Airoptic GasEye User manual

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GasEye Cross Duct SG and MG
Manufacturer
:
Airoptic Sp. z
o.o.
Address:
Telephone number:
E-mail address:
Web ad
d
ress:
Ul. Rubiez 46B, 61-612 Poznan, Poland
[phone]
[email protected]
www.airoptic.pl
Product Information:
Application:
Brand name:
Gas analyzer
In-situ analyzer
GasEye
Cross D
uct
SG
and MG

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Table of Contents
INTRODUCTION ..................................................................................................................................... 9
GENERAL INFORMATION ...................................................................................................................... 9
WARRANTY CONDITIONS ...................................................................................................................... 9
DELIVERY INFORMATION ...................................................................................................................... 9
CALIBRATION INFORMATION ................................................................................................................ 9
GENERAL INFORMATION ABOUT THE ANALYZER ................................................................................ 10
INTRODUCTION ................................................................................................................................... 10
TYPES OF APPLICATIONS ..................................................................................................................... 10
ANALYZER ARRANGEMENT ................................................................................................................. 11
GASEYE CROSS DUCT SG MECHANICAL ASSEMBLY .............................................................................. 11
GASEYE CROSS DUCT MULTI GAS (MG) MECHANICAL ASSEMBLY ....................................................... 13
FUNCTIONAL DESCRIPTION ................................................................................................................. 15
PRINCIPLE OF OPERATION .................................................................................................................. 15
TECHNICAL DATA ................................................................................................................................ 15
DESIGN, ENCLOSURE ........................................................................................................................... 15
ELECTRICAL CHARACTERISTICS ............................................................................................................ 17
DYNAMIC PERFORMANCE ................................................................................................................... 17
ELECTRIC INPUTS AND OUTPUTS ......................................................................................................... 17
CUSTOMER INTERFACE ....................................................................................................................... 18
CLIMATIC CONDITIONS ....................................................................................................................... 18
PURGING ............................................................................................................................................ 18
PACKAGING ........................................................................................................................................ 19
CALIBRATION AND CALIBRATION CERTIFICATE ................................................................................... 20
INSTALLATION..................................................................................................................................... 22
SAFETY INFORMATION ........................................................................................................................ 22
MOUNTING ......................................................................................................................................... 23
MOUNTING CONDITIONS .................................................................................................................... 23
PREPARATIONS ................................................................................................................................... 23
OPTICAL PATH LENGTH DETERMINATION ........................................................................................... 24
PURGING TUBES.................................................................................................................................. 25
FLANGE INSTALLATION (3° OR 1° WEDGE WINDOW STANDARD VERSION) ......................................... 26
FLANGE INSTALLATION (1° WEDGE WINDOW EASY-TO-CLEAN VERSION “ETC”) ................................. 28
ALIGNMENT OF GASEYE CROSS DUCT ................................................................................................. 31
ALIGNMENT KIT .................................................................................................................................. 31
ALIGNMENT PROCEDURE .................................................................................................................... 33
SENSOR MOUNTING ........................................................................................................................... 39
HOUSING LID OPENING ....................................................................................................................... 42
ELECTRICAL INSTALLATION ................................................................................................................. 45
ELECTRICAL CONNECTIONS ................................................................................................................. 45
GASEYE CROSS DUCT SINGLE GAS ....................................................................................................... 46
GASEYE CROSS DUCT MULTI GAS ........................................................................................................ 47
GASEYE CROSS DUCT MULTI GAS MULTI POINT .................................................................................. 48
CENTRAL UNIT – ELECTRICAL TERMINALS ........................................................................................... 48
POWER SUPPLY ................................................................................................................................... 52
ANALOG OUTPUTS AND INPUTS ......................................................................................................... 53
ACTIVE ANALOG OUTPUTS .................................................................................................................. 55
PASSIVE ANALOG OUTPUTS ................................................................................................................ 56
ACTIVE ANALOG INPUTS ..................................................................................................................... 57
PASSIVE ANALOG INPUTS ................................................................................................................... 58
DOUT .................................................................................................................................................. 59
DIN...................................................................................................................................................... 60
RTD ..................................................................................................................................................... 61
LOOP (HYBRID) CABLE CONNECTION .................................................................................................. 64
RECEIVER UNIT – LOOP CABLE INSTALLATION INSTRUCTION: ............................................................. 65
CENTRAL UNIT – LOOP CABLE INSTALLATION INSTRUCTION: .............................................................. 71

