.1 (A3) Relay Contacts ........................................................... xvii
2.9.2 The terminal connections for the LELmeters-Warn
(A2) Relay Contacts ........................................................... xviii
2.9.3 The terminal connections for the ppmmeters-Alarm
(A1) Relay Contacts ........................................................... xviii
2.9.4 The terminal connections for the FAULT Relay Contacts.. xviii
2.9.5 General IR Source Brightness settings ...............................xix
2.10 Applying Power & Alignment Mode ................................................. xxii
2.10.1 Setup Mode ........................................................................ xxii
2.10.2 Alignment/Adjustment Mode .............................................. xxii
2.10.3 Alignment............................................................................ xxii
2.10.4 Response Test .................................................................. xxiii

3.0 Introduction ............................................................................................... 1


3.1 General Description............................................................................ 1
3.2 Features and Benefits ........................................................................ 2
3.3 Applications ........................................................................................ 2

4.0 IR5000 System ............................................................................................... 3


4.1 Infrared Detection Principles .............................................................. 3
4.1.1 Infrared Radiation .................................................................. 3
4.1.2 Beer-Lambert Law ................................................................. 3
4.1.3 IR5000 Detection Method...................................................... 3
4.1.4 Measurement Scale............................................................... 3
4.1.5 System................................................................................... 5
4.2 Control Electronics ............................................................................. 5

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5.0 Installation ............................................................................................... 6


5.1 Receipt of Equipment ......................................................................... 6
5.2 Location Considerations ..................................................................... 6
5.3 System Mounting................................................................................ 7
5.4 Conduit Sealing .................................................................................. 8
5.5 Terminal Connections......................................................................... 8
5.5.1 Terminal Block Operation...................................................... 8
5.5.2 Relay Output Connections .................................................. 10
5.5.3 General IR Source Brightness settings................................ 12
5.6 Applying Power & Alignment Mode .................................................. 15
5.6.1 Setup Mode ......................................................................... 15
5.6.2 Alignment/Adjustment Mode ............................................... 15
5.6.3 Alignment............................................................................. 15
5.6.4 Response Test .................................................................... 16
5.7 Operational Cautions........................................................................ 16
5.7.1 A rapid and massive liquid propane release........................ 16
5.7.2 A rapid and massive buildup of a high concentration
propane gas cloud................................................................ 16
5.7.3 Solutions to guard against these situations ......................... 16

6.0 Operation ............................................................................................. 17


6.1 Output Options ................................................................................. 17
6.2 - - Test Gas Mode .......................................................................... 17
6.3 SE Setup Mode .............................................................................. 17
6.3.1 Setup Mode Options Sheet ................................................. 19
6.4 AJ Alignment/Adjustment Mode..................................................... 20
6.5 Fi Finish.......................................................................................... 20
6.6 Maintenance ..................................................................................... 20
6.7 Display and Fault Codes .................................................................. 20
6.8 PPM & LEL Negative Drift Faults ..................................................... 21
6.9 Troubleshooting................................................................................ 21

7.0 Customer Support ....................................................................................... 23


8.0 Appendix ............................................................................................. 24
8.1 Specifications ................................................................................... 24
8.1.1 System Specifications ......................................................... 24
8.2 Warranty ........................................................................................... 24
8.3 Fault Codes ...................................................................................... 24
8.4 Response Time ................................................................................ 24
8.4.1 Linearity................................................................................ 24
8.5 Path Length ...................................................................................... 24
8.6 Approvals.......................................................................................... 24
8.7 Mechanical Specifications ................................................................ 25
8.7.1 Weatherproof Protection (Both): .......................................... 25
8.7.2 Electrical Specifications ...................................................... 25
8.8 Power................................................................................................ 25
8.8.1 Contact Relay Ratings ......................................................... 25
8.8.2 Analog Signal Output (600 ohms max.) ............................... 25
8.8.3 Recommended Cable Lengths ............................................ 26
8.8.4 Environmental Specifications............................................... 26
8.8.5 Vibration Specification.......................................................... 26
8.9 Engineering Documentation ............................................................. 27
8.9.1 Outline - Source Unit ........................................................... 27
8.9.2 Outline - Receiver Unit ........................................................ 28
8.9.3 Outline Source & Receiver European Units ..................... 29

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8.9.4 IR5000 Block Diagram ........................................................ 30


8.9.5 Grounding Connections....................................................... 31
8.9.6 Mounting Arm...................................................................... 31
8.9.7 Aperture Plate...................................................................... 32
8.10 Ordering Information......................................................................... 33
8.10.1 System Components ........................................................... 33
8.10.2 Spare Parts.......................................................................... 33
8.10.3 Accessories ......................................................................... 33

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Table of Figures
Figure 1 Indoor Gas Cloud.......................................................................................xii
Figure 2 Outdoor Gas Cloud....................................................................................xii
Figure 3 LNG Storage Tank Application .................................................................xiv
Figure 4 System Mounting Hardware .....................................................................xiv
Figure 5 Terminal Block Operation Diagram ...........................................................xv
Figure 6 Wire Strip Length Diagram .......................................................................xvi
Figure 7 Relay Contact Protection for AC / DC Loads........................................... xvii
Figure 8 Source Terminal Block Location ............................................................xix
Figure 9 European Union Source Terminal Block Location..................................xx
Figure 10 Receiver Terminal Block Location ..........................................................xx
Figure 11 European Union Receiver Terminal Block Location..............................xxi
Figure 12 European Union IR5000 Junction Boxes..................................................xxi
Figure 13 IR5000 Receiver / Source Unit ................................................................... 1
Figure 14 Indoor Gas Cloud........................................................................................ 4
Figure 15 Outdoor Gas Cloud..................................................................................... 4
Figure 16 LNG Storage Tank Application ................................................................... 7
Figure 17 System Mounting Hardware ....................................................................... 7
Figure 18 Terminal Block Operation ........................................................................... 8
Figure 19 Wire Strip Length Diagram ......................................................................... 9
Figure 20 Relay Contact Protection for AC / DC Loads............................................ 10
Figure 21 Source Terminal Block Location ............................................................ 12
Figure 22 European Union Source Terminal Block Location................................. 13
Figure 23 IR Receiver Terminal Block Location ....................................................... 13
Figure 24 European Union IR Receiver Terminal Block Location ............................ 14
Figure 25 European Union IR5000 Junction Boxes.................................................. 14
Figure 26 Outline Drawing, Source........................................................................... 27
Figure 27 Outline Drawing, Receiver ........................................................................ 28
Figure 28 Junction Box Assembly of IR50000 Receiver & Source European Units. 29
Figure 29 IR5000 Block Diagram.............................................................................. 30
Figure 30 Grounding Connections ............................................................................ 31
Figure 31 Mounting Bracket Assembly ..................................................................... 31
Figure 32 Aperture Plate ........................................................................................... 32

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Table of Tables
Table 1 Example Readings of Methane Gas Clouds 0-5000 ppmmeter range .............xiii
Table 2 Example Readings of Methane Gas Clouds 0-5 LELmeter range....................xiii
Table 3 Example Readings of Methane Gas Clouds 0-5000 ppmmeter range ............... 5
Table 4 Example Readings of Methane Gas Clouds 0-5 LELmeter range...................... 5
Table 5 PPM & LEL Faults ..............................................................................................21
Table 6 Recommended Cable Lengths Receiver Unit (+24VDC)...................................26
Table 7 Recommended Cable Lengths Source Unit (+24VDC) .....................................26
Table 8 Recommended Cable Lengths Analog Output ..................................................26

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E C Declaration of Conformity in accordance with EC & ATEX Directives


We at General Monitors Ireland Ltd., Ballybrit Business Park, Galway, Republic of Ireland, hereby
declare that the equipment described below, both in its basic design and construction, and in the
version or versions marketed by us, conforms to the relevant safety and health related requirements
of the appropriate EC Directives, only as follows:

a) Conforms with the protection requirements of Council Directive 89/336/EEC, + Amd


92/31/68/EEC relating to Electromagnetic Compatibility, by the application of:

A Technical Construction File No. GM 97002 and Competent Body Report No. 4473/1K5

and

b) Conforms with the protection requirements of IEC 1010-1: 1990 + Amd 1:1992 +Amd 2: 1995
relating to safety by the application of:

A Technical Construction File No. GM 97002 and Competent Body Certificate No. 4146/1093/9367
issued by:

ERA Technology Ltd. Cleeve Road, Leatherhead Surrey KT22 7SA, England. Tel: +44 1372 367000

This declaration shall cease to be valid if modifications are made to the equipment without our
approval.

Models: IR5000 OPGD

It is ensured through internal measures and our ISO9001: 1994 certifications, that series production
units conform at all times to the requirements of these current EC Directives and relevant standards.

Note: The Following Information applies to ATEX.


This equipment has not been assured for use as a safety related device under the terms of Directive
94/9/EC EHSR 1.5. (Contact General Monitors Ireland Ltd for further details)

General Monitors Ireland Ltd. in order to comply with ATEX, will provide this Instruction Manual in a
European Language required to operate the product upon request. Should this be necessary,
General Monitors Ireland Ltd. should be notified of this request to allow adequate time to process the
request.

ATEX Certificate Markings.

II 2 G Sira02ATEX1172
Model: IR5000

0518 EExd IIB T4


-40 C to +60C

Responsible Person: Date: 08-07-02

Denis Connolly
General Manager European Operations

The signatory acts on behalf of company management, and with full power of attorney

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1.0 Warranty
General Monitors warrants the Model IR5000 to be free from defects in workmanship
or material under normal use and service within two (2) years from the date of
shipment. General Monitors will repair or replace without charge any such defective
equipment found to be defective during the warranty period. General Monitors
personnel will make full determination of the nature of, and responsibility for
defective equipment. Defective or damaged equipment must be shipped prepaid to
General Monitors plant or representative from which shipment was made. In all
cases, this warranty is limited to the cost of the equipment supplied by General
Monitors. The customer will assume all liability for the misuse of this equipment by its
employees or other personnel.

NOTE - The Model IR5000 Infrared Open Path System is easy to install; however,
this manual should be read and understood before attempting to operate the system.

As with other Infrared devices, the Model IR5000 does NOT detect Hydrogen gas.

All warranties are contingent upon proper use in the application for which the product
was intended and do not cover products which have been modified or repaired
without General Monitors approval or which have been subjected to neglect,
accident, improper installation or application, or on which the original identification
marks have been removed or altered. Except for the express warranty stated above,
General Monitors disclaims all warranties with regard to the products sold, including
all implied warranties of merchantability and fitness and the express warranty stated
herein are in lieu of all obligations or liabilities on the part of General Monitors for
damages including, but not limited to, consequential damages arising out of/or in
connection with the use or performance of the product.

1.1 Warning
The Model IR5000 Open Path System contains components which can be damaged
by static electricity. Special care must be taken when wiring the system to ensure
that only the connection points are touched.

TOXIC, COMBUSTIBLE AND FLAMMABLE GASES & VAPORS ARE VERY


DANGEROUS. EXTREME CAUTION SHOULD BE USED WHEN THESE
HAZARDS ARE PRESENT.

The IR5000 is manufactured from stainless steel or Aluminium with nitrile rubber
seals and glass windows. The performance of these materials with respect to attack
by aggressive substances that may be present in the hazardous area should be
considered before installation.

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Model IR5000

1.2 System Integrity Verification


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 the respective product instruction
manual. Remember, these products are for your safety.

To ensure operation at optimum performance, General Monitors recommends that


certain maintenance items are performed.

1.3 Commissioning Safety Systems


Before power up, verify wiring, terminal connections and stability of mounting for all
integral safety equipment including, but not limited to:

Power supplies
Control modules
Field detection devices
Signaling / output devices
Accessories connected to field and signaling devices

After the initial application of power (and any factory specified warm-up period) to the
safety system, verify that all signal outputs, to and from devices and modules, are
within the manufacturers specifications. Initial calibration / calibration checking /
testing should be performed per the manufacturers recommendations and
instructions.

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.

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1.4 Periodic Testing/Calibration of Field Devices


Periodic testing/calibrating should be performed per the manufacturers
recommendations and instructions. Testing/Calibrating procedures should include,
but not be limited to:

Verify zero reading


Apply a known concentration of gas, or a simulated test device provided by the
manufacturer
Verify integrity of all optical surfaces and devices

When testing produces results outside of the manufacturers 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.

1.5 Periodic System Verification


The following system verifications should be performed at least annually:

Verify wiring, terminal connections and stability of mounting for all integral safety
equipment including, but not limited to:

Power supplies
Control modules
Field detection devices
Signaling / output devices
Accessories connected to field and signaling devices

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.

Calibration intervals should be independently established through a documented


procedure, including a calibration log maintained by plant personnel, or third party
testing services.

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Quick-Start Guide

2.0 Quick Start Guide


2.1 Receipt of Equipment
All equipment shipped by General Monitors is pre-packed in shock absorbing
containers which provide protection against physical damage (original containers
should be kept for future shipping or storage needs).

Shipping container contents should be carefully removed and checked against the
packing list. If any damage has occurred or there is any discrepancy in the order,
please notify General Monitors as soon as possible.

All correspondence with General Monitors must specify the equipment part number
and serial number.

Each unit is tested by the factory, however, a complete system check-out is suggested
upon initial installation to ensure system integrity.

2.2 Location Considerations


There are no standard rules for placement, since the optimum location varies with
each application.

