MODEL IR400

Infrared Point Detector for

Hydrocarbon Gas Applications

The information and technical data disclosed in

this document may be used and disseminated
only for the purposes and to the extent
specifically authorized in writing by General
Monitors.
Instruction Manual 05-18
General Monitors reserves the right to change
published specifications and designs without
prior notice.

MANIR400

Part No. MANIR400

Revision M/05-18
 Model IR400

This page intentionally left blank.

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 Model IR400

Table of Contents
MODEL IR400 ................................................................................................................................. I

INFRARED POINT DETECTOR FOR HYDROCARBON GAS APPLICATIONS ........................ I

TABLE OF CONTENTS ............................................................................................................ III

TABLE OF FIGURES................................................................................................................ IV

TABLE OF TABLES ................................................................................................................. IV

QUICK-START GUIDE .............................................................................................................. 1

1.0 INTRODUCTION .................................................................................................................. 4

1.1 Protection for Life ................................................................................................................. 4
1.2 Special Cautions and Warnings ............................................................................................ 4
1.3 Installation, Operation, and Maintenance .............................................................................. 4

2.0 PRODUCT DESCRIPTION................................................................................................... 5

3.0 INSTALLATION ................................................................................................................... 7

3.1 Attaching the IR400 to a Junction Box, S5000, IR4000S or IR4000M .................................... 8
3.2 Mounting Instructions.......................................................................................................... 10
3.3 Wiring Connections ............................................................................................................ 13
3.4 Applying Power .................................................................................................................. 15

4.0 OPERATION AND CONFIGURATION ............................................................................... 17

4.1 Zeroing, Gas Check Tests, and Calibration ......................................................................... 17
4.2 IR400 Stand-alone Operation and Configuration ................................................................. 20
4.3 HazardWatch Mode ............................................................................................................ 23
4.4 Gas Check Mode ................................................................................................................ 23
4.5 Detector Response Time .................................................................................................... 23

5.0 MAINTENANCE ................................................................................................................. 25

5.1 Developing a Maintenance Schedule .................................................................................. 25
5.2 Gas Checks, Zeroing and Recalibration .............................................................................. 25
5.3 Cleaning and Lubricating the IR400 and S5000 Units ......................................................... 26
5.4 Storage .............................................................................................................................. 26

6.0 TROUBLESHOOTING ....................................................................................................... 27

7.0 MODBUS INTERFACE ...................................................................................................... 29

8.0 CUSTOMER SUPPORT ..................................................................................................... 30

9.0 APPENDIX ......................................................................................................................... 31

9.1 Warranty ............................................................................................................................ 31
9.2 Principle of Operation ......................................................................................................... 32

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 Model IR400

9.3 Specifications ..................................................................................................................... 33

9.4 Environmental Specifications .............................................................................................. 36
9.5 Communications................................................................................................................. 36
9.6 Engineering Documentation................................................................................................ 37
9.7 Ordering Information........................................................................................................... 38

Table of Figures
Figure 1: IR400 with 31305 Junction Box .......................................................................................................... 1
Figure 2: Wiring Diagram from IR400 to Control Equipment .............................................................................. 3
Figure 3: Model IR400 ...................................................................................................................................... 5
Figure 4: Model IR400 with a 31305 Junction Box ............................................................................................ 8
Figure 5: Dimensions for IR400 mounted with S5000 Gas Monitor ...................................................................10
Figure 6: Wiring Diagram from IR400 to Control Equipment .............................................................................16
Figure 7: IR400 Zero Switch / LED During Zeroing and Calibration ..................................................................20
Figure 8: IR400 Optical Window Locations .....................................................................................................26
Figure 9: Outline and Dimensional Drawing, IR400, Inch Measurements..........................................................37

Table of Tables
Table 1: Wiring Chart ....................................................................................................................................... 2
Table 3: IR400 without HART Option ...............................................................................................................19
Table 4: IR400 with HART Option ....................................................................................................................19
Table 5: Locations ...........................................................................................................................................30
Table 6: Analog Current Output .......................................................................................................................35
Table 7: Maximum Distance between IR400 and Power Source ......................................................................35
Table 8: Maximum Distance between IR400 and Analog Input Device .............................................................35

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 Model IR400

Quick-Start Guide
Mounting and Orientation
The Model IR400 should be mounted horizontally (Figure 1) 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 1. Apply the supplied thread lubricant/sealant to all
conduit entries before use to prevent binding.

Figure 1a: IR400 with 31305 Junction Box

Figure 1b: IR400 with 31421 European Junction Box

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 Model IR400

Wiring Connections

TERMINAL WIRE COLOR SIGNAL

1 BLACK COM
2 GREEN FIELD GROUND (FG)
3 RED +24 V
4 WHITE 4-20 mA
5 BLUE MOD1+
6 WHT/BLU MOD1 -
7 BROWN CAL
8 - MOD2+ (no connection for IR400)
9 - MOD2 - (no connection for IR400)
10 - No Connection
Table 1: Wiring Chart
NOTE: Power should remain disconnected until all other wiring connections are made.

Power Connections
To supply power to the IR400, connect the red lead from the IR400 to the +24 VDC terminal on
the power supply. Connect the black lead from the IR400 to the power supply Common. Refer
to the manual of the power source being used, for more detailed instructions.
NOTE: If the Model IR400 is being used with a +24 VDC power supply and an industrial analog
to digital (A/D) converter, then the negative supply (Common) of all three must be
connected.

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 2 minutes before normal operation. IR400 Ethylene start-up can take
up to 10 minutes. As a unit warms up, output may briefly be negative.
After power is applied, the IR400 should be allowed to stabilize for approximately 60 minutes
while the unit attains the proper operating temperature. After stabilization, it is recommended
that the IR400 be zeroed, per the procedure in section 4.1 (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 32548) to perform this check.

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 Model IR400

General Monitors Control

Junction Box Equipment

IR400 Wires Terminals

Shield

BLACK 1 COM COM

GREEN/YELLOW 2 FG

RED 3 +24V +24V

Shield
WHITE 4 4-20mA 4-20mA IN
CAL (optional)
BLUE 5 MOD1+
MOD+ (optional)
BLUE/WHITE 6 MOD1-
MOD- (optional)
BROWN 7 CAL

8 MOD 2+

9 MOD 2-

10

BLACK
RED
General Monitors Zero
BROWN Switch

Figure 2: Wiring Diagram from IR400 to Control Equipment

The instrument is now ready to operate. Please further consult this manual for more information
on the instrument’s many features.