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CUSTOMER CABLE CONNECTION ......................................................................................................... 73
CUSTOMER CABLE INSTALLATION INSTRUCTION: ............................................................................... 73
ETHERNET CONNECTION ..................................................................................................................... 77
ETHERNET CABLE INSTALLATION INSTRUCTION: ................................................................................. 78
ETHERNET CABLE INSTALLATION INSTRUCTION (ATEX VERSION): ....................................................... 79
INDUSTRIAL PROTOCOLS CONNECTION .............................................................................................. 81
MODBUS RTU (RS485) ......................................................................................................................... 81
MODBUS TCP .................................................................................................................................... 117
PROFINET .......................................................................................................................................... 117
ADD-ON MODULE ............................................................................................................................. 117
STARTUP PROCEDURE ....................................................................................................................... 121
HMI – FRONT PANEL DISPLAY ........................................................................................................... 122
OVERVIEW ........................................................................................................................................ 122
MENU ............................................................................................................................................... 123
SETTINGS .......................................................................................................................................... 124
DIAGNOSTIC ...................................................................................................................................... 125
MEASUREMENTS ............................................................................................................................... 126
ANALOG INPUT ................................................................................................................................. 129
ANALOG OUTPUT .............................................................................................................................. 130
SIGNALS ............................................................................................................................................ 131
BUTTONS .......................................................................................................................................... 131
EDITING PARAMETERS ...................................................................................................................... 132
EDITING NETWORK SETTINGS ........................................................................................................... 134
EDITING AIN/AOUT SCALING ............................................................................................................. 135
WEBSERVER APPLICATION ................................................................................................................ 137
ESTABLISHING COMMUNICATION WITH THE INSTRUMENT .............................................................. 137
USER ACCESS LEVEL ........................................................................................................................... 141
MEASUREMENT TAB ......................................................................................................................... 143
SHOW TABLE ..................................................................................................................................... 144
SHOW GRID ....................................................................................................................................... 145
SHOW PLOT ...................................................................................................................................... 146
SETTINGS .......................................................................................................................................... 147
MEASUREMENT GROUPS .................................................................................................................. 148
8.3.3.1. MP1 -> PROCESS ...................................................................................................................... 148
8.3.3.2. MP1 -> CONCENTRATION ......................................................................................................... 149
8.3.3.3. MP1 -> LASER ........................................................................................................................... 149
8.3.3.4. TEC -> TEC0 .............................................................................................................................. 150
8.3.3.5. TEC -> TEC1 .............................................................................................................................. 150
8.3.3.6. TEC -> TEC2 .............................................................................................................................. 151
8.3.3.7. TEC -> TEC3 .............................................................................................................................. 151
8.3.3.8. SYSTEM -> SYSTEM ................................................................................................................... 152
8.3.3.9. IO -> AOUT (ANALOG OUTPUT MEASUREMENT) ...................................................................... 152
8.3.3.10. IO -> AIN (ANALOG INPUT MEASUREMENT) ............................................................................. 153
8.3.3.11. IO -> DIGITALINOUT ................................................................................................................. 154
PARAMETERS TAB ............................................................................................................................. 156
PARAMETER GROUPS ........................................................................................................................ 158
8.4.1.1. MP1 -> PROCESS (PROCESS ENVIRONMENT CONFIGURATION) ................................................ 158
8.4.1.2. MP1 -> GAS101 ........................................................................................................................ 160
8.4.1.3. MP1 -> GAS102 ........................................................................................................................ 161
8.4.1.4. MP1 -> GAS103 ........................................................................................................................ 162
8.4.1.5. MP1 -> GAS104 ........................................................................................................................ 163
8.4.1.6. MP1 -> GAS105 ........................................................................................................................ 164
8.4.1.7. MP1 -> GAS106 ........................................................................................................................ 165
8.4.1.8. MP1 -> GAS107 ........................................................................................................................ 166
8.4.1.9. MP1 -> GAS108 ........................................................................................................................ 167
8.4.1.10. MP1 -> TEMP ........................................................................................................................... 168
8.4.1.11. IO -> DOUT (DIGITAL OUTPUT OPERATING MODE CONFIGURATION) ...................................... 169