Some factors to consider when selecting locations:

The system should be accessible for occasional response checks.


The Receiver Unit should be mounted so that the display is visible to aid in
alignment.
Do not mount near strong magnetic fields or degradation of performance may result.

The line of sight between the Source and Receiver Units should be free from:

Items that may block the beam (i.e. a parked truck or moveable machinery).
Interruptions caused by frequent human or animal crossings.
The units should be reasonably protected (i.e. covered by a hood if temperatures
exceed the specifications in Section 8.7.2).
The units are RFI resistant, but should not be mounted too close to radio transmitters
or similar equipment.
Mount the Receiver unit so that direct sunlight does not enter the front window.
Locate the units away from concentrated sources of heat.
Mount away from sources of excessive vibration and away from high voltage/high
current power lines.
If the path length is less than 15 meters (<50 feet), an aperture plate is required.

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2.3 IR5000 Detection Method


The Model IR5000 uses a single beam, dual wavelength method of infrared absorption
detection. One wavelength is where absorption of a specific gas (or gases) occurs,
(the absorbing wavelength) and the other wavelength is adjacent to it (the reference
wavelength) but at a wavelength not absorbed by the gas (or gases). By comparing
the signals from these two wavelengths the concentration of the gas can be measured
(i.e. differential absorption technique).

The reference wavelength is chosen to compensate for interferences that can


otherwise occur from atmospheric variation (e.g. humidity, rain, dust, snow, fog,
steam, temperature, etc.).

NOTE - Extremely dense fog, steam or interruptions of the beam by a person or


object, may cause the system to enter into a temporary beam blocked condition until
the line-of-sight clears. This condition is signaled by 1.5mA output level so as to
discriminate it from an instrument True Fault. If preferred, the menu allows a level of
0mA (Fault) to be selected.

This method of detection comes under what is commonly known as the non-dispersive
infrared (NDIR) absorption principle.

2.3.1 Measurement Scale


With the Model IR5000 Open Path System, as there is no fixed path length, the
reading is reported in concentrationmeters. The Model IR5000 reports concentrations
in the ppmmeters range (highly sensitive to low levels of hydrocarbons) and the
LELmeters range (large hazardous levels of hydrocarbons). The Model IR5000 has
one auto-ranging two-digit display, the two ranges are differentiated by lighting an LED
below the display for ppmmeters and above the display for LELmeters. In general, an
open path monitor can give similar responses to large, low concentration gas clouds
and small, high concentration gas clouds as shown in Figures 1 and 2.

* - 0 to 2000 ppmmeter and 0 to 1 LELmeter on the Heavy Hydrocarbon (Propane)


Unit.

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Quick-Start Guide

Typical gas cloud configuration:

No Wind

Figure 1 Indoor Gas Cloud

Figure 2 Outdoor Gas Cloud

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Quick-Start Guide

2.4 System
2.4.1 Gas cloud measurements

Example readings of Methane gas clouds by the standard Model IR5000 are:

Size of gas cloud IR5000 Display


50 ppm x 2 meters 100 ppmmeter
25 ppm x 4 meters 100 ppmmeter
10 ppm x 10 meters 100 ppmmeter
100 ppm x 5 meters 500 ppmmeter
50 ppm x 10 meters 500 ppmmeter
500 ppm x 5 meters 2500ppmmeter
100 ppm x 25 meters 2500ppmmeter
5% LEL x 1 meter 2500ppmmeter
1% LEL x 5 meters 2500ppmmeter
.5% LEL x 10 meters 2500ppmmeter
Table 1 Example Readings of Methane Gas Clouds
0-5000 ppmmeter range
Size of gas cloud IR5000 Display
20% LEL x 1 meter 0.2 LELmeter
10% LEL x 2 meters 0.2 LELmeter
100% LEL x 2 meters 2.5 LELmeter
50% LEL x 5 meters 2.5 LELmeter
100% LEL x 1 meter 1.0 LELmeter
50% LEL x 2 meters 1.0 LELmeter
25% LEL x 4 meters 1.0 LELmeter
10% LEL x 10 meters 1.0 LELmeter
Table 2 Example Readings of Methane Gas Clouds
0-5 LELmeter range

2.5 Control Electronics


Both the Model IR5000 Source and Receiver units operate from a +24VDC (nominal)
input. This unregulated +24 volt source is fed to on-board power supplies that produce
all of the necessary voltages for the Model IR5000 Source and Receiver units.

In normal operation the microprocessor program constantly monitors the two infrared
wavelengths and performs mathematical operations on this information in conjunction
with values obtained during the factory calibration process.

The microprocessor derives output information and feeds it to the digital to analog
converter to produce two 4 to 20 milliampere (mA) signals that are proportional to the
0 to 5000 ppmmeters and 0 to 5 LELmeters* concentration of gas at the sensor. The
microprocessor program also monitors other conditions such as the supply voltage,
the optical path integrity (beam block) and automatic gain control.

* - 0 to 2000 ppmmeter and 0 to 1 LELmeter on the Heavy Hydrocarbon (Propane)


Unit.

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Quick-Start Guide

2.6 System Mounting


The Model IR5000 units are shipped with the pan and tilt assembly already mounted.
After the mounting location has been established, mount the support arms. Apply
Lithium grease on both taper joints before attaching the unit to the support arm. Add
the supplied bolt and washer, 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 tap
the bolt head to release taper (see Figures 4 and 32).

Possible installation:
LNG Storage Tanks

Figure 3 LNG Storage Tank Application

Figure 4 System Mounting Hardware

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Quick-Start Guide

2.7 Conduit Sealing


Each conduit run from a hazardous to a non-hazardous location should be sealed so
that gases, vapors and/or flames cannot pass from one electrical installation to
another through the conduit system.

The customer must connect a section of flex conduit to the Source and the Receiver
units to allow movement of the units during alignment (see Figures 8 through 11).

General Monitors requires the use of a drain loop or conduit seal in the conduit to
prevent moisture from entering the unit housing.

CAUTION - Acetic Acid will cause damage to metal components, metal hardware,
ceramic ICs, etc. If damage results from the use of a sealant that outgases Acetic
Acid (RTV) the two-year warranty will be void.

2.8 Terminal Connections


To make the wiring connections to the Model IR5000, loosen the retaining screws at
the bottom/rear of each unit using the supplied T-wrench, then unscrew the rear cover
of the Source and Receiver housings. All output connections are made inside the
Receiver housing (see Figures 8 through 11 for Terminal Block locations).

NOTE - Contact with printed circuit board (PCB) components should be avoided to
pre-vent damage by static electricity.

2.8.1 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 5). 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.

Figure 5 Terminal Block Operation Diagram

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Quick-Start Guide

The terminal block is designed to accept 16 AWG to 22 AWG stranded or solid-wire


(14 AWG wire can be used if it is carefully inserted). Each wire should be stripped as
shown in Figure 6.

Figure 6 Wire Strip Length Diagram


Primary DC voltage power must be provided by the customer. Since the Model IR5000
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.

The Receiver and Source common must be connected to the chassis. This is
accomplished by connecting the power supply common to earth-ground and
connecting the earth-ground to the chassis. To ground the Receiver and Source
chassis, the earth-ground wire must be connected to the inside or outside chassis
grounding screw (see Figure 8).

2.8.2 The terminal connections for the Input Power

Source:
 TB1-1 Common
 TB1-2 +24 VDC

Receiver:
 TB4-6 Common
 TB4-5 +24 VDC

The maximum distance between the Model IR5000 and the power source is specified
in the Appendix (see Section 8.8.3).

(Two) 4 to 20mA output signals are provided by the Model IR5000 and can be sent to
any industrial device that can accept a 4 to 20mA signal for computer based multi-
point monitoring. The Analog Output Signals provide for a control room or other
location to display indications of operation and alarm conditions. See Section 8.7 for
the maximum distance between the Model IR5000 and the device connected to the
Analog Output Signal.

NOTE - If either Analog Output is not being used, it must be jumpered to the common
terminal.

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2.8.2.1 The terminal connections for the Analog Output Signals

Receiver:
TB4-4 LELmeters Common
TB4-3 LELmeters Current Output
TB4-2 ppmmeters Common
TB4-1 ppmmeters Current Output

2.8.2.2 The terminal connections for an External Relay Reset Switch

Receiver:
TB3-3 External Reset Switch
TB4-6 Switch Common

The Model IR5000 provides external Reset Switch terminations to allow remote
resetting of the alarms. Connect each end of a normally open SPST momentary switch
to the above terminals. To reset a latched relay, simply press and release the switch.

2.9 Relay Output Connections


Inductive loads (bells, buzzers, relays, etc.) on dry relay contacts must be clamped as
shown in Figure 7. Unclamped inductive loads can generate voltage spikes in excess
of 1000 volts. Spikes of this magnitude may cause false alarms and contact damage.

NOTE - All relay states shown with power applied.

Figure 7 Relay Contact Protection for AC / DC Loads

2.9.1 (A3) Relay Contacts


Receiver:
TB1-2 ALARM Common

De-Energized Relays Selected:

TB1-3 ALARM Normally Open Contact


TB1-1 ALARM Normally Closed Contact

Energized Relays Selected:

TB1-1 ALARM Normally Open Contact


TB1-3 ALARM Normally Closed Contact

Before making connections to these relay contacts, see Figures 8 through 11.

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2.9.2 The terminal connections for the LELmeters-Warn (A2) Relay Contacts

Receiver:
TB1-5 WARN Common

De-Energized Relays Selected


TB1-6 WARN Normally Open Contact
TB1-4 WARN Normally Closed Contact

Energized Relays Selected


TB1-4 WARN Normally Open Contact
TB1-6 WARN Normally Closed Contact

Before making connections to these relay contacts, see Figures 8 through 11.

2.9.3 The terminal connections for the ppmmeters-Alarm (A1) Relay Contacts

Receiver:
TB2-2 ALARM Common

De-Energized Relays Selected


TB2-3 ALARM Normally Open Contact
TB2-1 ALARM Normally Closed Contact

Energized Relays Selected


TB2-1 ALARM Normally Open Contact
TB2-3 ALARM Normally Closed Contact

Before making connections to these relay contacts, see Figures 8 through 11.

*NOTE - The Energized/De-Energized option is software selectable (see Section 6.1).

2.9.4 The terminal connections for the FAULT Relay Contacts

Receiver:
TB2-5 FAULT Common
TB2-4 FAULT Normally Open Contact
TB2-6 FAULT Normally Closed Contact

Before making connections to these relay contacts, see Figures 8 through 11.

NOTE - The FAULT Relay is energized and non-latching in normal operation. There
are no software selectable options that are associated with the FAULT Relay.

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2.9.5 General IR Source Brightness settings


(General Guidelines: May be changed for varying applications.)

Distance Switch Position Closed

5 to 6 meters None
9 meters Pos 1, Pos 4
12 meters Pos 1, Pos 2 Aperture
19 meters Pos 1 Plate

20 meters Pos 1, Pos 8


40 meters Pos 1, Pos 2
60 meters Pos 1
100 meters Pos 1

IR Source Terminal Connections

NPT or M20x1.5 flexible


conduit connections (2 places as
required)

Figure 8 Source Terminal Block Location

Cover removed for clarity

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Quick-Start Guide

IR SOURCE - TERMINAL BLOCK LOCATION

COM
+ 24
LAMP
POWER
1 2 3 4
SUPPLY 1 2 3 4 5 6 7 8

J1
OPEN

24 VDC

FIELD WIRING DIAGRAM

Figure 9 European Union Source Terminal Block Location

RELAY RESET
DeEn En TB1

0-5 LEL ALARM 0-5 LEL


RELAY
ALARM

POWER SUPPLY
0-5 LEL 0-5 LEL
(BLK)

0-5 LEL 0-5LEL

FAULT
FAULT
TB2
ANALOG

ANALOG

Figure 10 Receiver Terminal Block Location

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DeEn En TB1 TB1


A3 NC NO 1 1
0-5 LE 2 2 ALARM 0 - 5 LEL
RELAY
3 3 ALARM NO NC 3 3
2 2 A2 NC NO 4 4
1 1 0-5 LE 5 5 0 - 5 LEL
6
COM WARN NO NC 6 6
6 (BLK)
5 +24VDC NC NO 1
5 (RED) A1 1
4 4 COM 0-5000 PPM 2 2 0 - 5000 PPM
0-20mA
3 3 0-5LEL WARN NO NC 3 3
0 - 5 LEL
2 2 COM NO 4 4
0-20mA
1 1 0-5000 PPM FAULT 5 5
TB4 TB4 NC 6 6
TB2

0 - 5000 PPM

Figure 11 European Union Receiver Terminal Block Location

Figure 12 European Union IR5000 Junction Boxes

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Model IR5000
Quick-Start Guide

2.10 Applying Power & Alignment Mode


2.10.1 Setup Mode
Before applying power to the system for the first time, all wiring connections should be
checked for correctness and the Receivers housing cover should be securely
fastened. Upon initial power-up, the Receiver will enter a two-minute setup mode, the
display will indicate SU.

The IR5000 contains a heater circuit to remove condensation from the windows. The
unit should be allowed to stabilize for approximately two hours before continuing with
the setup mode.

2.10.2 Alignment/Adjustment Mode


The unit now needs to be setup for the application. Place the magnet over the GMI
logo on the rear of the Receiver Unit until two flashing bars appear - -. Remove the
magnet and wait for the Alignment/ Adjustment code AJ to appear (it will follow the
Setup Mode code SE on the display). When AJ appears, re-apply the magnet until
a number between 0 and 99 appears (this is the alignment code).

