IRmax & IREX accessories

Accessories for IR products

Installation, operating and maintenance instructions

M07062
Issue 1 Oct 2010
Contents
1. The IRmax & IREX family............................................................................1
2. Sunshade for IRmax or IREX ....................................................................2
2.1 Kit contents......................................................................................2
2.2 Specifications....................................................................................2
3. Duct mounting kit......................................................................................3
3.1 Installation........................................................................................4
3.2 Testing and commissioning................................................................5
3.3 Specifications....................................................................................5
4. Auxiliary junction box ................................................................................6
4.1 Installation........................................................................................8
4.1.1 Mounting.................................................................................8
4.1.2 Cabling requirement ................................................................8
4.1.3 How to fit IRmax or IREX to a junction box.............................8
4.1.4 Field cable termination.............................................................8
5. PC communications kit...............................................................................9
5.1 Using the PC communications kit .....................................................9
5.2 The communications module ..........................................................10
Warranty...................................................................................................... 11
 1. The IRmax & IREX family
Crowcon IR detectors protect facilities against flammable gas hazards.

English
This manual contains instructions for the use of the following accessories for the IRmax:

Part Numbers Name Description

S012152 Sun shade/collector Can be fitted to IRmax to protect
cone against elevated temperatures due
to direct sunlight and/or to extend
the detector's footprint for detecting
lighter than air gases (e.g. methane).
S012169 Duct mounting kit Enables monitoring of ducts from
300 mm to 3000 mm, and air-flow
between 2 m/s and 20 m/s.
S012827 IRmax PC communications Communications module, software
S012828 IREX kit and lead to enable configuration of
the detector.
M20: S012295 Auxiliary junction box Provides space for connecting field
½” NPT: S012296 cables, and must be used where RS232
Modbus enabled versions of IRmax
are to be used and multi-dropped in
addressable networks.
M20 ATEX Spigot gland Allows IRmax or IREX to be fitted
S012147 directly to junction boxes with either
½” NPT ATEX M20 or ½” NPT cable entries.
S012190

Other accessories available for the IRmax or IREX:

Part Numbers Name Description

M041007 Calibration cap Fits over the standard weathercap
to enable calibration where local air
speed exceeds 2 metres per second.
S012130 Mounting bracket kit Enables mounting to a wall or 2"
(50 mm) pipe. Not required if the
detector is being fitted to an existing
junction box.
S012996 Flow adaptor For gas sampling applications.
C011210 Mirror cleaning kit Contains IPA impregnated wipes and
microfibre cloth.
C011206 Mirror replacement
kit

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 2. Sunshade for IRmax or IREX
The Sunshade should be installed to protect the detector from getting too hot due to
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exposure to strong direct sunlight and/or extend the footprint of the detector for lighter
than air gases.

2.1 Kit contents

Sunshade, bracket and four screws.

Collector cone

Mounting bracket

IR Display
Detector (optional)

Diagram 1

Use the screws supplied to fix the bracket to the body of the detector. Attach the sunshade
to the bracket using remaining screws. The sunshade may be fitted to IRmax supplied with
or without an IR Display module.

2.2 Specifications
Material: Stainless steel 304-2B

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 3. Duct mounting kit
The duct mounting kit is designed to be used with the IREX and IRmax for monitoring
potentially hazardous gases within ventilation ducts.

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The air flow rate within the duct must be between 0.5 metres and 20 metres per second.

Flange Detector
Gasket

Tube
End cap

Duct wall
Calibration
Airflow
gas tube

IREX/IRmax

Bracket can
be mounted
internally or Inlet hole
Air outlet
externally to should be in
(must be facing
the duct the centre line
downwards to
of duct facing
allow water to
the direction of
escape)
flow

Diagram 2

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 Duct mounting kit
3.1 Installation
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1. A standard 1m length of sampling tube is supplied. Cut the open end so the tube is
the correct length: the gas entry window is half way across the duct.
2. To avoid the adverse effects of turbulence, the duct mounting kit should be installed in
the centre of a straight section of duct which has a length at least six times its width.
If the section of duct is shorter, the adequacy of the flow should be tested with a mix
of gas and air in the duct.
3. Check the air flow direction in the air duct system.
4. Use the duct mount boss to mark up the duct ready for drilling the required holes as
indicated on Diagram 4. Make sure that the centre line is positioned equidistant from
the two edges of the duct.
Direction of airflow

Mount duct kit on

midline of duct

Diagram 3 Calibration gassing hole

Not to scale

All dimensions in millimetres

Diagram 4

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 Duct mounting kit

5. Check that the midline hole indicated corresponds to the direction of the flow in the air

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duct.
6. Using a centre punch, mark the six centres indicated (Diagram 4 on page 4). At each
corner, there needs to be a hole for a screw. In the centre, the hole needs to be big
enough to accommodate the duct boss. If remote calibration is required, there has to
be an extra hole at the top as shown on Diagram 3 and Diagram 4 on page 4.