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8.4.1.12. IO -> AOUT (ANALOG OUTPUT CONFIGURATION) .................................................................... 171
8.4.1.13. IO -> AIN (ANALOG INPUT CONFIGURATION) ........................................................................... 175
8.4.1.14. IO -> RTD (RESISTANCE TEMPERATURE SENSOR CONFIGURATION) ......................................... 177
8.4.1.15. IO -> AMB_PRESS (AMBIENT PRESSURE SENSOR CONFIGURATION) ........................................ 178
8.4.1.16. NETWORK -> NET (SERVICE ETHERNET PORT CONFIGURATION) .............................................. 179
8.4.1.17. NETWORK -> MODBUSRTU (MODBUS SLAVE TRANSMISSION CONFIGURATION) .................... 180
8.4.1.18. NETWORK -> DATARANGE ....................................................................................................... 181
8.4.1.19. SYSTEM -> RTC (REAL TIME CLOCK CONFIGURATION) .............................................................. 183
8.4.1.20. SYSTEM -> HMI (HUMAN-MACHINE INTERFACE CONFIGURATION) .......................................... 183
8.4.1.21. SYSTEM -> ALARM ................................................................................................................... 184
SETTINGS TAB ................................................................................................................................... 189
TABLE 54. SETTINGS WINDOW FUNCTIONALITIES. ..................................................................................... 189
FACTORY CONFIG TAB ....................................................................................................................... 191
ABOUT TAB ....................................................................................................................................... 191
PURGING (NON-ATEX) ...................................................................................................................... 192
HOUSING PURGING (OPTIONAL) ....................................................................................................... 193
SINGLE GAS ....................................................................................................................................... 193
MULTI GAS ........................................................................................................................................ 194
TUBE AND PROCESS PURGING .......................................................................................................... 198
ATEX (ZONE 1 AND 21 PURGING SYSTEM INSTALLATION) ................................................................. 201
BASIC REQUIREMENTS AND SAFE USE .............................................................................................. 201
ATEX MARKING ................................................................................................................................. 203
SPECIAL CONDITIONS FOR SAFE USE ................................................................................................. 203
OVERVIEW OF ZONE 1 AND 21 PURGING SYSTEM FOR GASEYE CROSS DUCT SINGLE GAS ................ 204
OVERVIEW OF ZONE 1 AND 21 PURGING SYSTEM FOR GASEYE CROSS DUCT MULTI GAS ................. 206
TECHNICAL PARAMETERS.................................................................................................................. 208
ZONE 1/21 PURGING SYSTEM ........................................................................................................... 209
ZONE 1 AND 21 PURGING SYSTEM INSTALLATION WITH GASEYE CROSS DUCT SINGLE GAS.............. 209
ZONE 1 AND 21 PURGING SYSTEM INSTALLATION WITH GASEYE CROSS DUCT MULTI GAS .............. 216
DIFFERENCES BETWEEN SINGLE GAS AND MULTI GAS SYSTEMS .............................................. 221
ZONE 1 AND 21 PURGING SYSTEM ENCLOSURES MOUNTING .................................................. 222
ZONE 1 AND 21 PURGING SYSTEM ADJUSTMENT POSSIBILITIES .............................................. 224
SYSTEM PRESSURIZATION FAILURE ALARM ............................................................................. 225
SYSTEM ELECTRICAL CONNECTIONS - INTRINSIC SAFETY WARNINGS ....................................... 226
SYSTEM CONSERVATION FOR ZONE 1 AND 21 ......................................................................... 227
CONTACT INFORMATION ......................................................................................................... 227
IECEX (ZONE 2 AND 22 PURGING SYSTEM INSTALLATION) ................................................................ 228
BASIC REQUIREMENTS AND SAFE USE .............................................................................................. 228
IECEX MARKING ................................................................................................................................ 230
SPECIAL CONDITIONS FOR SAFE USE ................................................................................................. 230
OVERVIEW OF ZONE 2 AND 22 PURGING SYSTEM FOR GASEYE CROSS DUCT SINGLE GAS ................ 231
OVERVIEW OF ZONE 2 AND 22 PURGING SYSTEM OF GASEYE CROSS DUCT MULTI GAS ................... 234
TECHNICAL PARAMETERS.................................................................................................................. 236
ZONE 2 AND 22 PURGING SYSTEM INSTALLATION WITH GASEYE CROSS-DUCT SINGLE GAS ............. 237
ZONE 2 AND 22 PURGING SYSTEM INSTALLATION WITH GASEYE CROSS-DUCT MULTI GAS .............. 240
DIFFERENCES BETWEEN SINGLE GAS AND MULTI GAS SYSTEMS ....................................................... 243
ZONE 2 AND 22 PURGING SYSTEM ENCLOSURES MOUNTING .................................................. 243
ZONE 2 AND 22 PURGING SYSTEM ADJUSTMENT POSSIBILITIES .............................................. 246
SYSTEM PRESSURIZATION FAILURE ALARM ............................................................................. 247
SYSTEM ELECTRICAL CONNECTIONS - INTRINSIC SAFETY WARNINGS ....................................... 248
SYSTEM CONSERVATION FOR ZONE 2 AND 22 ......................................................................... 249
TROUBLESHOOTING .......................................................................................................................... 250
APPENDIX 1. PARAMETERS LIST. ................................................................................................................ 251
APPENDIX 2. MEASUREMENTS LIST ............................................................................................................ 254