2.10.3 Alignment
To ensure optimal performance of the Model IR5000, the final alignment code must be
between 87 and 99. To align the Source and Receiver Units, use the following
guidelines:

1. Turn the Source units lamp to full power and perform a rough alignment by sight
until a maximum number is displayed on the Receiver. Tighten the horizontal and
vertical adjustment screws on each unit. Set the Source units brightness as
specified in Section 2.9.5.
2. Loosen the Source units horizontal adjustment screw and move the unit from side
to side until a maximum value is displayed on the Receiver unit. Tighten the
horizontal adjustment screw and loosen the vertical adjustment screw. Move the unit
up and down to obtain a maximum value on the display. Tighten the vertical
adjustment screw.
3. Adjust the Receiver unit from side to side and then up and down to obtain a
maximum display value, tightening the adjustment screws after each adjustment.
4. If a flashing 99 is displayed after alignment, reduce the Source lamp brightness. If
a value lower than 87 is displayed after alignment, increase the Source lamp
brightness (see Section 2.9.5).
5. Re-align the Receiver unit to obtain a maximum display value.

Repeat steps 4 and 5 each time the Source lamp brightness is changed.

If the unit is displaying a number less than 87 or a flashing 99, the IR5000 will not
exit the alignment/adjustment mode.

DO NOT intentionally misalign the Model IR5000 to get below a flashing 99. Turn
down the source lamp brightness. It is important to obtain the highest alignment
number possible within the allowed range. Alignment at high temperatures may result
in alignment numbers at the low-end of the alignment range. Alignment at low
temperatures may result in high alignment numbers.

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Model IR5000
Quick-Start Guide

Once a number within the 87 to 99 range is attained, tighten the Source and
Receivers rear covers and verify that the alignment number has not changed. Apply
the magnet until a flashing CP is displayed (Calibration in Progress Mode). Remove
the magnet and the unit will set the zero value. After approximately 2 minutes, the
unit will return to normal operation.

Ensure that there is no significant amount of background gas when the unit is setting
the zero value, as this will alter the Model IR5000s performance. If there is normally
gas present, try setting-up the IR5000 on a breezy day, as this will dissipate the gas. If
the unit cannot set a zero value, an F8 fault code will appear. The above procedure
should then be repeated. If the unit fails to align properly, check the line of sight
carefully, then contact your GMI representative or the factory direct.

2.10.4 Response Test


After initial alignment, a test of the IR5000 should be carried out using the Test Gas
Filters Kit (P/Ns 30878-1, 30878-2). Follow the testing instructions listed on the inside
label of the filters.

NOTE - The instrument is now ready to operate! Please consult the manual for more
information on the instruments many features.

NOTE - If you have any problems in the setup or testing of the detector, please refer to
the Troubleshooting Section, or call the factory direct.

Worldwide Service is available by calling:

Lake Forest, CaliforniaPhone: +1-949-581-4464


(24 hr. service) Fax: +1-949- 581-1151

Houston, Texas Phone: +1-281-855-6000


Fax: +1-281-855-3290

Ireland Phone: +353-91-751175


Fax: +353-91-751317

Singapore Phone: +65-6748-3488


Fax: +65-6748-1911
United Arab Emirates Phone: +971-4-8815751
Fax: +971-4-8817927
United Kingdom Phone: +44-1625-619-583
Fax: +44-1625-619-098

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Model IR5000

3.0 Introduction
3.1 General Description
The Model IR5000 Infrared Open Path System is a microprocessor-based hydrocarbon
gas detector (Figure 13). The system consists of an IR Source unit and a Receiver unit
that may be placed from 5-100 meters (approx. 15-300 feet) apart. The General Monitors
Model IR5000 is calibrated at the factory and needs no further calibration. The sensitivity
of the Model IR5000 can be checked by placing a Test Gas Filter in front of the Receiver
unit. It is also relatively maintenance free, requiring only a periodic cleaning of the
windows to assure dependable performance.

The Model IR5000 Infrared Open Path System continuously monitors hydrocarbon gases
in both the 0 to 5000 ppmmeter and 0 to 5 LELmeter range*. It provides two 4 to 20mA
analog signals proportional to each of the above ranges, in addition to a digital display
and an A3 (LELmeters-Alarm), A2 (LELmeters-Warn), A1 (ppmmeters-Warn) and
FAULT relay contacts.

The Model IR5000 Infrared Open Path System is easily aligned using the digital display
and adjustable mounting arms, therefore not requiring any bulky setup equipment (e.g.
Digital Volt Meters, Alignment Scopes, etc).

Sensor data and status information from the Model IR5000 can be transmitted up to 9000
feet to any industrial analog to digital (A/D) converter for use in multipoint computer-based
monitoring.

The Model IR5000 Infrared Open Path System operates from an unregulated +24 volt DC
power supply which must be supplied by the customer.

* The Model IR5000 Heavy Hydrocarbon unit (Propane) displays 0 to 2000 ppmmeter
and 0 to 1 LELmeter ranges.

Receiver Source

Figure 13 IR5000 Receiver / Source Unit

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Model IR5000

3.2 Features and Benefits


The advantageous features and benefits of the Model IR5000 Infrared Open Path System
include:

Single detection beam: Benefit - eliminates drift and false alarms.


Dual detection ranges (ppmmeters & LELmeters): Benefit - sensitive to low-level
leaks.
Unitized design - digital readout, 4 relays and two 4 to 20mA outputs: Benefit -
wide variety of outputs.
Digital AutoTRACK alignment: Benefit - easy, no tools alignment.
NEMA 4X, IP66 weatherproof rating: Benefit - highly durable unit.
Fail-to-safe operation: Benefit no undetected faults.
Automatic gain control: Benefit - compensates for dirty optics, rain and fog.
Power supply input reversal protection: Benefit - protection against miswiring
damage.

3.3 Applications
This is a partial list of applications suitable for the Model IR5000 Infrared Open Path
System:

Drilling and production platforms


Fuel loading facilities
Compressor stations
Liquefied natural gas/liquefied petroleum gas processing and storage facilities
Wastewater treatment
Gas turbines
Tank farms
Petrochemical plants
Fence line monitoring

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Model IR5000

4.0 IR5000 System


4.1 Infrared Detection Principles
4.1.1 Infrared Radiation
Most gases absorb infrared radiation. Infrared gas detection is based upon the fact that all
hydrocarbon gases absorb infrared radiation of specific wavelengths or bands but with
different degrees of absorption. The wavelength that these gases absorb radiation at is a
characteristic of the gas (fingerprint) and the amount of absorption is a function of the gas
concentration and the infrared beams path length.

4.1.2 Beer-Lambert Law


The Model IR5000 is based on measuring absorption of infrared radiation passing
through a volume of hydrocarbon gas. Absorption of the radiation follows the Beer-
Lambert Law, which states the transmittance (T) of radiation through an absorbing
medium decreases exponentially by the product of the extinction coefficient (A), the
concentration (C) and the path length (L):
T = exp(-ACL)

4.1.3 IR5000 Detection Method


The Model IR5000 uses a single beam, dual wavelength method of infrared absorption
detection. One wavelength is where absorption of a specific gas (or gases) occurs, (the
absorbing wavelength) and the other wavelength is adjacent to it (the reference
wavelength) but at a wavelength not absorbed by the gas (or gases). By comparing the
signals from these two wavelengths, the concentration of the gas can be measured (i.e.
differential absorption technique).

The reference wavelength is chosen to compensate for interferences that can otherwise
occur from atmospheric variation (e.g. humidity, rain, dust, snow, fog, steam, temperature,
etc.).

NOTE - Extremely dense fog, steam or interruption of the beam by an object or person
may cause the system to enter into a temporary beam blocked condition until the line-of-
sight clears. This condition is signaled by 1.5mA output level so as to discriminate it from
an Instrument true Fault. If preferred, the menu allows a level of 0mA (Fault) to be
selected.

This method of detection comes under what is commonly known as the non-dispersive
infrared (NDIR) absorption principle.

4.1.4 Measurement Scale


With the Model IR5000 Open Path System, as there is no fixed path length, the reading is
reported in concentrationmeters. The Model IR5000 reports concentrations in the
ppmmeters range (highly sensitive to low levels of hydrocarbons) and the LELmeters
range (large hazardous levels of hydrocarbons). The Model IR5000 has one auto-ranging
two-digit display, the two ranges are differentiated by lighting an LED below the display
for ppmmeters and above the display for LELmeters. In general, an open path monitor
can give similar responses to large, low concentration gas clouds and small, high
concentration gas clouds as shown in Figures 14 and 15.

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Model IR5000

Typical gas cloud configuration:

No Wind

Figure 14 Indoor Gas Cloud

Figure 15 Outdoor Gas Cloud

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Model IR5000

4.1.5 System
Gas cloud measurements

Example readings of Methane gas clouds by the standard Model IR5000 are:

Size of gas cloud IR5000 Display


50 ppm x 2 meters 100 ppmmeter
25 ppm x 4 meters 100 ppmmeter
10 ppm x 10 meters 100 ppmmeter
100 ppm x 5 meters 500 ppmmeter
50 ppm x 10 meters 500 ppmmeter
500 ppm x 5 meters 2500ppmmeter
100 ppm x 25 meters 2500ppmmeter
5% LEL x 1 meter 2500ppmmeter
1% LEL x 5 meters 2500ppmmeter
.5% LEL x 10 meters 2500ppmmeter
Table 3 Example Readings of Methane Gas Clouds
0-5000 ppmmeter range

Size of gas cloud IR5000 Display


20% LEL x 1 meter 0.2 LELmeter
10% LEL x 2 meters 0.2 LELmeter
100% LEL x 2 meters 2.5 LELmeter
50% LEL x 5 meters 2.5 LELmeter
100% LEL x 1 meter 1.0 LELmeter
50% LEL x 2 meters 1.0 LELmeter
25% LEL x 4 meters 1.0 LELmeter
10% LEL x 10 meters 1.0 LELmeter
Table 4 Example Readings of Methane Gas Clouds
0-5 LELmeter range

4.2 Control Electronics


Both the Model IR5000 Source and Receiver units operate from a +24VDC (nominal)
input. This unregulated +24 volt source is fed to on-board power supplies that produce all
of the necessary voltages for the Model IR5000 Source and Receiver units.

In normal operation, the microprocessor program constantly monitors the two infrared
wavelengths and performs mathematical operations on this information in conjunction
with values obtained during the factory calibration process.

The microprocessor derives output information and feeds it to the digital to analog
converter to produce two 4 to 20 milliampere (mA) signals that are proportional to the 0 to
5000 ppmmeters and 0 to 5 LELmeters* concentration of gas at the sensor. The
microprocessor program also monitors other conditions such as the supply voltage, the
optical path integrity (beam block) and automatic gain control.

* 0 to 2000 ppmmeter and 0 to 1 LELmeter on the Heavy Hydrocarbon (Propane) Unit.

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Model IR5000

5.0 Installation
5.1 Receipt of Equipment
All equipment shipped by General Monitors is pre-packed in shock absorbing containers
which provide protection against physical damage (original containers should be kept for
future shipping or storage needs).

Shipping container contents should be carefully removed and checked against the
packing list. If any damage has occurred or there is any discrepancy in the order, please
notify General Monitors as soon as possible.

All correspondence with General Monitors must specify the equipment part number and
serial number.

Each unit is tested by the factory, however, a complete system check-out is suggested
upon initial installation to ensure system integrity.

5.2 Location Considerations


There are no standard rules for placement, since the optimum location varies with each
application.

Some factors to consider when selecting locations:

The system should be accessible for occasional response checks.


The Receiver Unit should be mounted so that the display is visible to aid in alignment.
Do not mount near strong magnetic fields or degradation of performance may result.
The line of sight between the Source and Receiver Units should be free from items that
may block the beam (i.e. a parked truck or moveable machinery).
The units should be reasonably protected (i.e. covered by a hood if temperatures
exceed the specifications in Section 8.8.4).
The units are RFI resistant, but should not be mounted too close to radio transmitters or
similar equipment.
Mount the Receiver unit so that direct sunlight does not enter the front window.
Locate the units away from concentrated sources of heat.
Mount away from sources of excessive vibration and away from high voltage/high
current power lines.
If the path length is less than 20 meters (<65 feet), an aperture plate is required.

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Model IR5000

5.3 System Mounting


The Model IR5000 units are shipped with the pan and tilt assembly already mounted.

After the mounting location has been established, mount the support arms. Apply Lithium
grease on both taper joints before attaching the unit to the support arm. Add the supplied
bolt and washer, 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 tap the bolt head to
release taper (see Figures 17 and 32).

Possible installation:

LNG Storage Tanks

Figure 16 LNG Storage Tank Application

Figure 17 System Mounting Hardware

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Model IR5000

5.4 Conduit Sealing


Each conduit run from a hazardous to a non-hazardous location should be sealed so that
gases, vapours and/or flames cannot pass from one electrical installation to another
through the conduit system.

The customer must connect a section of flex conduit to the Source and the Receiver units
to allow movement of the units during alignment (see Figures 26 and 27).

General Monitors requires the use of a drain loop or conduit seal in the conduit to prevent
moisture from entering the unit housing.