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 Model IR400

1.0 Introduction
1.1 Protection for Life
General Monitors’ mission is to benefit society by providing solutions through industry-leading
safety products, services and systems that save lives and protect capital resources from the
dangers of hazardous flames, gases and vapors.
The safety products you have purchased should be handled carefully and installed, calibrated
and maintained in accordance with this instruction manual. Remember, these products are for
your safety.

1.2 Special Cautions and Warnings

This instruction manual includes numerous cautions and warnings that are included to prevent
injury to personnel and prevent damage to equipment.
WARNING: TOXIC, COMBUSTIBLE, AND FLAMMABLE GASES AND VAPORS ARE VERY
DANGEROUS. USE EXTREME CAUTION WHEN THESE HAZARDS ARE PRESENT.

1.3 Installation, Operation, and Maintenance

Before power up, verify wiring, terminal connections and stability of mounting for all integral
safety equipment.
Proper system operation should be verified by performing a full, functional test of all component
devices of the safety system, ensuring that the proper levels of alarming occur.
Fault/malfunction circuit operation should be verified.
Periodic testing/calibrating should be performed per the manufacturer’s recommendations and
instructions.
When testing produces results outside of the manufacturer’s specifications, re-calibration or
repair/replacement of the suspect device(s) should be performed as necessary. Calibration
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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 Model IR400

2.0 Product Description

General Description
The Model IR400 infrared (IR) point detector is a microprocessor-based combustible gas
detector, is calibrated at the factory and needs no routine field calibration. Applying a test gas
to the unit can check the sensitivity of the IR400. It is also relatively maintenance free, requiring
only a periodic cleaning of the windows and re-zeroing to ensure dependable performance.
The IR400 continuously monitors combustible gases in the lower explosive limit (LEL) range
and provides a 4 to 20 mA analog signal proportional to the 0 to 100% LEL concentration. Gas
calibration is available to LEL values defined by ISO 10156/NFPA 325 and IEC 60079-20. A
Modbus communications interface is also provided for informational / programming purposes.
Sensor data and status information from the IR400 can be transmitted to a variety of General
Monitors’ readout units.
The IR400 operates from a +24 volt DC supply.

Figure 3: Model IR400

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 Model IR400

Features and Benefits

This is a partial list of features and benefits for the Model IR400 infrared point detector:
 No routine calibration required
 Fail-to-safe operation
 T90 response time < 3 seconds
 4-20 mA output
 Modbus communications link
 Optional HART interface
 Heated optics 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 rated enclosure
 Interfaces directly with the DC110 controller & TA102A trip amplifier
 Expanded capabilities when used with S5000, IR4000S Single and IR4000M Multi-
Point monitors

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 Model IR400

3.0 Installation
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.
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 IR400 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 IR400 is EMI/RFI resistant, it should not be mounted
close to radio transmitters, high magnetic or electrical fields or similar equipment. Proper wiring
and grounding is essential for optimum performance. Snap-on ferrite filters can provide
additional resistance to electromagnetic and radio frequency interference.
NOTE: The Model IR400 cannot detect hydrogen (H2) gas.

Some other factors to consider when selecting a detector location:

 Emission temperature and vapor density of the gas. The IR400 should be located near the
floor for gas vapors that are heavier than air.
 Do not locate the IR400 in areas that exceed the maximum operating temperature of the
unit, such as gas turbine exhaust.
 Locate the IR400 where prevailing air currents contain the maximum concentration of gas.
 Locate the IR400 as near as possible to the likely source of a gas leak.
 Observe the temperature range of the IR400 and locate the unit away from concentrated
sources of heat or light.
 Mount the IR400 away from sources of excessive vibration.
WARNING: Each IR400 is completely tested at the factory. However, a complete system
checkout is required upon initial installation and start-up to ensure system
integrity.
NOTE: The Model IR400 is factory calibrated and needs no routine calibration. However, if the
IR400 is to be installed at altitudes greater than 1000 ft (300m), it must be re-calibrated
on-site (Section 4.1).

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 Model IR400

3.1 Attaching the IR400 to a Junction Box, S5000, IR4000S or

IR4000M
Before you can mount an IR400 device, you must first attach it to an IR400 junction box,
S5000, IR4000S single point monitor, or an IR4000M multi-point monitor.
CAUTION: To prevent damage by static electricity, avoid contact with PCB components. All
wire connections should be made to the terminal blocks.
To Attach an IR400 to a Junction Box, S5000, IR4000M, or IR4000S
1. Apply the supplied thread lubricant/sealant to all conduit entries of the IR400, junction box,
S5000, IR4000M, or IR4000S, as needed to prevent binding.
2. Remove the cover from the junction box, S5000, IR4000M, or IR4000S.
3. Strip and trim the wires from the IR400 as needed and thread them into either the right or
left wiring conduit of the junction box, S5000, IR4000M, or IR4000S.
4. Once the wires are threaded into the enclosure, screw the IR400 securely into the junction
box, S5000, IR4000M, or IR4000S. An example is shown below.

Figure 4a: Model IR400 with a 31305 Junction Box

Figure 4b: IR400 with 31421 European Junction Box

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 Model IR400

5. Fasten the IR400 wires to a wiring connector inside the junction box, S5000, IR4000M or
IR4000S enclosure. Once the two units are attached, you may replace the cover on the
enclosure attached to the IR400 using the four captive screws, or leave it off until additional
cabling from the enclosure is completed.

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 Model IR400

3.2 Mounting Instructions

The IR400 is mounted using the bolt holes on an attached junction box, S5000, IR4000M or
IR4000S enclosure. The S5000 or IR4000M(S) is often mounted remote from the IR400 units,
in order to locate it within easy reach and at eye level.
3.2.1 Mounting an IR400 with an Attached Enclosure
The following figure shows the overall and mounting dimensions for the Model IR400 with an
attached S5000 enclosure.