7. Remove burrs and sharp edges around the six holes.

8. The next step is to attach the duct tube to the duct mount boss. This has to be done
in such a way that the inlet to the pipe faces the airflow, while the air outlet faces
downwards for drainage, and the calibration gassing hole is vertically above the main
ring. This is to ensure that the drain hole of the plate is below the pipe. Plan this carefully
to ensure the orientation will be correct.
9. Fit the nuts provided and tighten.
10. Secure the casting to the duct using suitable bolts.
11. Remove and discard the detector’s weatherproof cover to reveal a suitable thread for
attaching the IRmax to the duct boss. Install the IREX or IRmax by screwing it into the
duct boss (about 3 turns).
12. Connect the cable as instructed in the installation, operating, and maintenance
instruction manual supplied with the detector.
13. CHECK THAT THERE IS NO AIR LEAKAGE INTO THE SAMPLING CHAMBER FROM
OUTSIDE THE DUCT, THROUGH THE PROBE JOINTS, CABLE GLANDS OR COVER GASKET.
USE PTFE ON THE IREX/IRMAX THREAD IF REQUIRED.

3.2 Testing and commissioning

Calibrate the detector according to its instructions. Test the operation of the duct probe by
introducing a gas and air mix into the duct. This step is particularly important if the length
of the section of duct is less than six times its width.
WARNING: It is essential to ensure that procedures are in place to prevent people
and/or equipment being affected by any test gas introduced into the ventilation
system.

3.3 Specifications
Air speeds 0.5 m (1.6 ft)/s to 20m (65.6 ft)/s
Operating temperature range 0°C to 60°C

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 4. Auxiliary junction box
An IRmax or IREX gas detector can be installed using an auxiliary junction box. Cast
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from 316 stainless steel and available with two M20 or ½" NPT cable entries, the auxiliary
junction box is ATEX and IECEx certified for use in zone 1 or 2 hazardous areas.
The auxiliary junction box provides ample space for connecting field cables - see the
dimensioned drawing (Diagram 6 on page 7), and must be used where RS485 Modbus
enabled versions of IRmax are to be used and multi-dropped in addressable networks.
A Crowcon spigot gland must be used to connect the detector to the auxiliary junction
box.
Unused cable entries on the auxiliary junction box must be sealed using a certified blanking
gland.

Diagram 5

If the IRmax are to be multi-dropped into an addressable network, RS485 Modbus enabled
IRmax must be connected to auxiliary junction boxes as shown in Diagram 5 above.

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 Auxiliary junction box
Slots to suit M6
or 1/4" fixings for

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ceiling mount

M20 or 1/2" NPT M20 or 1/2" NPT

cable entry cable entry

Slots to suit
M6 or 1/4"
fixings

155.5 Overall

146
CRS Height 111

166.3 Overall
Diagram 6 Auxiliary junction box showing dimensions in millimetres

Diagram 7 Detector assembled on an auxiliary Junction box

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 Auxiliary junction box
4.1 Installation
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4.1.1 Mounting
The auxiliary junction box should be installed at the designated location with the detector
entry pointing down.

4.1.2 Cabling requirement

The spigot gland has five wires running through it to enable the user to connect one end
to the detector and the other end to the junction box. Correct connection of wires at each
end can easily be achieved through colour coding of the wires (as shown in Diagram 7).

4.1.3 How to fit IRmax or IREX to a junction box u

1. Carefully remove the outer section u of the spigot gland
(see Diagram 8). w
2. Screw the narrow end v of the spigot gland into the
auxiliary junction box. v
3. Raise the detector to the auxiliary junction box and pass
the wires through the assembly and into the auxiliary
junction box. Secure the detector by screwing the collar
tightly to the cable gland. Tighten grub screw w.
4. The main body of the detector can be swivelled
horizontally at any angle, provided it is mechanically
secure, does not interfere with other equipment and is
accessible for maintenance.

Diagram 8

4.1.4 Field cable termination

Field cables must be terminated to the auxiliary junction box using Exd certified cable glands
suitable for the type of cable used.

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 5. PC communications kit
The IRmax or IREX can be linked to a computer using a PC communications kit, a small

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unit with appropriate power and data input and output ports. An LCD shows the output
signal from the detector.
Connecting the detector to a PC opens up the possibility of uploading data from the
detector, as well as performing other functions such as zeroing and calibration.
Full details of how to carry out these functions are detailed in the PC communications kit
manual to be found on the CD supplied with the kit, which also holds the software to be
installed on the PC.

Warning:
The PC communications kit is not certified for use in a hazardous area. For
monitoring the IRmax in a hazardous area, choose a model incorporating the
IR Display.