CAUTION - Acetic Acid will cause damage to metal components, metal hardware,
ceramic ICs, etc. If damage results from the use of a sealant that outgases Acetic Acid
(RTV) the two-year warranty will be void.

5.5 Terminal Connections


To make the wiring connections to the Model IR5000, loosen the retaining screws at the
bottom/rear of each unit using the supplied T-wrench, then unscrew the rear cover of the
Source and Receiver housings. All output connections are made inside the Receiver
housing (see Figures 21 through 24 for Terminal Block locations).

NOTE - Contact with printed circuit board (PCB) components should be avoided to
prevent damage by static electricity.

5.5.1 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 18). 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.

Figure 18 Terminal Block Operation

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Model IR5000

The terminal block is designed to accept 16 AWG to 22 AWG stranded or solid-wire (14
AWG wire can be used if it is carefully inserted). Each wire should be stripped as shown
in Figure 19.

Figure 19 Wire Strip Length Diagram

Primary DC voltage power must be provided by the customer. Since the Model IR5000
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.

The Receiver and Source common must be connected to the chassis. This is
accomplished by connecting the power supply common to earth-ground and connecting
the earth-ground to the chassis. To ground the Receiver and Source chassis, the earth-
ground wire must be connected to the inside or outside chassis grounding screw.

5.5.1.1 The terminal connections for the Input Power

Source:
 TB1-1 Common
 TB1-2 +24 VDC

Receiver:
 TB4-6 Common
 TB4-5 +24 VDC

The maximum distance between the Model IR5000 and the power source is specified in
the Appendix (see Section 8.8.3).

(Two) 4 to 20mA output signals are provided by the Model IR5000 and can be sent to any
industrial device that can accept a 4 to 20mA signal for computer based multi-point
monitoring. The Analogue Output Signals provide for a control room or other location to
display indications of operation and alarm conditions. See Section 8.8.3 for the maximum
distance between the Model IR5000 and the device connected to the Analogue Output
Signal.

NOTE - If either Analogue Output is not being used, it must be jumpered to the common
terminal.

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Model IR5000

5.5.1.2 The terminal connections for the Analog Output Signals

Receiver:
TB4-4 LELmeters Common
TB4-3 LELmeters Current Output
TB4-2 ppmmeters Common
TB4-1 ppmmeters Current Output

5.5.1.3 The terminal connections for an External Relay Reset Switch

Receiver:
TB3-3 External Reset Switch
TB4-6 Switch Common

The Model IR5000 provides external Reset Switch terminations to allow remote resetting
of the alarms. Connect each end of a normally open SPST momentary switch to the
above terminals. To reset a latched relay, simply press and release the switch.

5.5.2 Relay Output Connections


Inductive loads (bells, buzzers, relays, etc.) on dry relay contacts must be clamped as
shown in Figure 20. Unclamped inductive loads can generate voltage spikes in excess of
1000 volts. Spikes of this magnitude may cause false alarms and contact damage.

NOTE - All relay states shown with power applied.

Figure 20 Relay Contact Protection for AC / DC Loads


5.5.2.1 The terminal connections for the LELmeters-Alarm (A3) Relay Contacts

Receiver:
TB1-2 ALARM Common

De-Energized Relays Selected:

TB1-3 ALARM Normally Open Contact


TB1-1 ALARM Normally Closed Contact

Energized Relays Selected:

TB1-1 ALARM Normally Open Contact


TB1-3 ALARM Normally Closed Contact
Before making connections to these relay contacts, see Figures 21 through 24.

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Model IR5000

5.5.2.2 The terminal connections for the LELmeters-Warn (A2) Relay Contacts

Receiver:
TB1-5 WARN Common

De-Energized Relays Selected


TB1-6 WARN Normally Open Contact
TB1-4 WARN Normally Closed Contact

Energized Relays Selected


TB1-4 WARN Normally Open Contact
TB1-6 WARN Normally Closed Contact

Before making connections to these relay contacts, see Figures 21 through 24.

5.5.2.3 The terminal connections for the ppmmeters-Alarm (A1) Relay Contacts

Receiver:
TB2-2 ALARM Common

De-Energized Relays Selected


TB2-3 ALARM Normally Open Contact
TB2-1 ALARM Normally Closed Contact

Energized Relays Selected


TB2-1 ALARM Normally Open Contact
TB2-3 ALARM Normally Closed Contact

Before making connections to these relay contacts, see Figures 21 through 24.

*NOTE - The Energized/De-Energized option is software selectable (see Section 6.1).

5.5.2.4 The terminal connections for the ppmmeters-Alarm (A1) Relay Contacts

Receiver:
TB2-2 ALARM Common

De-Energized Relays Selected


TB2-3 ALARM Normally Open Contact
TB2-1 ALARM Normally Closed Contact

Energized Relays Selected


TB2-1 ALARM Normally Open Contact
TB2-3 ALARM Normally Closed Contact

Before making connections to these relay contacts, see Figures 21 through 24.

*NOTE - The Energized/De-Energized option is software selectable (see Section 6.1).

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Model IR5000

5.5.2.5 The terminal connections for the FAULT Relay Contacts

Receiver:
TB2-5 FAULT Common
TB2-4 FAULT Normally Open Contact
TB2-6 FAULT Normally Closed Contact

Before making connections to these relay contacts, see Figures 21 through 24.

NOTE - The FAULT Relay is energized and non-latching in normal operation. There are
no software selectable options that are associated with the FAULT Relay.

5.5.3 General IR Source Brightness settings


(General Guidelines: May be changed for varying applications.)

Distance Switch Position Closed

5 to 6 meters None
9 meters Pos 1, Pos 4
12 meters Pos 1, Pos 2 Aperture
19 meters Pos 1 Plate

20 meters Pos 1, Pos 8


40 meters Pos 1, Pos 2
60 meters Pos 1
100 meters Pos 1

IR Receiver Terminal Connections

NPT or M20x1.5 flexible


conduit connections (2 places as
required)

Figure 21 Source Terminal Block Location


Cover removed for clarity

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Model IR5000

IR SOURCE - TERMINAL BLOCK LOCATION

COM
+ 24
LAMP
POWER
1 2 3 4
SUPPLY 1 2 3 4 5 6 7 8

J1
OPEN

24 VDC

FIELD WIRING DIAGRAM

Figure 22 European Union Source Terminal Block Location

RELAY RESET
DeEn En TB1

0-5 LEL ALARM 0-5 LEL


RELAY
ALARM

POWER SUPPLY
0-5 LEL 0-5 LEL
(BLK)

0-5 LEL 0-5LEL

FAULT
FAULT
TB2
ANALOG

ANALOG

Figure 23 IR Receiver Terminal Block Location

Cover removed for clarity


Standard Unit Shown

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Model IR5000

DeEn En TB1 TB1


A3 NC NO 1 1
0-5 LE 2 2 ALARM 0 - 5 LEL
RELAY
3 3 ALARM NO NC 3 3
2 2 A2 NC NO 4 4
1 1 0-5 LE 5 5 0 - 5 LEL
6
COM WARN NO NC 6 6
6 (BLK)
+24VDC
5 5
(RED) A1 NC NO 1 1
4 4 COM 0-5000 PPM 2 2 0 - 5000 PPM
0-20mA
3 3 0-5LEL WARN NO NC 3 3
0 - 5 LEL
2 2 COM NO 4 4
0-20mA
1 1 0-5000 PPM FAULT 5 5
TB4 TB4 NC 6 6
TB2

0 - 5000 PPM

Figure 24 European Union IR Receiver Terminal Block Location

Figure 25 European Union IR5000 Junction Boxes

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Model IR5000

5.6 Applying Power & Alignment Mode


5.6.1 Setup Mode
Before applying power to the system for the first time, all wiring connections should be
checked for correctness and the Receivers housing cover should be securely fastened.
Upon initial power-up, the Receiver will enter a two-minute set-up mode, the display will
indicate SU.

The IR5000 contains a heater circuit to remove condensation from the windows. The unit
should be allowed to stabilize for approximately two hours before continuing with the
setup mode.

5.6.2 Alignment/Adjustment Mode


The unit now needs to be setup for the application. Place the magnet over the GM logo
on the rear of the Receiver Unit until two flashing bars appear - -. Remove the magnet
and wait for the Alignment / Adjustment code AJ to appear (it will follow the Setup Mode
code SE on the display). When AJ appears, re-apply the magnet until a number
between 0 and 99 appears (this is the alignment code).

5.6.3 Alignment
To ensure optimal performance of the Model IR5000, the final alignment code must be
between 87 and 99. To align the Source and Receiver Units, use the following
guidelines:

1. Turn the Source units lamp to full power and perform a rough alignment by sight until a
maximum number is displayed on the Receiver. Tighten the horizontal and vertical
adjustment screws on each unit. Set the Source units brightness as specified in
Section 5.5.3.
2. Loosen the Source units horizontal adjustment screw and move the unit from side to
side until a maximum value is displayed on the Receiver unit. Tighten the horizontal
adjustment screw and loosen the vertical adjustment screw. Move the unit up and down
to obtain a maximum value on the display. Tighten the vertical adjustment screw.
3. Adjust the Receiver unit from side to side and then up and down to obtain a maximum
display value, tightening the adjustment screws after each adjustment.
4. If a flashing 99 is displayed after alignment, reduce the Source lamp brightness. If a
value lower than 87 is displayed after alignment, increase the Source lamp brightness
(see Section 5.5.3).
5. Re-align the Receiver unit to obtain a maximum display value.

Repeat steps 4 and 5 each time the Source lamp brightness is changed.

If the unit is displaying a number less than 87 or a flashing 99, the IR5000 will not exit
the alignment/adjustment mode.

DO NOT intentionally misalign the Model IR5000 to get below a flashing 99. Turn down
the source lamp brightness. It is important to obtain the highest alignment number
possible within the allowed range. Alignment at high temperatures may result in alignment
numbers at the low-end of the alignment range. Alignment at low temperatures may result
in high alignment numbers.

Once a number within the 87 to 99 range is attained, tighten the Source and
Receivers rear covers and verify that the alignment number has not changed. Apply the
magnet until a flashing CP is displayed (Calibration in Progress Mode). Remove the
magnet and the unit will set the zero value. After approximately 2 minutes, the unit will
return to normal operation.

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Model IR5000

Ensure that there is no significant amount of background gas when the unit is setting the
zero value, as this will alter the Model IR5000s performance. If there is normally gas
present, try setting-up the IR5000 on a breezy day, as this will dissipate the gas. If the
unit cannot set a zero value, an F8 fault code will appear. The above procedure should
then be repeated. If the unit fails to align properly, check the line of sight carefully, then
contact your General Monitors representative or the factory direct.

5.6.4 Response Test


After initial alignment, a test of the IR5000 should be carried out using the Test Gas
Filters Kit (P/Ns 30878-1 and 30878-2). Follow the testing instructions listed on the inside
label of the filters.

5.7 Operational Cautions


WARNING: During operation, the line of sight between the source and the receiver
should be free from blockage caused by frequent human or animal crossings. The IR5000
will not respond to gas leaks upon complete IR beam blockage. Interruptions of the IR
beam will delay the response time of this unit, and thus lead to a potentially unsafe
situation.

The Heavy Hydrocarbon version of the Model IR5000 Open Path System will perform
accurately and reliably for propane gas detection applications in extreme industrial
environments. However, there are certain conditions, which one needs to account for,
when designing the gas detection system. Users are cautioned that under the following
two situations the Heavy Hydrocarbon IR5000 could give a beam block indication rather
than a gas reading or alarm:

5.7.1 A rapid and massive liquid propane release


A sudden release of large amount of liquid propane can form very cold gas clouds due to
cooling resulting from gas expansion and liquid propane evaporation. This is an intrinsic
problem for all open path optical detection technologies. Installing the Model IR5000 at a
distance (~10 meters) away from potential liquid propane leakage will reduce this problem.

5.7.2 A rapid and massive buildup of a high concentration propane gas cloud
For example, a propane gas cloud greater than 18 LEL-meter very rapidly and completely
placed in the gas path can indicate beam block instead of a gas reading.

5.7.3 Solutions to guard against these situations


Using complementary point detectors (e.g. Models IR2100, S4000C, or S4100C)
at potential sources of leaks of high concentration liquid propane, and
Using beam block signal as an alarm. To reduce the number of false alarms due
to physical beam block, there are user selectable time delays for the presence of
beam block. A signal will then be given if a beam block exceeds this time-period.

The ppmmeter range of the IR5000 Heavy Hydrocarbon Open Path Monitor should be
used as a warning that there is a gas-leak. This may allow action to take place before a
leak reaches a hazardous level, while the LELmeter range should be used for action
taken for a high gas alarm.

Please review our Technical bulletin on this subject for further details.

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Model IR5000

6.0 Operation
6.1 Output Options
The Model IR5000 allows the user to configure the units outputs via a magnetically
sensitive reed switch. To activate the reed switch, place the magnet supplied with the
Model IR5000 over the General Monitors logo on the label of the Receiver unit for
approximately five seconds. Remove the magnet when the flashing bars appear. The
display will cycle between the options until the magnet is re-applied, thereby accepting
the current option. These options are:
- - - Test Gas Mode
SE - Setup Mode
AJ - Alignment/Adjustment Mode
Fi - Finish, return to normal operation

6.2 - - Test Gas Mode


Apply the magnet when the flashing bars are showing and the unit will enter the Test Gas
Mode. While the unit is in this mode the optical faults and relays will be inhibited, the
analog signals will drop from 4mA to 1.5mA (0mA optional) and the display will flash.