Figure 5: Dimensions for IR400 mounted with S5000 Gas Monitor

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 Model IR400

To Mount the IR400

The IR400 must rest horizontally to reduce the possibility of dirt and dust building up on the
lens.
 The open slots of the gas passage must be straight up and down for the gas to rise up
and through the unit.
 If the detector is installed with the metal section blocking the gas flow, it will slow down
the detector’s response.
Mount the attached junction box or S5000 enclosure using the two bolt holes.
3.2.2 Cabling Safety Notices
CAUTION: The Model IR400 detector and S5000 gas monitor contain components that can be
damaged by static electricity. Special care must be taken when wiring the system to ensure that
only the connection points are touched.
WARNING: Under NO circumstances should equipment be connected or disconnected when
under power. This is contrary to hazardous area regulations and may also lead to serious
damage to the equipment. Equipment damaged in this manner is not covered under warranty.
3.2.2.1 European Union (EU) Approved Cable Armor and Screens
Interconnecting cables must have an overall screen or screen and armor. BS5308 cables are
suitable. Note that the terms ‘screen’ and ‘shield’ are equivalent for the purpose of this manual.
The cable armor must be terminated in a suitable cable gland at the detector to ensure a
positive electrical connection.
3.2.2.2 Cable Termination in Non-Hazardous Areas
 The cable armor must be connected to safety earth in the safe area.
 The cable screen (drain wire) must be connected to an instrument earth in the safe area.
 The power supply 0V 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, switch gear, arc lights
and other high frequency or high power switching process equipment.
 In general, maintain separation of at least 1 meter between the instrument and other
cables. Greater separations are required where long parallel cable runs are unavoidable.
Avoid running instrument cable trenches close to lightning conductor earthing pits.
 Complete all cable insulation testing before connecting the cable at either end.

3.2.3 Conduit Entries

Please keep the following warnings and cautions in mind when you install the IR400 and S5000
units. Information on Class I Division 1 wiring methods can be found in NEC Article 501.10.
WARNING: Unused cable entry holes in each IR400 junction box and S5000 must be sealed
with approved explosion-proof stopping plugs. Red caps supplied by General Monitors are for
dust protection only, and must not be left on the unit when installed.
CAUTION: Acetic acid will cause damage to metal components, metal hardware, ceramic ICs,
etc. If damage results from the use of a sealant that contains acetic acid (RTV silicone), the
warranty will be void.

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 Model IR400

CAUTION: To prevent corrosion due to moisture or condensation, it is recommended that the

conduit connected to the display unit housing contain a drain loop.
3.2.4 European Junction Box 31421, Stopping Plug Installation
NOTE: The stopping plug, 311001-1, is fitted at the factory, the following instruction
will only be necessary if the stopping plug has been removed from its current location to
another entry of this product.

 Screw Earth/Stopping Plug (P/N 311001-1) into Top Entry of 31421 Housing.
 Fully tighten using a suitable hand wrench.
 Do not over tighten such that the O’Ring is damaged
 Screw Continuity Hex Nut (P/N 928-814) on the inside of the 31421 Housing to the
Earth/Stopping Plug (P/N 311001-1).
 Tighten to insure it is secure and making good contact with internal continuity plate.

 If removing the Earth/Stopping Plug (P/N 311001-1), unscrew Continuity Hex Nut (P/N
928-814) on the inside of the 31421 Housing from the Earth/Stopping Plug.
 Unscrew the Earth/Stopping Plug (P/N 311001-1) from the Top Entry of 31421 Housing.

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 Model IR400

3.3 Wiring Connections

WIRE WIRE COLOR SIGNAL

1 BLACK COM
2 GREEN FIELD GROUND (FG)
3 RED +24 V
4 WHITE 4-20 mA
5 BLUE MOD1+
6 WHT/BLU MOD1-
7 BROWN CAL
8 - MOD2+ (no connection for IR400)
9 - MOD2 - (no connection for IR400)
10 - No Connection
Table 2: Wiring Chart
The IR400 operates on nominal power of +24 VDC. The customer must provide primary DC
voltage power, unless a General Monitors readout/relay display module with an internal power
supply is used. Since the IR400 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 IR400 and the power source is specified in Section 9.3.3.
3.3.1 Power Connections
To supply power to the Model IR400 connect the red lead from the IR400 to the +24 VDC
terminal on the power supply. Connect the black lead from the IR400 to the power supply
Common. Refer to the manual of the power source being used, for more detailed instructions.
NOTE: If the IR400 is being used with a +24 VDC power supply and an industrial analog to
digital (A/D) converter, then the negative supply (Common) of all three must be
connected.

An internal diode protects the system in the event of inadvertent supply reversal.
3.3.2 4- 20 mA Output
A 4 to 20 mA output signal is provided by the Model IR400 and can be sent to a General
Monitors’ readout/relay display module or any industrial device that can accept a 4 to 20 mA
signal for computer based multi-point monitoring. The Analog Output connection provides a
signal for use in displaying current LEL readings, special operation or fault conditions. The
maximum distance between the IR400 and the device connected to the Analog Output signal is
specified in Section 9.3.5.
To access the 4-20 mA signal, connect the white lead from the IR400 to the signal-in terminal
of the input unit. Refer to the manual of the display or other device being used for detailed
instructions.
Connect the black lead from the IR400 to the device Common. The Common connection
serves both the analog signal and the power connections.

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 Model IR400

3.3.3 Dual Modbus Interface

To access the Modbus (Modbus-RTU) interface, connect the blue lead from the IR400 to the
Modbus (+) terminal and the blue/white lead to the Modbus (-) terminal on the customer’s
Modbus capable device. For a description of the data available from the IR400 and the
programming interface, please refer to the separate IR400 Modbus manual.
3.3.4 HART Interface
A standard HART interface is available which provides a digital data channel at 1200 baud over
the 4-20 mA current loop. See the IR400 HART Manual Addendum for additional information.
3.3.5 Magnetic Switch
The IR400 also provides a lead for connecting a +24 VDC powered magnetic switch. The
brown lead from the IR400 must be connected to the powered side of the switch so that when
the switch is activated, the brown lead is grounded. General Monitors can supply a junction box
with an integral magnetic switch to ease the connection of the IR400 in the field.

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 Model IR400

3.4 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 2 minutes before normal operation. IR400 Ethylene start-up can take
up to 10 minutes. As a unit warms up, output may briefly be negative.
After power is applied, the IR400 should be allowed to stabilize for approximately 60 minutes
while the unit attains the proper operating temperature. After stabilization, it is recommended
that the IR400 be zeroed, per the procedure in Section 4.1 (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 32548-x) to perform this check. If the unit does not respond properly, calibrate
per the procedure in Section 4.2.3 (steps 1-4).
 When connecting the IR400 to a safety system, the +24 VDC (red) wire should be the last
wire connected and first wire disconnected when removing the unit to protect the system
from shorting.
 If the analog (4-20 mA) output is not used, then the white signal wire must be connected to
ground to prevent a fault condition.

