Crowcon IRmax

Crowcon IRmax is designed for dependable hydrocarbon gas and vapour detection in the most challenging process conditions. Its compact infrared sensing technology delivers rapid response and fail-safe signalling, while good stability and repeatability support consistent performance over time. Proven operation in extreme hot, cold, wet and saline atmospheres makes it well suited to offshore platforms, marine vessels, coastal facilities and exposed industrial sites where corrosion, temperature swings and high humidity are routine.

The detector’s 316 stainless steel enclosure and high ingress protection rating resist corrosion and water ingress, extending service life in aggressive environments. A wide operating temperature range and suitability for high humidity allow deployment in both freezing and high-heat climates, while electromagnetic compatibility supports reliable operation alongside other industrial equipment.

The IRmax optical system incorporates Crowcon’s STAY-CLIR design, using coated optical components to help prevent condensation-related faults. By managing condensation at the optical surface, the detector avoids the need for heaters on the optics. This removes a common source of failure and eliminates heater-related power draw and local heat build-up, contributing directly to lower energy consumption and stable measurement performance in high humidity or rapidly changing ambient conditions.

IRmax consumes less than 1W of power, typically far lower than many conventional infrared gas detectors. This enables the use of smaller power supplies and more compact battery back-up systems, which is particularly valuable on offshore platforms, remote facilities and applications with constrained power budgets or panel space. The low current demand also supports incremental expansion of existing gas detection systems without extensive rework of power distribution, helping engineering teams increase coverage with minimal infrastructure changes.

The small footprint and versatile mounting options allow IRmax to be positioned precisely where risks are highest. The detector can be wall mounted, fitted to a 50mm (2″) pipe, or connected via an auxiliary junction box to accommodate site layouts, existing cable routes and access requirements. A single M20 or 1/2″ NPT cable gland entry simplifies electrical connection and speeds installation.

A dedicated accessory range enables the same detector platform to be used across diverse applications. Sun shades help manage high ambient temperatures on exposed structures, while collector cones support effective detection of lighter-than-air gases. Duct mounting kits allow monitoring of air ducts across a wide span of sizes and airflow conditions, and flow adaptors and calibration caps support sampling and calibration in high air-speed environments. RS‑485 Modbus networking can be implemented via an Exd junction box, and a GRP Exe junction box option helps meet specific termination requirements such as NORSOK and Exe standards.

IRmax is available as a detector-only unit or with an integral local display for clear indication of gas level and operating status at the point of risk. Where detectors are installed in hard-to-reach or hazardous positions, a compact remote gas/status display can be mounted up to 30 metres away. This allows personnel to confirm readings and status from safer, more convenient locations, helping to reduce the need for scaffolding, rope access or confined space entry during routine checks and functional tests.

The detector is engineered to minimise routine maintenance effort and disruption. Remote non-intrusive calibration allows test gas to be applied without opening the detector or accessing live terminals, supporting safer, faster maintenance in classified areas and helping to reduce permit requirements and downtime. Remote calibration boxes further improve accessibility on offshore and other hazardous installations.

Low zero drift and good measurement repeatability support extended intervals between calibrations. Automatic optical obscuration monitoring continuously checks the cleanliness of the optics and provides an early warning signal when contamination reaches a configurable level, followed by a distinct fault output at higher obscuration to maintain fail-safe operation. This enables planned cleaning and servicing before gas detection performance is affected. For sites using intrinsically safe handheld tools, an optional I.S. barrier module enables calibration via an I.S. display or calibrator, supporting safe working practices without removing power from the detector.

Crowcon IRmax integrates readily into new or existing safety systems. An industry-standard 4–20mA output, configurable as current sink or source, ensures compatibility with most gas detection panels and distributed control systems. Optional HART 7 and RS‑485 Modbus communications provide enhanced diagnostic and configuration capabilities where host systems support them, enabling more efficient commissioning, status checking and fault finding.

IRmax is validated for functional safety up to SIL 2, supporting its use in safety instrumented systems where confirmed performance levels are required. It carries hazardous area approvals for flammable gas atmospheres and, in some variants, combustible dust atmospheres, including suitability for Zone 1 and Zone 2 areas. Relevant temperature classifications and dust ignition protection ratings on applicable models extend its use across a broad range of flammable environments.

An annual proof-test interval aligns with functional safety regimes, enabling periodic verification without excessive test frequency. A comprehensive documentation set, including approvals certificates, datasheets and manuals, is available to support project design, certification, installation and audit activities. Taken together, these attributes allow Crowcon IRmax to deliver reliable hydrocarbon gas monitoring with a low cost of ownership across safety-critical industrial, offshore and marine applications.