This mode allows the user to check the IR5000s response to gas cells without activating
the relays. After verifying the response (see Section 5.6), remove the gas, the unit will
return to normal operation If the gas is not removed after 5 minutes, the unit will revert to
fault condition. If left in this mode for 5 minutes, the unit will return to normal operation
automatically.

6.3 SE Setup Mode


Apply the magnet when SE is showing and the unit will enter the Setup Mode.

This mode allows the user to change various attributes concerning the analog and relay
outputs. Following is the order in which the options are displayed (to change, apply
magnet when the desired option is showing):

Display - Description

bb - Beam Block
5 to 60 - Seconds before analog output changes.
0, 1.5 2.0mA - Analog output value during beam block.
0 to 60 - Minutes before entering optical fault.
Fi - Exits the current option and goes on to next.

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Model IR5000

01 - Analogue #1 (0-5000 / 0-2000 ppmmeters)


on or oF - On or Off*
* If turned off, the ppmmeters range, including A1 relay, will not be available. Unit will
only display LELmeters range.
0 or 1.5 - mA signal output during Test Gas Setup, Adjustment and Startup Modes
.
Fi - Exits the current option and goes on to next.

02 - Analog #2 (0-5 / 0-1 LELmeters)


0 or 1.5 - mA signal output during Test Gas Setup, Adjustment and Startup Modes
Fi - Exits the current option and goes on to next.

A1* - Alarm Relay #1 (0-5000 / 0-2000 ppmmeters)


En or dE - Energized or De-energized.
LA or nL - Latching or Non-Latching.
2000 to 4500 - Alarm level, increments by 500 or
800 to 1800 - Alarm level, increments by 200.
(Value increments each time magnet is applied)
Fi - Exits the current option and goes on to next.

A2 - Warn Relay #2 (0-5 / 0-1 LELmeters)


En or dE - Energized or De-energized.
LA or nL - Latching or Non-Latching.
0.5 (0.1) to A3 - Alarm level, increments by 0.5 (0.1).
(Value increments each time magnet is applied)
Fi - Exits the current option and goes on to next.

A3 - Alarm Relay #3 (0-5 / 0-1 LELmeters)


En or dE - Energized or De-energized.
LA or nL - Latching or Non-Latching.
A2 to 4.5 (1.8) - Alarm level, increments by 0.5 (0.1).
(Value increments each time magnet is applied)
Fi - Exits the Setup Mode, saves the current settings and returns to normal
operation.

Fi - Exits the Setup Mode, saves the current settings and returns to normal operation.

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Model IR5000

6.3.1 Setup Mode Options Sheet

SE - Apply Magnet when this code is showing to enter Setup Mode.

bb - Apply magnet when this code is showing to alter the options for Beam Block
5 to 60 - Select how many seconds before sending beam block fault ____________
0, 1.5 or 2.0 - Select analog output value during beam block fault ____________
0 to 60 - Select minutes of beam block before sending optical fault ____________
Fi - Exits Beam Block setup.

01 - Apply magnet when this code is showing to alter the options for Analog Output #1
on or oFf - Select whether 0-5000 (0-2000) ppmmeters range is available _____________
0 or 1.5 - Select analog output level for Test Gas Mode ____________
Fi - Exits Analog Output #1 setup.

02 - Apply magnet when this code is showing to alter the options for Analog Output #2
0 or 1.5 - Select analog output level for Test Gas Mode ____________
Fi - Exits Analog Output #2 setup.

A1 - Apply magnet when this code is showing to alter the options for Alarm Relay #1
En or dE - Select whether relay is Energized or De-energized ____________
LA or nL - Select whether relay is Latching or Non-latching ____________
2000 to 4500 (800 to 1800) - Select where relay alarm level is set
(in ppmmeters) ____________
Fi - Exits Warn Relay #1 setup.

A2 - Apply magnet when this code is showing to alter the options for Warn Relay #2
En or dE - Select whether relay is Energized or De-energized ____________
LA or nL - Select whether relay is Latching or Non-latching ____________
0.5 (0.1) to A3 level - Select where relay alarm level is set (in LELmeters) _____________
Fi - Exits Warn Relay #2 setup.

A3 - Apply magnet when this code is showing to alter the options for Alarm Relay #3
En or dE - Select whether relay is Energized or De-energized ____________
LA or nL - Select whether relay is Latching or Non-latching ____________
A2 level to 4.5 (0.8) - Select where relay alarm level is set (in LELmeters) _____________
Fi - Saves changes and exits Setup Mode.

Fi - Apply magnet when this code is showing to save changes and exit Setup Mode.

NOTE - Values in parentheses are for the Heavy Hydrocarbon (Propane) unit.

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Model IR5000

6.4 AJ Alignment/Adjustment Mode


Apply the magnet when AJ is showing and the unit will enter the Alignment/Adjustment
Mode.

This mode allows the user to re-align the Model IR5000 and set a new zero value. This
mode is covered in Section 5.6 (Applying Power).

6.5 Fi Finish
Apply the magnet when Fi is showing and the unit will exit the Options Mode, save any
changes that were made and return to normal operation. This is the only way changes
made in setup mode will be saved.

6.6 Maintenance
After the Model IR5000 has been initially aligned, very little must be done to maintain the
unit. Although calibration is not required, response should be tested from time to time
using the Test Gas Filters designed for the IR5000 (see Section 5.6 for details).

If the Model IR5000 is operated under dusty or dirty conditions, the windows should be
cleaned periodically. This is accomplished by gently wiping them with a soft, clean cloth,
which has had a commercial window cleaning solution applied. The cleaning should be
done in test mode to prevent false alarms.

NOTE - The IR5000 will see alcohol and other cleaning solvents.

6.7 Display and Fault Codes


The display codes during normal operation are:

SU Start-Up - This is displayed immediately after power is applied and lasts for
approximately two minutes.

SF Re-Start from an optical Fault - This is displayed when an optical Fault condition
has been corrected.

0-50 Steady Numeric Indications - This is displayed when a concentration of gas is


detected in the operational mode. Lower LED is lit when displaying ppmmeters,
upper LED is lit when displaying LELmeters.

0-50 Flashing Numeric Indications - This is displayed when a concentration of test


gas is at the detector in the test gas mode. Lower LED is lit when displaying
ppmmeters, upper LED is lit when displaying LELmeters.

Other codes that can appear on the display are Fault codes, which are listed on the
following page.

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Model IR5000

6.8 PPM & LEL Negative Drift Faults


The PPM negative fault occurs when the IR5000 is zeroed with a small background gas
and strong wind conditions dissipate the remaining gas. Such conditions will cause the
PPM range current to go to a fault condition (0.0 MA).

A LEL negative drift is an IR5000 source or receiver problem. It is unsafe to use the
IR5000 in this condition. A LEL negative drift causes both currents go to zero and the fault
relay to de-energize. The LEL negative drift may occur when the system is first installed
and not yet zeroed.

Negative drift on the PPM range is not a dangerous condition as with a LEL negative drift.
The PPM negative drift does not put the IR5000 into a total fault. It will however return the
PPM current to zero.

The following table summarizes the IR5000 action:


Condition PPM current LEL current Fault relay Remarks
Normal 4.0 ma 4.0 ma Energize
Unit Fault 0.0 ma 0.0 ma De-energize After time delay
Negative PPM 0.0 ma 4.0ma Energize After time delay
Negative LEL 0.0 ma 0.0 ma De-energize After time delay
Table 5 PPM & LEL Faults

6.9 Troubleshooting
If equipment or qualified personnel required to troubleshoot are not available, it is
recommended that the defective unit be returned to General Monitors for repair.

CAUTION - General Monitors warranty will be voided if damage results from repair
attempts other than routine replacement of recommended spare parts. Repairs performed
by persons other than General Monitors authorized personnel may void the warranty.
Please read the warranty statement carefully (see inside front page). A defective IR5000
Infrared Open Path System should be returned to the factory for repair even if the
warranty has expired. A complete written description of the problem should be included
with all returned equipment.

The Model IR5000 Infrared Open Path System will indicate a fault code number on the
two-digit display as an aid to troubleshooting. The following list identifies the Fault codes,
gives a description of the Fault and indicates the corrective action that should be taken:

Multiple Faults will result in alternating fault codes being displayed. All faults have a 10-
second delay before activating, unless otherwise noted.

F1* The Receiver Unit is seeing less than optimum infrared from the Source Unit. The
units windows should be cleaned and optical path checked for blockage.
F2 Motor stalled. Timing error will try to restart the motor for up to five minutes.
The unit must be sent in for repair.
F3 The infrared source is too dim. The units optical path should be checked for
blockage and/or windows cleaned. If this continues, the unit should be returned
for repair. Activates Fault relay after user defined Beam Block time-out period.
F4 This code is displayed if there is excess infraredenergy being received by the
Receiver Unit. This may occur if there is a bright IR source in line with the detector
window.

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Model IR5000

F5 This code is displayed when there is a sudden large change in the infrared energy
being received by the detector. This will occur during the cleaning of the optics, or if
any obstruction is placed in the optical path.

NOTE - Heavy Hydrocarbon IR5000: If the unit attains a ppm warn level, then goes into
an F5 fault within 2 seconds, the unit will activate the LEL alarm relay and Analog Output
will go to 20.0mA as this situation is indicative of a catastrophic Propane leak.

F6* The unit is receiving a low line voltage. This will be displayed if the Receiver
unit is being supplied with less than 18VDC.
F7 Internal system failure. The unit must be returned for repair.
F8 The unit failed to acquire a zero during alignment/adjustment mode or is
responding to a loss of background gas. Recalibrate unit.
F9* Open current loop. One or both of the Analog Outputs are open. These must be
jumpered, if not being used.
* - During the F1, F6 and F9 faults, the unit will attempt to output an alarm if gas is
present.

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Model IR5000

7.0 Customer Support


GENERAL MONITORS OFFICES

Area Phone/Fax/Email

UNITED STATES

Corporate Office: Phone: +1-949-581-4464


26776 Simpatica Circle Fax: +1-949-581-1151
Lake Forest, CA 92630 Email: sales@generalmonitors.com

9776 Whithorn Drive Phone: +1-281-855-6000


Houston, TX 77095 Fax: +1-281-855-3290
Email: gmhou@generalmonitors.com

UNITED KINGDOM
Heather Close Phone: +44-1625-619583
Lyme Green Business Park Fax: +44-1625-619098
Macclesfield, Cheshire, Email: info@generalmonitors.co.uk
United Kingdom, SK11 0LR

IRELAND
Ballybrit Business Park Phone: +353-91-751175
Galway, Republic of Ireland Fax: +353-91-751317
Email: info@gmil.ie

SINGAPORE
No. 2 Kallang Pudding Rd. Phone: +65-6748-3488
#09-16 Mactech Building Fax: +65-6748-1911
Singapore 349307 Email: genmon@gmpacifica.com.sg

MIDDLE EAST
LOB12, #G20 Phone: +971-4-8815751
P.O. Box 61209 Fax: +971-4-8817927
Jebel Ali, Dubai Email: gmme@emirates.net.ae
United Arab Emirates

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Model IR5000

8.0 Appendix
8.1 Specifications
8.1.1 System Specifications
Sensor Type
Infrared Absorption Type

CAUTION - Hydrogen (H2) gas cannot be detected by the Model IR5000.

8.2 Warranty
Two Years

8.3 Fault Codes


F1, F3, F4 - Low/High IR concentrations
F2 - Timing/Motor failure
F5 - Sudden Change in IR energy
F6 - Low DC supply voltage
F7 - Internal system failure
F8 - Zeroing time-out/Background gas change
F9 - Open current loop

8.4 Response Time


When exposed to full-scale gas concentration in ppm range
T50 < 8 seconds & T90 < 12 seconds

8.4.1 Linearity
+10% over full-scale
@ 25C & 0% Blockage

8.5 Path Length


5 to 100 meters (16 to 328 feet)

8.6 Approvals
CSA & ATEX approved, CE Marked.

* - Propane applied to Heavy Hydrocarbon unit.

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Model IR5000

8.7 Mechanical Specifications


Receiver Unit:
Length 16.7 inches 424 mm

Diameter 5.4 inches 137 mm

Weight 9 lbs. 4 kg

Source Unit:
Length 12 inches 305 mm

Diameter 6.4 inches 163 mm

Weight 10 lbs 5 kg

8.7.1 Weatherproof Protection (Both):


IP66, Type 4X Enclosure

8.7.2 Electrical Specifications

Electrical Classification
CSA = Class I, Division 1, Groups C and D
ATEX = EEx d IIB T4 Ta = -40C TO +60C
EEx de IIB T4 Ta = -40C TO +60C

8.8 Power
24 VDC @ 30 Watts (nominal) - Source
24 VDC @ 25 Watts (nominal) - Receiver
20 to 32 VDC range (maximum)

8.8.1 Contact Relay Ratings


SPDT,
5A @ 250 VAC,
5A @ 30 VDC,
Resistive Max

8.8.2 Analog Signal Output (600 ohms max.)

Range 0-22 mA
Malfunction 0 mA**
Beam Block 1.5 mA (std)
User selectable
Test Gas 1.5 mA (std)
User selectable
0 to 5000* ppmmeters 4-20 mA (01)
Proportional over full scale
0 to 5* LELmeters 4-20 mA (02)
Proportional over full scale
Overrange 20-22 mA

* - 0 to 2000 ppmmeters and 0 to 1 LELmeters on Heavy Hydrocarbon (Propane) unit.