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 Model IR400

General Monitors Control

Junction Box Equipment

IR400 Wires Terminals

Shield

BLACK 1 COM COM

GREEN/YELLOW 2 FG

RED 3 +24V +24V

Shield
WHITE 4 4-20mA 4-20mA IN
CAL (optional)
BLUE 5 MOD1+
MOD+ (optional)
BLUE/WHITE 6 MOD1-
MOD- (optional)
BROWN 7 CAL

8 MOD 2+

9 MOD 2-

10

BLACK
RED
General Monitors Zero
BROWN Switch

Figure 6: Wiring Diagram from IR400 to Control Equipment

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 Model IR400

4.0 Operation and Configuration

The methods used to operate and configure the IR400 will vary depending on whether you are
using the IR400 as part of an S5000 monitoring system, or as a stand-alone unit attached to a
junction box and control room devices, or to an IR4000S. Separate instructions are provided in
this chapter for each situation.
 If your IR400 is part of an S5000 system, you can operate and configure both the IR400
and the S5000 using the S5000 menu options and LED display. You can also send
Modbus or HART commands to the S5000 from connected control room devices, to
perform all the menu-driven functions, plus additional ones.
 If your IR400 is a stand-alone unit attached to a junction box, you can use the magnetic
switch attached to the junction box for zeroing and calibration. You can also send Modbus
or HART commands to the IR400 from control room devices to perform zero, calibration,
gas checks and configuration tasks.
 If your IR400 is a stand-alone unit attached to an IR4000S display device, then you can
use the IR4000S menus for operation and configuration.
NOTE: This chapter describes how to use the junction box magnetic switch for stand-alone
IR400 operation; the S5000 manual describes how to use the S5000 menus for IR400
system operation and configuration.

4.1 Zeroing, Gas Check Tests, and Calibration

Each IR400 is calibrated at the factory. However they will need occasional zeroing as well as
gas check tests after initial installation to make sure they are working properly. Before zeroing
or calibration, always check that the optics path is clear and the windows are clean. These are
the most important operations to ensure that the IR400 is measuring accurately.
Depending on your system configuration, you can use menus, Modbus/HART commands or
magnetic switch selection to initiate zeroing, gas checks and calibration, as described later in
this chapter. Some general guidelines are provided here that are useful no matter what method
is used.
NOTE: The IR400 is factory calibrated and needs no initial calibration. However, if the unit is to
be installed at altitudes greater than 1000 ft (308 m), it must be re-calibrated on-site.

NOTE: Entering Gas Check, Zeroing, or Calibration mode sends a 1.5 mA output signal that
disables the S5000 Warning and Alarm relay circuits.

4.1.1 Using Zero Air

If you suspect that combustible gasses are present, it is necessary to purge the sensor
environment with zero air before zeroing the unit, starting the gas check, or starting calibration.
4.1.2 Zeroing Guidelines
Zeroing the IR400 detector is necessary periodically in order to eliminate any background gas
fluctuations. You may wish to purge the sensor environment with zero air before zeroing the
unit.
4.1.3 Gas Check Test Guidelines
Running a gas check test enables you to verify whether the detector is functioning correctly, by
applying a known gas concentration and monitoring the % LEL reading while keeping the alarm
and warning relays disabled. To apply gas or a gas simulation during the test, you can use the
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 Model IR400

General Monitors gas check kit with portable purge calibrator equipment.

CAUTION – The S5000 and IR4000S turn off the Warn and Alarm relays during Gas Check,
but the current loop from the IR400 will still transmit the gas concentration level. Make
sure that any equipment monitoring the analog output is in alarm bypass mode before
performing a gas check with the S5000 or IR4000S.

4.1.3.1 Portable Purge Calibrator Equipment

The portable purge calibrator is a compact, accurate and safe system containing a non-
explosive gas concentration. The lecture bottle is filled with a standard 50% LEL mixture of
gas/air. Using a known gas/air mixture reduces the likelihood of error in field calibration.
The hose and cup adapter that are included allow for quick calibrations and gas checks.
Pre-mixed calibration gases at approximately 50% LEL are available in lecture bottles.
 Butane C4H10  Ethane C2H6
 Ethylene C2H4  Hexane C6H14
 Methane CH4  Pentane C5H12
 Propane C3H8
Spare bottles containing these gases may be ordered. Methane lecture bottles may be returned
to General Monitors for refilling with the standard 2.5% by volume methane (50% LEL per ISO
10156 and NFPA 325).
4.1.4 Calibration Guidelines
Calibrating the detector corrects any errors that may be affecting the % LEL measurement that
is taking place. You should use the General Monitors gas check kit for calibration. Section
4.1.3.1 describes the gas check kit equipment in more detail. You may need to calibrate the
IR400 detector under several circumstances.
 If the gas check test indicates that the detector needs adjustment.
 If you are reconfiguring the IR400 to detect a different type of gas.
 If you are moving the detector to a higher altitude location (every 1000 feet difference in
altitude requires recalibration).
General Monitors configures the IR400 with three calibration input options: magnetic switch
(default), manual solenoid, and automatic remote gas calibration device (ARGC). To use the
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 Model IR400

manual solenoid or ARGC, purchase a factory configured IR400 or change the calibration input
via Modbus or HART.
4.1.5 IR400 Analog Output (AO) Interpretation

Current Level (mA) Meaning

0 Startup mode and critical fault for non HART unit
1.5 Zero, Calibration and Gas Check Mode
2 Non critical fault
4 – 20 0 – 100% LEL or % by Volume
20.1 – 21.7 Over range
Table 3: IR400 without HART Option

Current Level (mA) Meaning

0 Startup mode and critical fault for non HART unit
1.25 Startup mode and critical fault if current range is low
1.5 Zero, Calibration and Gas Check Mode
2 Non critical fault
3.5 All faults and startup if unit is configured with current
range set to “high”
4 – 20 0 – 100% LEL or % by volume
20.1 – 21.7 Over range
Table 4: IR400 with HART Option

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 Model IR400

4.1.6 IR400 Zero Switch / LED flashing patterns

Flashing Pattern (ms) Description

1000 on, 1000 off Zero
950 on, 50 off Zero complete, calibration pending
100 on, 400 off Calibration, apply gas
500 on, 1000 off Gas present, calibration in progress
980 on, 20 off Calibration complete; remove gas
100 on, 100 off Fault
NOTE: This table is for Zero Switch / LED calibration input configurations only.