The kit contains the communications module (shown in section 5.2), USB and Molex
connection leads, and CD containing PC communications kit software and manual in pdf
format.
Separate versions of the PC communications kit are supplied for the IREX and IRmax. They
are not interchangeable.

5.1 Using the PC communications kit

1. Install the PC communications kit software on to a computer from the CD provided.
2. Connect the PC communications module to computer. The computer will provide power
to the communications module via the USB cable.
3. Connect the PC communications module to the detector. Power to the detector can
be supplied via the power cable or directly from a DC supply. The LCD will show signal
current in units of 10 microamps, 2000=20mA.
If the detector has a USB port, the connection to the communications module can be
made using the USB cable. Some IRmax detectors do not have such a port; in this case
use the 6-way Molex lead provided.
4. Launch the PC communications kit software. The computer will detect the
communications module and the interface can be used to monitor and control the
detector. Full instructions are provided in the PC communications kit manual (M07967)
which is on the CD provided.

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 PC communications kit

5.2 The communications module

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USB port to Input/output

carry data to to and from
PC (not on all detector
units)
IRmax
IRmax
power
USB cable
cable
Molex
cable

Molex port
for data (not required if
connection detector USB
with PC cable is used)

LEDs (see table below)

Screen shows signal
current in units of 10
microamps, 2000=20mA

Diagram 9

Legend Description
SK Sink
SO Source
IR IRmax or IREX
CO Comms

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 Warranty
This equipment leaves our factory fully tested and calibrated. If within the warranty period
of one year from despatch, the equipment is proved to be defective by reason of faulty

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workmanship or material, we undertake at our option either to repair or replace it free of
charge, subject to the conditions below.

Warranty Procedure
To facilitate efficient processing of any claim, contact our customer support team on
+44 (0)1235 557711 with the following information:
Your contact name, phone number, fax number and email address.
Description and quantity of goods being returned, including any accessories.
Instrument serial number(s).
Reason for return.
Obtain a Returns form for identification and traceability purposes. This form may be
downloaded from our website ‘crowconsupport.com’, along with a returns label.
Alternatively we can ‘email’ you a copy.
IRmax will not be accepted for warranty without a Crowcon Returns Number (CRN).
It is essential that the address label is securely attached to the outer packaging of
the returned goods.
The guarantee will be rendered invalid if the instrument is found to have been altered, modified,
dismantled, or tampered with. The warranty does not cover misuse or abuse of the unit.

Warranty Disclaimer
Crowcon accept no liability for consequential or indirect loss or damage howsoever arising
(including any loss or damage arising out of the use of the instrument) and all liability in
respect of any third party is expressly excluded.
This warranty does not cover the accuracy of the calibration of the unit or the cosmetic
finish of the product. The unit must be maintained in accordance with the instructions in
the manual.
The warranty on replacement consumable items (such as the mirror) supplied under warranty
to replace faulty items, will be limited to the unexpired warranty of the original supplied item.
Crowcon reserves the right to determine a reduced warranty period, or decline a warranty
period for any sensor supplied for use in an environment or for an application known to
carry risk of degradation or damage to the sensor.
Our liability in respect of defective equipment shall be limited to the obligations set out
in the guarantee and any extended warranty, condition or statement, express or implied
statutory or otherwise as to the merchantable quality of our equipment or its fitness for
any particular purpose is excluded except as prohibited by statute. This guarantee shall not
affect a customer’s statutory rights.

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Crowcon reserves the right to apply a handling and carriage charge whereby units returned
as faulty, are found to require only normal calibration or servicing, which the customer then
declines to proceed with.
For warranty and technical support enquiries please contact:
Customer Support
Tel: +44 (0) 1235 557711
Fax: +44 (0) 1235 557722
Email: customersupport@crowcon.com
UK Office USA Office
Crowcon Detection Instruments Ltd Crowcon Detection Instruments Ltd
2 Blacklands Way, 21 Kenton Lands Road,
Abingdon Business Park Erlanger,
Abingdon Kentucky 41018-1845
Oxfordshire OX14 1DY USA
United Kingdom Tel: +1 859 957 1039 or
Tel: +44 (0)1235 557700 1-800-527 6926
Fax: +44 (0)1235 557749 1-800-5-CROWCON
Email: sales@crowcon.com Fax: +1 859 957 1044
Web site: www.crowcon.com Email: salesusa@crowcon.com
Web site: www.crowcon.us

Netherlands Office Singapore Office

Crowcon Detection Instruments Ltd Crowcon Detection Instruments Ltd
Vlambloem 129 Block 194, Pandan Loop
3068JG, Rotterdam #06-20 Pantech Industrial Complex
Netherlands Singapore 128383
Tel: +31 10 421 1232 Tel: +65 6745 2936
Fax: +31 10 421 0542 Fax: +65 6745 0467
Email: eu@crowcon.com Email: sales@crowcon.com.sg
Web site: www.crowcon.com Web site: www.crowcon.com