** PPM Range Negative Drift only causes the ppm current to go to zero.

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Model IR5000

8.8.3 Recommended Cable Lengths


Power - The maximum distance between the IR5000 and the Power Source.

AWG FEET METERS


20 AWG 230 feet 70 meters
18 AWG 370 feet 110 meters
16 AWG 580 feet 180 meters
14 AWG 1000 feet 305 meters
Table 6 Recommended Cable Lengths Receiver Unit (+24VDC)

AWG FEET METERS


20 AWG 175 feet 55 meters
18 AWG 280 feet 85 meters
16 AWG 435 feet 135 meters
14 AWG 750 feet 230 meters
Table 7 Recommended Cable Lengths Source Unit (+24VDC)
Analog Output Signal - The maximum distance between the IR5000 and a device with a
250 ohms input impedance.

AWG FEET METERS


20 AWG 2400 feet 730 meters
18 AWG 3800 feet 1160 meters
16 AWG 5200 feet 1585 meters
14 AWG 9000 feet 2750 meters

Table 8 Recommended Cable Lengths Analog Output

8.8.4 Environmental Specifications


Operating Temperature Range
-40F to +140F -40C to +60C

Operating Humidity Range


0 to 95% Relative Humidity (non-condensing)

8.8.5 Vibration Specification


BS2011 Part 2.1 and ISA/CSA C22.2 No. 152

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Model IR5000

8.9 Engineering Documentation


8.9.1 Outline - Source Unit

Figure 26 Outline Drawing, Source

27
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Model IR5000

8.9.2 Outline - Receiver Unit

Figure 27 Outline Drawing, Receiver

28
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Model IR5000

8.9.3 Outline Source & Receiver European Units

Figure 28 Junction Box Assembly of IR50000 Receiver & Source European Units

29
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Model IR5000

8.9.4 IR5000 Block Diagram

Figure 29 IR5000 Block Diagram

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Model IR5000

8.9.5 Grounding Connections

Figure 30 Grounding Connections

8.9.6 Mounting Arm

Figure 31 Mounting Bracket Assembly

31
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Model IR5000

8.9.7 Aperture Plate

Used on the Source Unit for 5-20 Meter installations.

Figure 32 Aperture Plate

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Model IR5000

8.10 Ordering Information


8.10.1 System Components
Instruction Manual - Model IR5000; Part Number: MANIR5000

8.10.2 Spare Parts


To order spare parts and/or accessories, please contact your nearest General Monitors
Representative or General Monitors directly and give the following information:

Part Number
Description
Quantity

30878-1 Test gas filter set (standard unit)


30878-2 Test gas filter set (heavy HC unit)
30989-1 Mounting arm
30960-1 Source unit Contact Sales Representative or factory
for assistance when ordering
30900-1 Receiver unit
31080-1 Test gas filter set (standard unit)
31080-2 Test gas filter set (heavy HC unit)

NOTE - 31080-1 and 31080-2 are the upgrades of 30878-1 and 30878-2; respectively.
30878-1 and 30878-2 are still available for older units.

Recommended Spare Parts for one (1) Year:

Qty. Part# Description


1 31037-1 Magnet Assembly

8.10.3 Accessories
30880-1 Aperture Plate: Used on the Source Unit for 5-20 Meter installations (see
Figure 32)

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PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 102 of 125

3. INTRINSICALLY SAFE HEAT DETECTOR DT1101A-EX & SMOKE


DETECTOR DO1101A-EX

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
DO1101Ex, DT1101Ex, DT1102Ex Smoke & Heat detectors, collective
Description

1. Brief overview
OptoRex DO1101Ex
ThermoRex DT1101Ex / DT1102Ex
1.1. Characteristics
1.2. Design

2. Technical data
3. Principle of operation
4. Environmental influences
4.1. Influence of the ambient temperature
4.2. Other influencing variables

5. Application
5.1. Compatibility
5.2. Alignment functions
5.3. Application
5.4. Installation

6. Commissioning
7. Maintenance
7.1. Functional check
7.2. Overhaul
7.3. On-site measurement with the DZ1194 detector test set

103 / 125
1. Brief overview
OptoRex DO1101Ex ThermoRex DT1101Ex / DT1102Ex

Dimensions Dimensions
115 115
47 . . . 70 47 . . . 70

54,5
51
With base DB1101 With base DB1101

1.1. Characteristics

For applications in explosion-hazard areas of zones For applications in explosion-hazard areas of zones
1 and 2 1 and 2
Balanced response behavior and wide range of ap- Heat detectors to meet the highest requirements
plications DT1101Ex Category 1 heat detector with wide ap-
High reliability and stability through new, high-qual- plication range (up to +50C)
ity optoelectronic sensor system and fully automat- DT1102Ex Heat detector for high ambient tempera-
ic manufacturing and inspection processes tures (up to +70C)
Response behaviour immune to deceptive phenom-
ena with rapid and slow increase in temperature
through:
Intelligently designed differential characteristics
Precise maximum temperature alarm activation with
quality thermosensor
High degree of reliability and long-term stability
High resistance to:
Electromagnetic interference (EMI) intelligently designed
circuit
Soiling, temperature fluctuations, humidity and corrosion
achieved through custom developed, protective circuit board
coating
Together with detection line coupler and shunt Zener barrier,
compatible with Cerberus control units with collective signal
evaluation
Manufactured in state-of-the-art SMD technology
Bayonet fitting for connection to base simplifies detector re-
placement
Comprehensive range of detector base accessories for spe-
cial applications

Data and design subject to change without notice / Supply subject to availability
e1485a 06.96 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1996 1
104 / 125
1.2. Design

OptoRex DO1101Ex ThermoRex DT1101Ex / DT1102Ex


The OptoRex DO1101Ex is eminently suited to early The DT1101Ex/DT1102Ex ThermoRex is suitable for the
detection of smoldering fires, but it also quickly detects monitoring of rooms in which upon an outbreak of fire, a
flaming fires that produce smoke. The newly developed, rapid rise in temperature is to be expected.
high-quality optoelectronic system ensures a homoge- The DT1101Ex ThermoRex complies with standard EN
nous response behavior across a wide smoke spectrum, 54-5 and can be used for a wide range of applications. The
ranging from light-colored to dark smoke. DT1102Ex ThermoRex complies with standard EN 54-8
The OptoRex DO1101Ex conforms to EN 54 7/9 and is and is therefore suitable for higher ambient temperatures.
consequently a universal smoke detector.
The built-in response indicator (red LED) serves as a local status
indicator. An external response indicator can be connected to the
base.
For periodic factory cleaning the detector can be easily disas-
sembled.
The detectors are fully electronic and are not subject to wear and
tear. To protect it against environmental influences the electronic
circuit has a specially developed circuit board protective coating.
The DB1101 detector base is mounted on the ceiling direct on the
recess box direct, or surface-mounted using the DBZ1191 base at-
tachment and connected to the control unit via twin wire. The base is
fitted with spring terminals for connection.
The detectors are secured in the base DB1101 with a vibration-
proof bayonet fitting. Efficient installation and removal of a detector
is possible by means of the DZ1191 detector extractor. For testing of
the DO1101Ex serves the RE6 testing unit. DT1101Ex and
DT1102Ex can only be tested with RE6T in non-explosion hazard
areas. By means of extension tubes this work can be carried out up
to a height of 7 metres without additional tools.
A range of base accessories is available for installation in wet areas
and for protection against theft etc.

Data and design subject to change without notice / Supply subject to availability
2 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1996 06.96 e1485a
105 / 125
2. Technical data
Normal ambient conditions, if nothing else is specified:
Temperature Ta DO1101Ex = 20C (293K) DT1101Ex/DT1102Ex = 25C (298K)
Air pressure p = 1000hPa (750 Torr)
Parameters Symbol Unit DO1101Ex DT1101Ex DT1102Ex Conditions
Operating voltage Ub VDC 17 . . . . . . 24 16 . . . . . . 24 16 . . . . . . 24
(quiescent condition)
Max. permissible voltage Umax VDC max. 27 max. 27 max. 27
Starting current Ie A max. 160 max. 100 max. 100 max. 25s after switch-on
Operating current Ib A max. 100 max. 100 max. 100 for DT1101Ex Ta=25...50C
(quiescent condition) for DT1102Ex Ta=25...70C
Alarm voltage
at IA = 1 ... 10mA UA V 5 .....10 5 .....10 5 10
.....
at IA = 1...60mA UA V 5 .....12 5 .....12 5 12
.....

Max. alarm current, pulsed IA mA max. 100 max. 100 max. 100 must be limited externally
f0.5Hz, Duty Cycle 50%
Reset voltage UR V 2 ...... 6 2 ......6 2 ......6
Reset current IR A 20 .....500 40 500
..... 40 500
.....

Reset time (URA=2V) tR s max. 2 max. 2 max. 2


Response integrating time tA s typ. 7
Response sensitivity D1 %/m typ. 3,0 smoke sensitivity with paraffin
test aerosol (1m/s)
Electrical sensitivity
signal voltage U3A V 1,2 .... 2,8 measurement with DZ1194
Ext. response indicator:
Voltage Uie V 1.5 ... 6 1.5 ... 6 1.5 ... 6
Current Iie mA max. 50 max. 50 max. 50 f0.5Hz, Duty Cycle 50%
Flashing frequency Hz 1 1 1 depending on line module
Response sensitivity complies additionally with
temperature increase A 1 R according to pr EN 54-5
dT/dt = 10K/min. dT C 20 ...... 40 20 ...... 40 (ed 2, draft 4, 1992)
EN 54-5: grade 1
max. release temperature Ta C 54 ...... 62 complies additionally with
EN 54-8: range 1 BR according to pr EN 54-5
max. release temperature Ta C 74 . . . . . . 85 (ed 2, draft 4, 1992)
Electromagnetic compatibility V/m min. 50 min. 50 min. 50 1MHz ... 1GHz
Operating temperature Ta C 25 . . . +60 25 . . . +50 25 . . . +70
Humidity 34C 95% rel. 100% rel. 100% rel. transient condensation
>34C 35g/m3 abs. 35g/m3 abs. 35g/m3 abs. allowed
Storage temperature (continuous) Tl C 30 . . . +75 30 . . . +75 30 . . . +75
Protection category IP44 IP44 IP44
EN60529/IEC529
Colour white white white
RAL 9010 RAL 9010 RAL 9010
Standards
- for fire detectors EN54-7/9 EN54-5, EN54-8,
response temperature
grade 1 range 1
for explosion-hazard areas EN 50014 EN 50014 EN 50014
EN 50020 EN 50020 EN 50020
Application category IEC 721-3 3K6 3K8H 3K8H
Ex classification EEx ib IIC T4 EEx ia IIC T4 EEx ia IIC T4
(Ta 60C) (Ta 50C *) (Ta 70C *)
Ex approvals
PTB Nr. Ex-96.D.2060 Ex-95.D.2148 Ex-95.D.2148
ASEV Nr. 96.1.10358 95.1.11013 95.1.11013
Load factor KMK 1.6 1 1

* not Ex conditional
(Alarm release DT1101Ex 54C
DT1102Ex 74C)

Data and design subject to change without notice / Supply subject to availability
e1485a 06.96 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1996 3
106 / 125
3. Principle of operation
OptoRex DO1101Ex ThermoRex DT1101Ex / DT1102Ex
The OptoRex DO1101Ex is based on the principle that The ThermoRex DT1101/DT1102 measures the ambient
smoke scatters light. An infrared LED (IRED) transmits temperature with the NTC thermistor Rm in the tip of the
brief, intensive light pulses into the scattering chamber. sensor and measures the temperature in the detector
The receiving element is screened off from direct IR light housing with the NTC thermistor Rg. Rapid temperature
incidence and reflections. Smoke entering the chamber changes bring about a faster change of resistance with
scatters the light so that some of it reaches the receiver thermistor Rm than with thermistor Rg. This causes a posi-
whose signal is evaluated by the electronics. After three tive voltage shift at point P. As soon as this voltage ex-
positively evaluated pulses an alarm is transmitted to the ceeds a fixed threshold value, the threshold value detec-
control unit. tor 3 activates multivibrator 4 and an alarm is given. If,
Time base 2 in the integrated circuit 1 controls the logic due to a very slow increase in temperature, the resistance
unit 3 and produces pulses for controlling the IRED light values Rm and Rg fall to the same extent, upon reaching a
source 5 via the amplifier 4 . If the detector is not contam- maximum temperature determined by resistors 1 and 2
inated and the air is clean, no signal is available at the re- an alarm is given. At the same time resistor 2 accelerates
ceiver 6 . response for fast changes in temperature.