4.2 IR400 Stand-alone Operation and Configuration

The IR400 does not have built-in operation and configuration menus without an S5000.
However, zeroing and calibration can be accomplished using the Zero (magnetic) Switch / LED
on the junction box that is directly attached to the IR400. You should ‘zero’ the Model IR400
detectors occasionally to eliminate any background gas fluctuations. Calibration is necessary if
gas check readings show the unit is reading inaccurately.
In addition, many operational functions are available using the Modbus/HART interface from a
control room device, as described in separate General Monitors’ manuals (available from our
website).
4.2.1 To Zero and Calibrate a Stand-alone IR400 Using a Magnetic Switch
This procedure describes how to use the IR400 junction box magnetic switch to zero and
calibrate the IR400. Once zeroing or calibration begins, the alarm and warning relays are
automatically kept disabled, and the analog signal is held at 1.5 mA. As you follow the
procedure steps, refer to the figure shown below for the LED indicator.

2 Seconds

Zeroing Step 1

Zero Complete

Waiting for Gas Step 2

Gas Present

No Gas, Error Step 3

Fault

Re-Calibration
Complete

Figure 7: IR400 Zero Switch / LED During Zeroing and Calibration

20
 Model IR400

Review the general guidelines in Section 4.1 on Zeroing, Gas Check Tests, and Calibration. Make
sure the windows are clean and there is nothing blocking the optical beam.
4.2.2 Zero Only Calibration
The junction box used with the IR400 is fitted with a zero switch which eliminates any background
gas fluctuation.

Zero Switch
Zero the Unit. Apply the General Monitors magnet that was included with the unit to the Zero
Switch / LED 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 (Zeroing in the figure).
 When the unit has finished zeroing, the LED will turn on and flash off quickly once per
second for 30 seconds (Zero Complete in Figure 7).

NOTE: If an error occurs during the zeroing/calibration sequence, the LED will flash on and off
rapidly (Fault).

4.2.3 Full Span Calibration

If a full span calibration is required, a zero calibration must first be performed to eliminate any
background gas fluctuation. When the zero calibration is complete, a full span calibration may
optionally be performed.
1. Zero the Unit. Apply the General Monitors magnet that was included with the unit to the
Zero Switch / LED 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 (Zeroing in the figure).
 When the unit has finished zeroing, the LED will turn on and flash off quickly once per
second for 30 seconds (Zero Complete in Figure 7).

NOTE: If an error occurs during the zeroing/calibration sequence, the LED will flash on and off
rapidly (Fault).

21
 Model IR400

2. Return to Normal Operation or Start Calibration. If the magnet is not applied again, the
unit will return to normal operation. To continue on and calibrate, apply the magnet again
and the unit will enter the calibration mode.
The LED will flash off quickly once every half-second while the unit is waiting for gas to be
applied (Waiting for Gas).
3. Apply Gas. Apply a 50% LEL gas using a Gas Check Kit with portable purge calibrator
equipment (or 50% by volume of the gas being detected in nitrogen for units designed for
monitoring 0 to 100% by volume).
 When the unit detects the gas, the LED will flash on for a half second every one and
one-half seconds (Gas Present).
 If the unit does not detect the gas, the LED will flash off quickly once every half-second
while the unit is still waiting for gas to be applied (No Gas Error).
 Once calibration has been completed, the LED will turn on and flash off once every
second (Calibration Complete).
4. Return to Normal Operation. Remove the gas and the unit will return to normal operation
once the gas has fallen below 5% of full scale.

22
 Model IR400

4.3 HazardWatch Mode

The IR400 is compatible with the General Monitors HazardWatch System and can be calibrated
via the system interface for HazardWatch. To support calibrations initiated in HazardWatch, the
IR400 must be configured in the HazardWatch Mode. This mode prevents aborted calibrations
from being recorded as successful calibrations and ensures accurate logging in the
HazardWatch System.
To use this feature, purchase a HazardWatch-configured IR400 or change the mode via
Modbus. See the Modbus manual available from the MSA website for Modbus commands.

4.4 Gas Check Mode

1. Send Modbus or HART gas check command.
2. When the unit enters gas check mode, AO will be kept at 1.5 mA. Apply a 50% LEL gas
using a gas check kit with portable purge calibrator equipment.
NOTE: If the manual solenoid calibration input is configured, send the Modbus or HART
command to turn on the solenoid.

3. Once the detector is placed in gas check mode and the gas is applied, monitor the % LEL
reading for the detector to see if it is functioning properly using the S5000 or IR4000S
display or Modbus/HART commands. When the reading is stabilized, it should be 50%
LEL if the gas from the check kit is applied.
4. Remove the gas.
NOTE: If the manual solenoid calibration input is configured, send the Modbus or HART
command to turn off the solenoid.

The unit will return to normal operation when the concentration drops below 5% full-scale.
Since the IR400 zeros before calibrating, you must remove the gas completely before going to
calibration mode.

4.5 Detector Response Time

A valid response time of a gas detector must take into account a static gas presence as it
occurs in the field with a gas leak. Tests performed on site use a flow method to verify detector
function only as gas enters the optical path, with its splashguard in place, slowly. With regard to
the specified response times, these specifications were obtained by testing the gas detector,
with a splashguard, in accordance with agency performance requirements. A chamber is filled
with a known concentration of gas (static) and the IR400 is then exposed to the gas. This
method is defined by the approval agencies and allows us to fill instantaneously the optical path
of detector to achieve the stated response times for the IR400. It is not practical to perform this
type of test in the field since a potentially explosive gas (100% LEL) is used.
T response times: According to CSA C22.2, T50 equals time to 50% of full-scale meaning 50%
LEL and T90 which is 90% of the final reading.
CSA Standard C22.2 No. 152 Combustible Gas Detection Instruments, Section 6.9 states:
Beginning with the gas sensing element in clean air it shall be suddenly exposed to a
prepared mixture of gas in air having a concentration corresponding to 100% of the
full scale gas concentration. From the instant of exposure to this gas mixture the
instrument shall respond to provide an indication within the time specified as follows:
50% of full scale gas concentration in 10 sec, and 90% of maximum indicated gas
concentration in 30 sec.
23
 Model IR400

The products offered by General Monitors are not for the purpose of testing response time, but
as a method to allow a user to check that the unit is responding to gas and/or that final
response is within tolerance. If it’s required to demonstrate a reading of 50% LEL at site this
can be achieved using the calibration cup, however it should be noted that you need to apply
the test gas for approximately three minutes to get a reading of 50% LEL. This time is due to
the ambient air located in the optical path of the detector having to be replaced progressively by
the test gas. This replacement of ambient air is quicker at the beginning but longer for the last
percentage because it is linked to the slow replacement of air dilution by the test gas. This test
is only to indicate a gas level of 50% LEL within the calibration cup and is not a reflection of the
response time of the detector.