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Introduction
General information
This manual relates to an instrument that was manufactured with high attention to
detail in controlled conditions. By following the description provided in this document
our product will work safely and perform the intended measurements properly.
Warranty conditions
Our company guarantees a 12-month warranty period for the GasEye Cross Duct
instrument. This period becomes valid upon delivery of the instrument and will be
granted only if the product is installed, operated and maintained according to the
information provided in this manual.
Delivery information
The respective scope of delivery is listed on the shipping documents – enclosed with
the delivery – in accordance with the valid sales contract. When opening the
packaging, please observe the corresponding information on the packaging material.
Check the delivery for completeness and overall condition. In particular, you should
compare the Order No. on the rating plates with the ordering data. If possible, please
retain the packaging material, since you can use it again in case of return deliveries.
Calibration information
The GasEye Cross Duct system is factory calibrated using certified gas mixtures. The
instrument utilizes an internal in-line reference gas cell for real time verification of the
calibration status or a process gas normally present in the process gas stream. Thus,
we can assure long term stability an accuracy of the system and there is no need for
calibration of the system in field as long as the system status is operational.

General information about the analyzer
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General information about the analyzer
Introduction
The laser based GasEye Cross Duct spectrometer is a versatile analyzing tool for
industrial process applications. It can be configured to operate in the near-infrared
(NIR), mid-infrared (MIR) and infrared (IR) wavelength range thereby covering the
majority of all gases of interest in the industrial process monitoring.
Figure 1. Typical setup of the GasEye Cross Duct SG spectrometer.
Types of applications
GasEye Cross Duct SG instrument was designed and is used in many specified
applications, in industries such as:
 Power industry – monitoring of the combustion process
 Wood board production – operator safety, emission
 Chemical industry
 Cement industry
 Steel industry

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Analyzer arrangement
GasEye Cross Duct SG mechanical assembly
The GasEye Cross Duct SG (Single Gas) analyzer consists of a pair of cross-duct
sensors - a central unit with transmitter and a receiver unit. The central unit emits
laser radiation directly through the process containing the constituents of interest. The
receiver unit collects the radiation on the other side of the process duct. The receiver
unit is connected to the transmitter unit by means of a hybrid loop cable (included).
The GasEye Cross Duct utilizes an internal in-line reference gas cell or a process gas
(e.g. H2O) for real time verification of the calibration status.
Figure 2 shows the GasEye Cross Duct assembly with external mechanical parts
description.
Figure 2. GasEye Cross Duct SG instrument assembly.
ID Name
A1 Receiver unit housing (GasEye integral part)
A2 Cable glands/ purging connectors
A3 PE connector
A4 Receiver/central unit tube (GasEye integral part)
A5 Sanitary clamp
A6 Alignment flange
A7 Gaskets
A8 Purging tubes
A9 Central unit housing
Table 1. Descriptions of GasEye Cross Duct instrument assembly.