If the air contains smoke, the receiver sees a signal that is The weak current IB flows in non-alarm condition. As soon
transmitted via the amplifier 7 to the discriminator 9 . Inte- as the multivibrator 4 becomes conductive, the response
grated in the amplifier is a multiple coincidence circuit that indicator alarm current IA flows. At the same time the re-
generates the difference between a light and a dark mea- sponse indicator 6 built into the detector is activated via
surement which has the effect that no interference signals the driver stage 5 . One external response indicator 7
and only smoke induced signals are amplified and may be connected. The multivibrator remains in self-hold
transmitted. In circuit 8 a stable reference voltage Uaref is condition until the control unit is reset by briefly interrupt-
produced which in discriminator 9 forms the alarm ing the operating voltage, whereupon it reverts to its origi-
threshold. The detector sensitivity is set with the trimming nal state. The intrinsically safe detector circuit is isolated
resistor 10 . The signal voltage Usig at the output of the re- from the line circuit by protective diodes 8 .
ceiving amplifier can only be factory-measured with the
aid of special measuring equipment. The alarm threshold
Uaref is used for measuring the alarm stroke U3A on site
with the detector measuring instrument DZ1194.
The logic unit 3 evaluates the pulses of discriminator 9
and after the third pulse activates the alarm stage 11 inte-
grated in ASIC. Also activated in the event of an alarm are
the internal response indicator 12 and an external re-
sponse indicator 13 if available. The alarm stage 11 is self-
holding and is restored to the initial condition only when re-
set by the system control unit (through brief interruption of
the operating voltage). The intrinsically safe detector cir-
cuit is isolated from the line circuit by protective diodes 14 .

4
B
D
+ B
D
+
F F
2
12 13
1
6 7
ASIC 3
5 6 7 9
Operating voltage

Operating voltage

E MB
Rm
3 4
11
8 2 UB UB
P
E
Rg

1 IA
10
14 5 8
C IB C
Usig Uaref
A A
Shunt Zener Shunt Zener
Detector diode barrier Detector diode barrier
U3A Base Base

Fig. 1 Block diagram DO1101Ex Fig. 2 Block diagram DT1101Ex/DT1102Ex

Data and design subject to change without notice / Supply subject to availability
4 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1996 06.96 e1485a
107 / 125
4. Environmental influences

4.1. Influence of the ambient temperature


OptoRex DO1101Ex

[%/m]
5

4
DO1101A-Ex
3

0
10 0 10 20 30 40 50 60 [C]
Ambient temperature

Fig. 3 Smoke sensitivity of the OptoRex DO1101Ex as


a function of the ambient temperature

4.2. Other influencing variables


Ambient light, air drafts and fluctuations within the speci-
fied operating voltage range have no influence on the de-
tector.

Data and design subject to change without notice / Supply subject to availability
e1485a 06.96 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1996 5
108 / 125
5. Application
5.1. Compatibility
Control units: Compatible with all Cerberus control
units with collective signal evaluation to-
gether with input/output module DC1192
and shunt Zener barrier
Bases: DB1101

5.2. Alignment functions


None.

5.3. Application
OptoRex DO1101Ex ThermoRex DT1101Ex / DT1102Ex
The OptoRex DO1101Ex is suitable for applications in ex- The ThermoRex DT1101Ex/DT1102Ex is suitable for ap-
plosion-hazard areas of zones 1 and 2. Due to its EN 54 plications in explosion-hazard areas of zones 0, 1 and 2.
compliance, the OptoRex DO1101Ex can be used as a The ThermoRex DT1101Ex can be used up to a tempera-
universal smoke detector. ture of 50C and the DT1102Ex up to a temperature of
70C. The DT1101Ex/DT1102Ex are especially suitable for
monitoring rooms and installations in which in the event of
fire, a rapid increase in temperature is to be expected, or
where other types of detector cannot be used because
work processes cause smoke, dust, exhaust gases etc.
The recommended monitoring areas, distances between detectors
etc. can be found in the national guidelines, the Cerberus Guide-
lines for Planning and Application (CRP), Fire Detection in Explo-
sion-hazard Areas, document e1204, or the Security Guide.

5.4. Installation
Bases are connected together by twisted twin wire. Shielded cable
is only required for special applications, e.g. in the case of powerful
high frequency fields or special national guidelines.
For detailed information, see Fire Detection in Explosion-hazard
Areas, document e1204.

Non-explosion-hazard area Explosion-hazard area

Input/output
EOL22(Ex)

module DC1192
Detection line, SB3 Ex Ex Ex
control unit sided
max. 15 DO1011Ex
Supply 24VDC max. 25 DT1011/02Ex

End-of-line device
Shunt Zener diode barrier Equipotential bonding

Fig. 4 Connection diagram for DO1101Ex and DT1101Ex/DT1102Ex

Data and design subject to change without notice / Supply subject to availability
6 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1996 06.96 e1485a
109 / 125
6. Commissioning
To prevent unnecessary soiling during the construction phase,
the detectors should be inserted into the bases just before the
system is put into service.
For detailed information, see Fire Detection in Explosion-hazard
Areas, document e1204.

7. Maintenance

7.1. Functional check


A functional check of the detectors must be performed periodically
(usually once per year) by forcing each detector to respond by
means of a suitable testing device (RE6 or DZ1192 for DO1101Ex or
RE6T for DT1101Ex/DT1102Ex). Detectors that do not respond or
which are mechanically damaged must be replaced.

7.2. Overhaul
All detectors should be jointly replaced and factory overhauled in in-
tervals of 2 to 8 years, depending on the environmental conditions
and the severity of contamination.

Important: The DZ1193 and RE6T detector tester and the


DZ1194 detector test set must only be used in areas where
there is no explosion-hazard.

7.3. On-site measurement with the DZ1194 detector test set

OptoRex DO1101Ex ThermoRex DT1101Ex / DT1102Ex


The voltage U3A can be measured and alarm activation The operating current can be measured and alarm activa-
checked with the DZ1194 detector test set. The U3A volt- tion checked with the DZ1194 detector test set.
age measured is directly proportional to the remaining
voltage increase for alarm.
Detectors with values which lie outside those in the technical data
must be replaced.

Data and design subject to change without notice / Supply subject to availability
e1485a 06.96 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1996 7
110 / 125
Terms

ASIC Application Specific Integrated Circuit


CC11 Fire detection control unit AlgoControl
to fire detection system S11
CZ.. Fire detection control unit to fire detection system MS9
DB1101 Base for collective DS11 fire detectors
DBZ1191 Base attachment
DC1192 Input/output module
DO1101Ex OptoRex smoke detector, for explosion-hazard areas
DT1101Ex ThermoRex heat detector with static alarm threshold 60C,
for explosion-hazard areas
DT1102Ex ThermoRex heat detector with static alarm threshold 80C,
for explosion-hazard areas
DZ1191 Detector exchanger
DZ1194 Detector test set
EMC Electro Magnetic Compatibility
EMI Electro Magnetic Influence
ESD Electro Static Discharge
IRED Infra-Red Emitting Diode
KMK Load factor for collective elements
NTC-Thermistor Negative Temperature Coefficient Thermistor
RE6 Detector tester
RE6T Detector tester for heat detectors
Rg Measuring sensor for housing temperature
Rm Measuring sensor for ambient temperature
RI (AI..) Response indicator
S11 Generic term of fire detection system S11
SB Shunt Zener diode barrier

Data and design subject to change without notice / Supply subject to availability
8 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1996 06.96 e1485a
111 / 125
Sockel fr kollek-
DB1101A tive Brandmelder DB1101A Embase pour d- Base for collec-
tecteurs dincendie DB1101A tive Fire Detec-
DS11 collectifs DS11 tors DS11

Montageanleitung Instructions de montage Installation instructions

Ansprechindikator
Melder Indicateur daction
Dtecteur Response indicator
Detector min. 2cm

50cm

1 2
1 Platzbedarf 1 Encombrement 1 Space requirements
Fr Service- und Revisionsarbeiten muss Une fois mont, lembase doit tre parfai- For maintenance purposes the installed
der montierte Melder gut zugnglich sein. tement accessible pour les travaux de rvi- base must be easily accessible. Ensure
Melder mssen mit dem Melderaustau- sion et pour le service. Les dtecteurs doi- that it is possible to extract the detector us-
scher senkrecht von unten herausgenom- vent pouvoir tre retirs avec lchangeur ing exchanger or to test from a point di-
men und geprft werden knnen. Der de dtecteur ou vrifis verticalement et rectly below the base. The base must
Sockel muss seitlich min. 20mm Spiel- par le bas. Respecter au minimum 20mm have at least 20mm clearance on all sides.
raum haben. dloignement par rapport aux obstacles.

2 Montagelage 2 Position de montage 2 Mounting position


Der Ansprechindikator im Melder muss Lors de la reconnaissance, lindicateur The position of the built-in response indi-
vom Erkundungsweg aus gut sichtbar daction incorpor dans le dtecteur doit cator must ensure quick location of the de-
sein. tre parfaitement visible. tector in alarm.

Montage bei Unterputz-Leitungsverle- Montage lorsque les cbles sont poss Installation with concealed wiring
gung sous crpi

Ankommende und abgehende


Kabel einzeln dicht durchstossen
UP-Dose Passer sparment et de faon tan-
Bote encastre che les cbles arrivants et partants
Recess box Push through cables from last base
and to next base separately (tight fit)

Lage des Indikators beachten


Observer la position de lindicateur
Note position of indicator

Sockel
Embase DB1101A
Base

60...70mm

Schrauben
Vis max. 4mm
Screws

Data and design subject to change without notice / Supply subject to availability
x1336b 08.96 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1995 486 446 1
112 / 125
Aufputz-Montage in trockener Montage sur crpi dans environne- Surface mounting for dry
Umgebung ment sec application
              

              

              

Sockelzusatz verwenden               

Gewnschte Leitungseinfhrung
Utiliser auxiliaire dembase ausbrechen
Use base attachment               

Ebrcher lentre des cbles dsire


DBZ1191 (Art. Nr. 454 083) Break out required entry point
              

              

              

              

Lage des Indikators beachten


Observer la position de lindicateur               
Schrauben
Note position of indicator Vis max. 4mm
Screws

Sockel
Embase DB1101A
Base

Montage in feuchter Umgebung   


Montage dans environnement humide           
Mounting for wet application   

                

                

Sockelzusatz, feucht                 

Auxiliaire dembase pour application


humide                 

Base attachment for wet application


DBZ1192 (Art. Nr. 458 814)                 

                

                

                

                

                

                

Lage des Indikators beachten


Observer la position de lindicateur
Note position of indicator

Sockel
Embase DB1101A
Base

Data and design subject to change without notice / Supply subject to availability
2 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1995 08.96 x1336b
113 / 125
Anschluss Raccordement Connection

Draht einschieben
Insrer le fil Zum Einschieben des Leiters, Fe-
Insert wire derklemme mit Schraubenzieher
Nr. 0 (Klingenbreite max. 3,5mm)
Pro Klemme darf max. 1 Leiter entlasten
0,22,5mm2 angeschlossen werden Pour insrer le conducteur, dga-
1 conducteur de 0,22,5mm2 au max. ger la borne ressort avec un
peut tre raccord sur une borne tournevis no. 0 (largeur de la tige
Max. one conductor of 0.22.5mm2 in 3,5mm au max.)
each terminal In order to insert the wire, open
spring terminal with a screwdriver
no. 0 (blade width max. 3.5mm)

Drhte 8mm abisolieren


Dnuder les fils sur 8mm
Strip back 8mm insulation

Die Leiterschlaufen mssen flach


liegen und drfen die Klemmen-
hhe nicht bersteigen
Les boucles de conducteurs doi-
vent reposer platement et ne pas
dpasser la hauteur des bornes
The conductor loops must lie flat
and must not be higher than the
terminals

Bei eingesetztem Arretiernocken kann


der Melder nur mit einem Schraubenzie- max. Hhe fr Verkabelung
her entriegelt werden hauteur max. pour cblage
Si lembase est munie dergots de bloca- max. height for cabling
ge, le dtecteur ne peut tre dverrouill
quavec laide dun tournevis
When locking stud is fitted, detector can
only be unlatched with a screwdriver
DBZ1190 (Art. Nr. 458 526)

Montagemasse Melderkennzeichnungsschild, Meldermarkierung


Dimensions Plaque de dsignation, marquage du dtecteur
Dimensions 
Detector designation plate, detector marking
              

Markierung Ansprechindikator                

Marquage de lindicateur daction


Marking of response indicator                

               

               

               

               
113

               
4,3

               

Melderkennzeichnungsschild               

Plaque de dsignation du dtecteur


Detector designation plate
DBZ1193A (Art. Nr. 486 433)
               

               

21
               

47
               

70
               

Montageschablone                

Gabarit de perage
Drilling template 

Meldermarkierung               

Marquage du dtecteur
Detector marking
DBZ1193A-AA (Art. Nr. 500 982)

Data and design subject to change without notice / Supply subject to availability
x1336b 08.96 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1995 3
114 / 125
Anschluss Meldelinie fr Melder mit Raccordement ligne de dtection pour Connection detection line for detec-
kollektiver Adresse dtecteurs avec adresse collective tors with collective address

DB1101A DB1101A DB1101A

Linieneinschub
Tiroir de ligne
Zone module +
Achtung! Polaritt beachten!
Attention! Considrer la polarit! Zusatzklemme DBZ1190-AA/AB
Important! Observe polarity! Borne additionnelle
Auxiliary terminal

+ + +
DJ1192 DJ1192 DJ1191
DJ1191 DJ1191 DJ1192

Externe Ansprechindikatoren (DJ1191/ Indicateurs daction externes (DJ1191/ External response indicators (DJ1191/
DJ1192, DJ1193). Bei Ansteuerung von DJ1192, DJ1193). Lors de lasservisse- DJ1192, DJ1193). When activated by
mehr als einem Melder: Plus nur mit ei- ment de plus dun dtecteur: ne relier le more than one detector, connect positive
nem Sockel verbinden. plus quavec une seule embase. only from one base.
Max. 2 externe Ansprechindikatoren pro 2 indicateurs daction externes au max. Max. 2 external response indicators per
Sockel. par embase. base.
Linienabschluss (zentralenspezi- Aprs vrification de la ligne, placer Connect end-of-line unit (depending
fisch) jeweils nach Ausprfen der Lei- llment de fin de ligne (spcifique on control unit) in the last base after
tung in den letzten Sockel einsetzen lquipement de contrle et de signa- line has been checked
lisation) dans la dernire embase