24
 Model IR400

5.0 Maintenance
The Model IR400 is calibrated at the factory and is fail-to-safe; once it is correctly installed and
calibrated upon start-up, it requires little maintenance other than periodic cleaning, gas checks,
zeroing and recalibration to ensure system integrity. Integrity checks can be performed using
General Monitors’ Gas Check Kit (P/N 32548).
WARNING: Disconnect or inhibit external devices such as Trip Amplifiers, PLC’s, or DCS
systems before performing any maintenance.
NOTE: If an optical fault still occurs after cleaning and re-zeroing of an IR400 detector is
complete, then you must return the unit to the factory for service. The system’s full two-
year warranty will be voided if customer personnel or third parties damage the system
during repair attempts or maintenance activities. Gassing into the screened
splashguard will not provide a stable or accurate reading.

5.1 Developing a Maintenance Schedule

Maintenance requirements will vary with each installation; General Monitors recommends that a
schedule for periodic maintenance be established and followed, and that a maintenance
logbook be kept for each unit in operation.
More frequent cleaning and calibration checks are recommended if the equipment is impacted
by unusual environmental conditions such as mud collecting on the sensor head, sensors
accidentally being painted over, etc.
General Monitors is not implying that the customer should expect problems with sensor life or
stability, but calibration checks ensure the integrity of the life protecting equipment.

5.2 Gas Checks, Zeroing and Recalibration

The Model IR400 is calibrated at the factory and needs only occasional recalibration after initial
installation and start-up.
 For detailed instructions on initiating gas checks, zeroing and calibration using the S5000
menus, see the user manual for the S5000.
 For instructions on zeroing and recalibrating a stand-alone IR400 using the magnetic switch
on an attached junction box, see Section 4.2.1.
 For information on the Modbus IR400 and S5000 register Operating Mode commands for
gas checks, zeroing and calibration, refer to the separate Modbus manuals.

25
 Model IR400

5.3 Cleaning and Lubricating the IR400 and S5000 Units

5.3.1 Cleaning the IR400 and S5000 Units
The IR400 optical windows can be cleaned by removing the splashguard that covers them,
then gently wiping them with a soft, clean cloth or cotton swab that has had a commercial
window cleaning solution applied; water or ethanol are examples of suitable solvents. You can
remove particulate matter from the IR400, detector accessories, and S5000 units using an
appropriate halogen-free solvent, such as water or ethanol. Accessories should be thoroughly
dried with compressed air, if necessary, before refitting them to the detector.

Figure 8: IR400 Optical Window Locations

NOTE: Do not clean the windows while an IR400 unit is zeroing or in recalibration mode. The
unit must be re-zeroed after cleaning.

5.3.2 Lubricating IR400 and S5000 Units

If the neoprene rubber gasket (O-ring) in the cover of the S5000 enclosure is found dry, it
should also be lubricated with the lubricant/sealant that is included with the IR400/S5000 units,
or is available on order from General Monitors (P/N 916-062).

As an alternative to grease, PTFE (Teflon) tape may be used.

5.4 Storage
The Model IR400 Gas Detector and S5000 Gas Monitor should be stored in a clean, dry area,
and within the temperature and humidity ranges noted for environmental specifications in
Section 9.3.3 Electrical Specifications for the IR400, and the separate user manual for the
S5000. Insert the red dust caps into any vacant cable entry holes while the unit is stored.

26
 Model IR400

6.0 Troubleshooting
The IR400 will alert the operator that there are problems in a number of ways. The table on the
following page shows the value for the analog output, the value read through Modbus register 2
(if Modbus is being used), and the fault code, shown as F and a number, on the S5000 display
(if connected).
If the IR400 is connected to a zero switch, then the LED in the zero switch will blink at a rate of
5 flashes per second to show that the detector needs attention.

HART Troubleshooting

1. Verify that the IR400 is configured for HART

2. Verify that the HART modem or HART handheld device (375 or 475) is working by
checking it against another HART field device
3. Verify that the HART software or handheld device has the DD for the IR400. If the DD is
not present, download it from the HART Communication Foundation (HCF) website.
4. Verify the IR400 wiring
5. Verify that power is off when removing or attaching wires
- Red to power
- Black to common
- White to a 250 ohm resistor, and the other end of resistor to common. Resistor
tolerance should be +/-5% or less.
- Verify HART modem or 475 wiring: Leads are across the 250 ohm resistor
- After verifying the IR400 wiring, verify that power is on to the IR400 and to the HART
modem or handheld device
6. Verify IR400 4-20mA output. When no gas and no faults are present, a voltmeter across
the 250 ohm resistor will read 1.0 volt DC.

27
 Model IR400

Table showing the fault conditions and corrective action required:

MODBUS FAULT
FAULT
FLAG REGISTER DESCRIPTION POSSIBLE CAUSE CORRECTIVE ACTION
CODE ANALOG OUTPUT (mA)
2

HART non-HART
1)Fouling of the detector windows or
2mA for 30s 2mA for 30s Gas Concentration is
F0 Bits 3 & 14 beam path is excessive and requires 1) Clean detector beam path and windows.
then 1.25mA then 0mA Excessively Negative
attention
Gas Concentration is 1) Detector windows or beam path are
F1 Bits 0 & 1 2 2 1) Clean detector beam path and windows.
Negative beginning to be obscurred.

1) Cal bottle empty and time-out occurred 1) Obtained filled CAL bottle and re-CAL.

2) Failed to remove gas at end of CAL and

2) Remove gas when directed.
time-out occurred.
3a) Check CAL cup for proper seating on
Failed to Complete 3) Leaky CAL cup resulting in unstable unit.
F2 Bit 6 1.25 0 signal.
Calibration 3b) Check CAL cup seal and replace CAL
cup if damaged.

4) Attempted to CAL with too much wind 4) Calibrate at a much less windy time or
resulting in unstable signal. shield the unit and CAL cup from the wind.