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In
Figure 3 the details of each unit’s housing are highlighted.
Figure 3. Receiver and transmitter unit drawings.
ID Name
B1 Purge connector
B2 Cable gland M20
B3 PE connector
B4 Receiver front panel
B5 White LED
B6 Cable gland PG21
B7 Cable gland M20
B8 HMI button
B9 HMI front panel
B10 HMI green LED
B11 HMI red LED
B12 HMI window
Table 2. Descriptions of receiver and transmitter unit.
Receiver unit
Central unit

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GasEye Cross Duct Multi Gas (MG) mechanical assembly
The GasEye Cross Duct MG (Multi Gas) analyzer consists of a pair of cross-duct
sensors - a transmitter and a receiver unit as well as a central unit. The transmitter
unit emits laser radiation directly through the process containing the constituents of
interest. The receiver unit collects the radiation on the other side of the process duct.
The central unit, located close to transmitter unit (<2 meter) contains analyzer
electronics, MMI and I/O. The receiver unit is connected to the central unit by means
of a hybrid loop cable (included) and the transmitter unit is connected to the central
unit by 2 electrical cables
Figure 4. GasEye Cross Duct Multi Gas instrument assembly
ID Name
A1 Receiver unit housing (GasEye integral part)
A2 Cable glands/ purging connectors
A3 PE connector
A4 Receiver/transmitter unit tube (GasEye integral part)
A5 Sanitary clamp
A6 Alignment flange
A7 Gaskets
A8 Purging tubes
A9 Transmitter unit housing
A10 Purge connector
A11 Central unit housing
Table 3. Descriptions of receiver and transmitter unit.

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ID Name
B1 Purge connector
B2 Cable gland M20
B3 PE connector
B4 Receiver/transmitter front panel
B5 Laser connector M23
B6 Laser connector M23
B7 Cable gland M25
B8 Cable gland PG21
B9 Cable gland M20
B10 HMI button
B11 HMI green LED
B12 HMI red LED
B13 HMI front panel
B14 HMI window
Table 4. Descriptions of receiver, transmitter, and central unit housing
assembly.
Figure 5. Receiver, transmitter, and central unit drawings.
Central unit
Receiver unit
Transmitter unit

Technical data
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Functional description
Principle of operation
GasEye Cross Duct is a laser analyzer that utilizes tunable diode laser (TDL)
absorption spectroscopy. The central unit sends a laser light through the process
which is detected by the receiver unit mounted on the opposite side of the process.
When a gas of interest is present in this process, it will absorb the laser light. The
optical power detected in the receiver unit will depend on the concentration of the gas,
temperature, pressure and optical pathlength according to Lambert’s Beer law. Thus
in order to determine the gas concentration, the analyzer requires information
regarding temperature, pressure and optical pathlength. Temperature and pressure
signals can be provided by analog inputs, via industrial communication protocols or
as manual values via Webserver or HMI. Pathlength needs to be provided by the
user via HMI or Webserver.
In the GasEye Cross duct analyzer, the laser wavelength is specifically chosen to
match the fingerprint region of the particular gas of interest and is being continuously
scanned over the absorption lines(s). Since full spectral information is recovered with
very high spectral resolution the analyzer remains immune to foreign gas broadening
and is immune to cross-interferences from dust and any other gas constituents in the
process.
GasEye cross duct by design can operate in several wavelength regions from near
infrared to Mid-Infrared.
Technical data
Design, enclosure
Degree of protection: In accordance with IP65
Process windows: Leak tested and certified in accordance to EN1779:1999 norm.
Instrument dimensions:
SINGLE GAS
Central unit:
Width x height: 330 mm x 230 mm
Length: 350 mm
Receiver:
Width x height: 160 mm x 160 mm
Length: 330 mm
Weight:
Receiver unit: 13 kg