Zusatzklemmen Melderschutzkorb
Bornes additionnelles Corbeille protectrice
Auxiliary terminals Protective cage

1 2 2 1

Option: Zusatzklemmen fr Anschluss von 2 externen An-


sprechindikatoren oder Kabelabschirmung
Option: bornes additionnelles pour le raccordement de 2 indica-
teurs daction externes ou blindage de cble
Option: Auxiliary terminals for connection of 2 external re-
sponse indicators or cable shielding

Querschnitt
Section Ausbrechen und Schutzkorb festschrauben
Pos Type Cross-section Ebrcher et serrer le corbeille protectrice
Break out and fasten the protective cage
1 Zusatzklemme DBZ1190-AA 0.28 ... 0.5mm2 467 708 DBZ1194 (Art. Nr. 467 711)
Borne additionnelle
2 Auxiliary terminal DBZ1190-AB 1.0 ... 2.5mm2 494 234

Data and design subject to change without notice / Supply subject to availability
4 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1995 08.96 x1336b
115 / 125
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 116 of 125

4. INTRINSICALLY SAFE REMOTE INDICATOR DJ1192EX

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
Ansprechindikatoren
Indicateurs daction
Response indicators
DJ1191Ex
DJ1192Ex
Montageanleitung
Instructions de montage
Installation instructions

Anwendung Application Application


Ansprechindikatoren (DJ) dienen der opti- Les indicateurs daction (DJ) servent la Response indicators (DJ) are connected
schen Parallelanzeige automatischer signalisation lumineuse parallle de d- in parallel with automatic fire detectors to
Brandmelder tecteurs dincendie automatiques provide repeat alarm signals.
DJ1191Ex fr Zargenmontage DJ1191Ex pour montage dans des DJ1191Ex for mounting on door frames
DJ1192Ex fr Aufputzmontage mit oder chssis de portes DJ1192Ex for surface mounting with or
ohne Zusatzrahmen AI330 DJ1192Ex pour montage saillant avec without the AI330 adapter frame
ou sans cadre supplmentaire AI330
Montage Montage Installation
DJ1191Ex auf Trzargen DJ1191Ex sur chssis de portes DJ1191Ex on door frames
48 20 20
17

3,2
37

32

62

Grundplatte/Leuchtelement Lcher in Trzarge


Plaque de base/lment lumineux Trous dans le chssis de porte
Base plate/lamp Holes in door frame

Fr die Leitungseinfhrungen nach Be- Selon besoin, on percera dans le chs- 1 hole (7.5mm max.) may be drilled in
darf 1 Loch max. 7,5mm in die Trzar- sis de porte 1 trou max. 7,5mm pour the door frame as required for cable
ge bohren lintroduction des lignes entry
Weisse Abdeckung entfernen (ausra- Retirer (dcliqueter) le couvercle blanc Remove white cover plate (unlatching
sten) Fixer sur le chssis de porte la plaque de action)
Grundplatte/Leuchtelement mit 2 base avec llment lumineux au moyen Mount the base plate/lamp on the door
Schrauben max. 3mm auf Trzarge de 2 vis max 3mm frame with 2 screws (3mm max.)
befestigen Raccorder selon schma de raccorde- Connect up as described under connec-
Anschluss gemss Anschluss-Schema ment tion diagram
Weisse Abdeckung wieder aufsetzen Remettre en place (encliqueter) le cou- Replace white cover plate
und einrasten vercle blanc
DJ1192Ex Aufputz DJ1192Ex saillant DJ1192Ex surface mounted
60
25
85

56

4,1

56

Weisse Abdeckung entfernen (schwar- Retirer le couvercle blanc (en pressant Remove white cover plate by pressing
zen Nocken drcken) sur lergot noir) black lugs
Grundplatte mit 2...4 Schrauben max. Fixer la plaque de base sur la paroi ou la Mount the base plate on the wall or a re-
4mm auf Wand oder UP-Dosen mon- bote encastrer au moyen de 2...4 vis cess box with 2...4 screws (4mm
tieren max. 4mm max.)
Fr die Befestigung auf Dosen mit Eloigner llment lumineux pour la fixa- Remove the lamp before mounting on
60mm Lochdistanz das Leuchtelement tion sur des botes dont les trous se trou- recess boxes with holes spaced at
entfernen vent 60mm lun de lautre 60mm
Anschluss gemss Anschluss-Schema Raccorder selon schma de raccordem. Connect up as described under connec-
Weisse Abdeckung wieder einhngen Raccrocher et encliqueter le couvercle tion diagram
und einrasten blanc Replace white cover plate

Data and design subject to change without notice / Supply subject to availability
x1240a 09.96 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1994 485 900 1
117 / 125
Zusatzrahmen AI330 zu DJ1192Ex Cadre supplmentaire AI330 pour AI330 adapter frame for DJ1192Ex
DJ1192Ex

16

85
Der Zusatzrahmen wird mit 2 Schrau- Fixer le cadre supplmentaire sur la pa- Mount the adapter frame on the wall or
ben max. 4mm auf die Wand oder Do- roi ou la bote au moyen de 2 vis max. box with 2 screws (4mm max.). The
se montiert. Je nach Dose kann die 4mm. La distance entre les vis peut tre distance between mounting holes can
Schraubendistanz beliebig gewhlt choisie conformment la bote be chosen as required according to the
werden Fixer lindicateur daction sur le cadre box used
Der Ansprechindikator wird seinerseits supplmentaire au moyen de 2 vis Mount the response indicator on the
mit 2 Holz- oder Blechschrauben bois ou vis Parker max. 3mm, lon- adapter frame with 2 wood or metal
3mm , max. 16mm lang, auf dem Zu- gueur max. 16mm screws (3mm max., 16mm long)
satzrahmen befestigt

Leitungsanschluss Connexion des lignes Connecting leads


Anschlussklemmen / Bornes de raccordement / Terminals Schema / Schma / Diagram
Schraubenlose Steckklemmen
Bornes sans vis
Screwless plug-in terminals
+

Schlitz zum ffnen der Klemmen


Fente pour louverture des bornes
Slot for opening terminals

Steckanschlsse fr einen Leiter Bornes sans vis pour un conducteur de Plug-in connection for one lead
0,25...1,5mm2 bzw. 0,6...1,3mm 0,25...1,5mm2, soit 0,6...1,3mm 0.25...1.5mm2 or 0.6...1.3mm
Anschlussdrhte ca. 7...8mm abisolie- Dnuder les conducteurs sur une lon- Insulate leads approx. 7...8mm
ren gueur denv. 7...8mm Insert wired in terminals
Drhte in die Klemmen einstecken Pousser les fils dans les bornes In order to be able to connect smaller
Um dnnere Drhte einstecken zu kn- Ouvrir les bornes pour pouvoir engager wire, or release wires already con-
nen oder bereits eingeklemmte Drhte des fils plus minces ou dgager des fils nected, open the terminals by inserting
zu lsen, die Klemmen durch Drcken coincs. Engager et pousser cet effet and pushing a screwdriver in the termi-
mit einem Schraubenzieher dans les fentes un tournevis de nal slots (screwdriver blade
0,35...0,6mm, DIN 5264, ffnen 0,35...0,6mm selon DIN 5264 0.35...0.6mm, DIN 5264)

Beispiele fr das Leitungsnetz Exemplespourconnexiondes lignes Examples for supply network

DJ1191Ex
DJ1192Ex

+ +

Ex Ex Ex Ex
Melder Dtecteurs Detectors

Data and design subject to change without notice / Supply subject to availability
2 Copyright by CERBERUS AG, CH-8708 Mnnedorf / Switzerland, 1994 09.96 x1240a
118 / 125
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 119 of 125

5. INTRINSICALLY SAFE BARRIER MTL5061

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
Hazardous area Safe area

MTL5061 FIRE/SMOKE
DETECTOR INTERFACE To earth
leakage
two-channel, loop-powered detector

Ch 2 Fire detectors 6 7
+
5
I 8

6 to
I Ch 2
4 9 35V dc
The MTL5061 is a loop-powered two-channel interface for use with
+
To earth leakage detector 3 10
conventional fire and smoke detectors located in hazardous areas. In +
2
I 11

6 to
I Ch 1
operation, the triggering of a detector causes a corresponding change 1 12 + 35V dc
Ch 1 Fire detectors
in the safe-area circuit. The unit has reverse input polarity protection,
while non-fail earth fault detection on either line can be provided by
connecting an earth leakage detector to terminals 3 or 6.

SPECIFICATION
See also common specification
Terminal Function
Number of channels 1 Output ve (channel 1)
Two 2 Output +ve (channel 1)
Location of detectors 3 Earth leakage detection (channel 1)
Zone 0, IIC, T46 hazardous area if suitably certified 4 Output ve (channel 2)
Div. 1, Group A hazardous location 5 Output +ve (channel 2)
Current range 6 Earth leakage detection (channel 2)
1 to 40mA, nominal 8 Input ve (channel 2)
Integral input polarity protection 9 Input +ve (channel 2)
Input circuit protected against reverse polarity 11 Input ve (channel 1)
No-fail earth fault protection (optional) 12 Input +ve (channel 1)
Enabled by connecting terminals 3 and 6 to the MTL4220 earth
leakage detector. If a fault on either line of each channel is
proclaimed: unit continues working.
Note: 1. The earth leakage detector introduces a 100A, 1Hz
ripple to the field circuit.

Minimum output voltage Vout at 20C


Vin (0.38 x current in mA) 2V
21V (0.35 x current in mA)
whichever is the lower
Response time to step input
Settles to within 500A of final value within 30ms
Hazardous-area output
Maximum output voltage 28V from 300
Transfer accuracy at 20C
Better than 400A
Temperature drift
<10A/C (20 to 60C)
Loop supply voltage
6 to 35V dc
Quiescent safe-area current at 20C
(hazardous-area terminals open-circuit)
<400A/ channel, Vin = 24V dc
Maximum power dissipation within unit
0.7W at 24V with 40mA signal (each channel)
1.2W at 35V with 40mA signal (each channel)
Safety description
28V, 300, 93mA; Um = 250V rms or dc

EUROPE (EMEA) Tel: +44 (0)1582 723633 Fax: +44 (0)1582 422283
AMERICAS Tel: +1 603 926 0090 Fax: +1 603 926 1899
ASIA PACIFIC Tel: +65 487 7887 Fax: +65 487 7997
June 2004
E-mail: enquiry@mtl-inst.com Web site: www.mtl-inst.com
120 / 125
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 121 of 125

6. PULL HANDLE 81300

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 122 of 125

I- INSTALLATION

1- Unscrew the fout screws (pull-handle for removing the two screws - Wrench Allen n5)

2- Draw the vertical position of the pull-handle on the choosed wall.


Now install in the wall the fitted nuts.
See attachment for the recommended high.

3- Screw the base plate on the wall with stainless steel screws.
You have to do a serious fixation supporting the own weight of the pull-handle and the tractive
effort given for unlock it.

4- Now remove the switch cover (spanner n10).


Join your cable on the internal terminal block of the switch.
(After crossed it through the cable-gland).

5- When wiring in finished, do all the operation in back way.

II- DIRECTIONS FOR USE

TO UNLATCH ALARM

1- If an alarm must be sent from a call point, just pull the handle to-wards you, till the handle be
locked down.
Now the electrical circuit is on.

TO LATCH ALARM

1- Unscrew the left or right plug


Turn back the triangular axis with the key. (P.N.88 005 or equivalent)
2- The handle return home.
3- Screw the plug in place.
4-The pull-handle is ready for use.

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 123 of 125

III-INSPECTION-MAINTENANCE

Our pull-handle is a maintenanceless designed product, yet a minimum of attention is


necessary to have the maximum security of good working.

ONCE A MONTH

Unlatch all the pull-handle (one after one) of the protected area and verify that :
a) The Handle Well Lock Down
b) The Electrical Signal Neaded Is Present
c) When Turning Back The Key, Handle Come Back Up In The Housing.
d) The Plug Will Be Well Tight.(No Enter Of Humidity)

TWICE A YEAR

Remove the hood and verify that no dust or insect are inside the instrument.

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 124 of 125

ATTACHEMENT

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006
PT NISCONI

Doc. Title : OPERATING AND MAINTENANCE MANUALS Page 125 of 125

7. NPT ADAPTERS
Manufacturer : RCN
Material : Nickel plated brass
Certification : EExd / EExe
Protection : IP66
Size model : M20x1.5 to 1/2 NPT
Size model : M3/4 NPT to 1/2 NPT

8. RESISTOR

Manufacturer : NEOHM
Category : Carbon film
Type : 0.5 W
Resistance : 6.8 k & 2.2 k
Maximum voltage : 350V
Resistance tolerance : 5%
Operating temperature : -55 to 155C

SISI NUBI FIELD DEVELOPMENT PROJECT -Phase 1 Doc. No : 5956-06


SN1/EPSC 3 Rev. : C
Status : C
Date : 03/10/2006