1) Detector windows or beam path are

blocked by dirt, spider webbing or other 1) Clean detector beam path and windows.
2mA for 30s 2mA for 30s foreign matter.
F3 Bit 2 Beam Block
then 1.25mA then 0mA
2) The IR400 must be returned to the factory
2) Detector or source failure.
or authorized service center for repair.
1) Ensure baud rate, data format and
Communications Fault 1) Incorrect communications set-up. address matches at both the IR400 and the
F4 1.25 0 (Applies to IR4000M bus master.
display only) 2) Communications wiring open. 2) Check and correct wiring.
3) Communications wiring shorted. 3) Check and correct wiring.
CAL Wire (brown) 1) Check and ensure proper connection of
F5 Bit 4 1.25 0 1) CAL Wire (brown) not in connector
Shorted wire to board connector
1) Power supply not outputing greater 1) Check the supply voltage and replace
than 20VDC. power supply if necessary
F6 Bit 5 1.25 0 Low Supply Voltage 2) Check the supply voltage at the IR400
2) Voltage loss due to wiring. field and adjust supply to +24VDC at the
IR400 or replace wiring with larger gauge.

1) Cycle power, wait 2 minutes, if the fault

1) Internal memory glitch clears then check all menu settings and
F7 Bits 9 - 13 & 15 1.25 0 Electronics Error recalibrate the IR400.
2) Call your local General Monitors
2) Internal error with the electronics.
representative for advice.
1) Ensure clean air is available for zeroing
F8 Bit 7 1.25 0 Failed to Zero 1) Unstable signal due to gas present. or provide zero air to the IR400 during
zeroing.

CAL Check Period 1) Test gas still present after gas check
F9 Bit 8 1.25 0 1) Remove the gas
Exceeded completed.

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 Model IR400

7.0 Modbus Interface

The IR400 has a single Modbus compatible interface for connection to control room equipment
such as programmable logic controllers (PLCs). The Modbus interface is also used to connect
IR400 detectors to the IR4000M multi-point monitor.
A separate manual for the IR400 Modbus registers and a programming guide is available from
the MSA website.

29
 Model IR400

8.0 Customer Support

AREA PHONE/FAX/EMAIL

UNITED STATES
26776 Simpatica Circle Phone: +1-949-581-4464
Lake Forest, CA 92630 Email: [email protected]

IRELAND
Ballybrit Business Park
Galway Phone: +353-91-751175
Republic of Ireland Email: [email protected]

MIDDLE EAST
P.O. Box 54910
Dubai Airport Freezone Phone: +971-4-294-3640
United Arab Emirates Email: [email protected]

SINGAPORE
35 Marsiling Industrial Estate, Road 3
#04-01 Phone: +65-6748-3488
Singapore 739257 Email:

Table 5: Locations
Additional locations can be found on our web site, www.MSAsafety.com

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 Model IR400

9.0 Appendix
9.1 Warranty
General Monitors warrants the Model IR400 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.
NOTE: The Model IR400 Infrared Point Detector is easy to install; however, you should read and
understand this manual before attempting to install or operate the device. It includes
important safety information.

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.

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 Model IR400

9.2 Principle of Operation

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 IR400 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 IR400 uses a dual source, single detector measurement method. One source
operates at a wavelength where absorption of a specific gas (or gases) occurs (the active
wavelength). The reference source operates at 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.).

Control Electronics
The Model IR400 operates from an unregulated +24 VDC (nominal) input, which is fed to an
onboard 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 analog converter to
produce a 4 to 20 milliampere (mA) signal that is proportional to the 0 to 100% LEL (or
methane % by volume) 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 IR400 provides a two-wire RS-485 addressable communications link conforming to
the Modbus protocol that is used to monitor the IR400’s status and settings in order to simplify
installation and maintenance.

32
 Model IR400

9.3 Specifications
9.3.1 System Specifications

Detector Type: Infrared absorption

Detector Life: Greater than 5 years
Measuring Range: 0 to 100% LEL
Zero Drift: < 2% per year
Response Time:
(With 100% LEL methane applied) T50  1.5 seconds, T60  1.5 seconds
T90  3 seconds
(With 100% LEL ethylene applied) T50  1.5 seconds, T60  2 seconds
T90  4 seconds
All times are with the splash guard with screen
Accuracy @ 25º C: ±3% FS  50% FS, ±5% FS > 50% FS
Gas Calibrations Methane, Propane, Ethane, Ethylene, Butane,
Hexane, Pentane at LEL levels defined by ISO
10156/NFPA 325 and at levels defined by IEC
60079-20.
Consult factory for other calibrations.
Readout/Relay Display DC110: Multi-Channel, Rack Mounted1
Modules: TA102A: Single Channel, Zero Two Series2
IR4000 or S5000 display and relay alarms
Malfunctions Monitored: Re-calibration Error
Optics Failure/Blockage
Low Supply Voltage
Reference or Active Lamp Failure
Heater Failure
Time to Re-zero unit
Program Memory Checksum Error (EPROM)
Data Non-Volatile Memory Checksum Error
(EEPROM)
Short Circuit on CAL_IO Wire
Warranty: Two years
Approvals: CSA, FM, ATEX (Sira 07ATEX1253), IECEx (SIR
07.0080), DNV, CE Marking, SIL 3 suitable.
Performance Certified to CSA 22.2 No 152, FM
6310/6320, EN 60079-29-1.

FM required statement: “This Approval does not include or imply Approval of apparatus to
which the subject instrumentation may be connected. In order to maintain an FM Approved
system, the apparatus to which this instrument is connected, must also be Approved by FM
Approvals.”

1
DC110 is not approved for use in ATEX installations
2
Rev E S/W and up for EU installations
33
 Model IR400

9.3.2 Mechanical Specifications

Length: 8.87 inches (225 mm)
Diameter: 2.9 in (74 mm)
Weight: 3 lbs (1.35 kg) for aluminum
6 lbs (2.7 kg) for stainless steel
Mounting: 3/4" NPT threads
Enclosure: Marine Aluminum or Stainless Steel; Explosion
proof, IP66, Type 4X

9.3.3 Electrical Specifications

Input Power:
Absolute min 20 V
Nominal 24 V
Absolute max 36 V
Max. wattage 4.8 W @ +24 VDC
Max. current 200 mA @ +24 VDC
Ripple maximum allowed 1 V pk-pk
NOTE: Customer supplied PSU must meet requirements IEC 61010-1 limiting current to 8A
under Fault conditions, in order to comply with CE Marking requirements.