Technical data
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Transmitter unit: 15 kg
Figure 6. GasEye Cross Duct Single Gas overview.
MULTI GAS
Transmitter:
Width x height: 230 mm x 202 mm
Length: 350 mm
Receiver:
Width x height: 160 mm x 160 mm
Length: 330 mm
Central unit:
Width x height: 330 mm x 230 mm
Length: 110 mm
Weight:
Receiver unit: 13 kg
Transmitter unit: 14 kg
Central unit 6 kg

Technical data
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Figure 7. GasEye Cross Duct Multi Gas overview.
Electrical characteristics
Power input: 24 VDC nominal (19-30 VDC)
Power consumption: < 15VA (single gas)
< 25VA (multi gas)
EMC immunity: In accordance with EN 61326-1
Electric safety: In accordance with 61010-1
Dynamic performance
Warm-up time: approx. 6 minutes. It takes approximately 60 minutes for the system
to be fully operational.
Electric inputs and outputs
Inputs:
4 x analog input (4 – 20 mA)
8 x digital input (isolated)

Technical data
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Outputs:
4 x analog output (4 – 20 mA, isolated)
8 x digital output (isolated)
WARNING
Analog outputs
GasEye Cross Duct may have active or passive analog outputs, depending on the
customer requirement. Please ensure that the outputs are handled according to
their type. For details, please refer to Chapter
5
of this manual.
Customer interface
Ethernet (RJ-45);
WebServer based software for real-time logging of the gas concentration and optical
transmission
Windows - based Logger application
Climatic conditions
Ambient temperature: -20ºC to +55ºC
Ambient pressure: 800 - 1200 hPa
Ambient humidity: RH < 99%, non-condensing
Purging
Sensors purging flow rate: 0.2 – 7 l/min
Process purging flow rate: 5 - 50 l/min for each flange

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Packaging
Each analyzer is shipped in an appropriate box. A stretch foil is used to secure the
interior of the box from moisture. There are identification labels on each box which
are doubled on the stretch foil. On the outside of the box there are also shipping
documents and delivery note.
The interior of the box contains the following items
Analyzer:
Central unit
Receiver unit
Process flanges
Purging tubes
Graphite gaskets
Hybrid loop cable (length according to the POC)
Customer cable
Purging tubing connectors (OD 6 mm)
Flange screws, nuts and washers
Ethernet cable (used for analyzer-to-computer connection)
Documents:
Packing list
Calibration certificate
Analyzer test report
Process flange certificates
Tools:
Wrench size 24
Hex 6 mm
Hex 14 mm
Flat-head screwdriver (for electrical connections)

Technical data
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Calibration and calibration certificate
The analyzer is calibrated using certified gas sample in the factory. One of the key
parameters of the analyzer is its limit of detection (LOD) which determines the lowest
measurable concentration. This quantity is estimated for each application and is
determined for each device before shipping to our customers. For every GasEYE
analyzer we determine the limit of detection during a 12-hour cycle in a climate
chamber. The analyzer is placed on a test gas cell and a zero sample is introduced.
A zero sample is either nitrogen or dry air to purge out the constituent of interest. The
climate chamber temperature is then varied between
-20°C to +55°C and the concentration signal is logged, as well as other important
analyzer parameters. Based on the concentration reading during the temperature
cycle the limit of detection is calculated using the following equation:
𝐿𝑂𝐷 = 2 ∗ 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛(𝑔𝑎𝑠 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛)
Limit of detection is usually quantified in ppm x meter units. This allows to easily
recalculate the limit of detection for arbitrary path length. For example: Limit of
detection for standard carbon monoxide application at room temperature is LOD 0.2
ppm x m. If the process path length is 2.5 meters the actual limit of detection at this
distance will be:
𝐿𝑂𝐷 (@ 2.5 𝑚𝑒𝑡𝑒𝑟𝑠)= 𝐿𝑂𝐷
𝑃𝑟𝑜𝑐𝑒𝑠𝑠 𝑝𝑎𝑡ℎ 𝑙𝑒𝑛𝑔𝑡ℎ = 0.2 𝑝𝑝𝑚 𝑥 𝑚 2.5 𝑚 = 0.08 𝑝𝑝𝑚
Before shipment, each analyzer is accompanied with individual calibration certificate,
see Figure 8, where all calibration and performance information are given.