Analog Signal:
Range 0 - 21.7 mA
Load (max. resistance) 600 Ω
Current Level (mA): Meaning
0 Startup mode and critical fault for non HART unit
1.25* Startup mode and critical fault for HART unit
1.5* Zero, Calibration and Gas Check Mode
2* Dirty Optics
4 – 20 0 – 100% LEL
20.1 – 21.7 Over range
* HART units can be configured to never output current less than 3.5 mA if the host equipment
is incapable of working below this level.
Area Classification:
IR400
Class I, Divisions 1 & 2, Groups B, C and D (Ta = -40°C to
+75°C), (Ta = -40°C to +60°C for ethylene only), IP66, Type
4X
Ex db, IIB+H2 T5 Gb, IP66 (Ta = -60°C to +75°C)
Ex tb IIIC T100°C Db

IR400 Junction Box / Zero Switch Assembly

Ex db eb mb IIB+H2 T5 Gb
Ex mb tb IIIC T100°C Db
(Ta = -40°C to +70°C)
IP66 and IP67

RFI/EMI Protection: Complies with EN50270, EN61000-6-4

34
 Model IR400

9.3.4 Analog Current Output

The following table shows the values of the analog output when in certain modes or fault
conditions.
HART Override
Condition Type Non-HART Units HART Units
Mode*
Start Up, Fault 0 mA 1.25 mA 3.5 mA
Zero, Gas Check or Cal 1.5 mA 1.5 mA 3.5 mA
Dirty Optics 2.0 mA 2.0 mA 3.5 mA
0-100% LEL 4 – 20 mA 4 – 20 mA 4 – 20 mA
Over-range 21.7 mA 21.7 mA 21.7 mA
Table 6: Analog Current Output
* HART units can be configured to never output current less than 3.5 mA if the host equipment
is incapable of working below this level.

9.3.5 Recommended Cable Lengths

Power – The maximum distance between the IR400 and the power source varies according to
the wire size. Maximum cable resistance = V drop / I device = 4.0 V / 0.20 A = 20Ω, where V
drop = V supply – V device and V supply =+24 VDC. Example distances are below.
AWG Stranded Cable (Ω/1000 ft) Feet Meters
12 1.71 5840 1780
14 2.73 3660 1120
16 4.35 2290 700
18 6.92 1440 440
20 10.9 910 280
Table 7: Maximum Distance between IR400 and Power Source
Analog Output Signal – The maximum distance = Cable loop resistance / (2 x cable
resistance / 1000 feet). Example distances are given below for an analog input device with 250
ohms input resistance and a cable loop resistance of 50 ohms..
AWG Stranded Cable (Ω/1000 ft) Feet Meters
14 2.73 9150 2780
16 4.35 5740 1740
18 6.92 3610 1100
20 10.9 2290 690
Table 8: Maximum Distance between IR400 and Analog Input Device

35
 Model IR400

9.4 Environmental Specifications

Temperature Range:
Operating -40°F to +167°F (-40°C to +75°C)
(Ethylene only) -40°F to +140°F (-40°C to +60°C)
Storage -76°F to +185°F (-60°C to +85°C)
Humidity Range: 10% to 95% RH non-condensing
Accuracy is not affected by humidity as long as no
condensation accumulates on the windows

9.5 Communications
9.5.1 RS-485 Interface
The Model IR400 has built-in serial communications in the form of a half duplex RS-485 digital
serial interface designed to conform to EIA-485 specifications. The default settings are 9600
baud with 1 start bit, 8 data bits, 1 stop bit and no parity. The interface supports Modbus RTU
communications.
9.5.2 Modbus RTU
A programming manual is available from the MSA website that gives details on all the available
Modbus RTU commands.
9.5.3 HART
The IR400 HART Field Device Specification provides details on HART commands. The
specification is available from the MSA website.

36
 Model IR400

9.6 Engineering Documentation

IR400 wires are 12” ± 0.13” long.

Figure 9: Outline and Dimensional Drawing, IR400, Inch Measurements

37
 Model IR400

9.7 Ordering Information

9.7.1 System Components
Description Model or Part No.
Model IR400 Infrared Point Detector IR400
Standard (Methane)
Instruction Manual - Model IR400 MANIR400
DC110 Eight Channel Readout/Relay DC110
Display Module, Rack Mounted
TA102A Single Channel Zero Two Series TA102A
Trip Amplifier
IR4000 multi-point monitor for up to 8 IR400s IR4000M
connected via Modbus
IR4000 single-point monitor connected using IR4000S
analog output and CAL signal
S5000 Gas Monitor S5000

9.7.2 Spare Parts and Accessories

To order spare parts and/or accessories, please contact the nearest General Monitors
representative, or General Monitors directly, and give the following information:
1. Part Number
2. Description
3. Quantity
9.7.3 Recommended Spare Parts for One (1) Year
31037-1 Double-Magnet Assembly if a zero switch is used

38
 Model IR400

9.7.4 Accessories
31305-1 Junction Box with magnetic switch, CSA/FM
31305-2 Junction Box without magnetic switch, CSA/FM
31305-3 Junction Box with magnetic switch, SST, CSA/FM
31305-4 Junction Box without magnetic switch, SST, CSA/FM
31305-5 Junction Box without magnetic switch, Painted, Flameproof,
ATEX/IECEx
31305-6 Junction Box without magnetic switch, Flameproof, ATEX/IECEx
31305-7 Junction Box without magnetic switch, Flameproof, SST,
ATEX/IECEx
31421-3 Junction Box with magnetic switch, ATEX/IECEx
31421-4 Junction Box without magnetic switch, ATEX
32554-1 Calibration Cup / Flow Block
32545-1 Splash Guard standard
32545-2 Splash Guard for use with remote cal
32545-3 Splash Guard with no screen for areas with occasional moisture
32545-4 Splash Guard with no screen for remote cal
31306-1 Duct Mount Junction Box
32548-Specify Gas Gas bottle with regulator and calibration cup
31420-1 Flow Block for gas sampling system
31545-1 Rain Guard Assembly

39
 Model IR400

ADDENDUM

This product may contain hazardous and/or toxic substances.

EU Member states shall dispose according to WEEE regulations. For further WEEE disposal
information please visit: www.MSAsafety.com

All other countries or states: please dispose of in accordance with existing federal, state and local
environmental control regulations.

40