SICK GM901-02 User manual

OPERATING INSTRUCTIONS
GM901-02
Carbon Monoxide Gas Analyzer
Probe version

Described product
GM901-02
Probe version
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
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reserved for SICK AG. Reproduction of this document or parts of this document is
only permissible within the limits of the legal determination of Copyright Law. Any modi‐
fication, abridgment or translation of this document is prohibited without the express
written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 7
1.1 Function of this document....................................................................... 7
1.2 Scope of application................................................................................. 7
1.3 Target groups............................................................................................ 7
1.4 Further information................................................................................... 7
1.5 Symbols and document conventions...................................................... 7
1.5.1 Warning symbols...................................................................... 7
1.5.2 Warning levels / Signal words................................................. 8
1.5.3 Information symbols................................................................ 8
1.6 Data integrity............................................................................................. 8
2 Safety information............................................................................ 9
2.1 Basic safety information........................................................................... 9
2.2 Intended use............................................................................................. 9
2.2.1 Purpose of the device.............................................................. 10
2.2.2 Responsibility of user.............................................................. 11
3 Product description........................................................................... 12
3.1 Product identification............................................................................... 12
3.2 Product features....................................................................................... 12
3.2.1 Cross-sensitivities.................................................................... 12
3.3 Device variants......................................................................................... 15
3.4 Layout........................................................................................................ 16
3.5 Measuring probes..................................................................................... 17
3.6 Control unit................................................................................................ 20
3.7 Accessories .............................................................................................. 20
4 Transport and storage....................................................................... 23
4.1 Storage...................................................................................................... 23
5 Mounting............................................................................................. 24
5.1 Safety......................................................................................................... 24
5.2 Preparing the measuring point................................................................ 24
5.3 Checking the scope of delivery................................................................ 24
5.4 Installation sequence............................................................................... 25
5.4.1 Installation steps overview...................................................... 25
5.4.2 Installing the flange with tube................................................. 25
5.4.3 Installing the control unit........................................................ 27
6 Electrical installation........................................................................ 29
6.1 Safety......................................................................................................... 29
6.2 Connection overview................................................................................ 30
6.2.1 Connection overview for standard version............................. 30
6.2.2 Overview of control unit electrical connections..................... 31
6.3 Uninstalling the electrical system............................................................ 32
CONTENTS
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7 Commissioning.................................................................................. 33
7.1 Safety......................................................................................................... 33
7.1.1 Important information on GPP measuring probe.................. 35
7.2 Tools required............................................................................................ 35
7.3 Material required...................................................................................... 35
7.4 Commissioning steps overview................................................................ 35
7.5 Removing the transport safety devices of the measuring probe........... 36
7.5.1 Removing the transport safety device of the GMP measur‐
ing probe.................................................................................. 36
7.5.2 Removing the transport safety device of the GPP measur‐
ing probe.................................................................................. 37
7.6 Fitting the T-piece on the measuring probe............................................ 37
7.7 Aligning transmitter and receiver optically.............................................. 37
7.8 Fitting the sender and receiver on the T-piece....................................... 38
7.9 Connecting the sender and receiver....................................................... 39
7.10 Calibration................................................................................................. 39
7.10.1 Material required..................................................................... 39
7.10.2 Calibrating the GM901-02 standard...................................... 39
7.10.3 Calibrating the GM901-02 with extended calibration........... 40
7.11 Zero adjust................................................................................................ 40
7.11.1 Manual SPAN test (optional)................................................... 41
7.11.2 Online SPAN test according to EPA Guidelines...................... 42
7.11.3 Automatic SPAN test................................................................ 45
7.12 Fitting the measuring device on the duct................................................ 46
7.13 Installing the weatherproof cover............................................................ 47
7.14 Preset parameter values.......................................................................... 49
8 Operation............................................................................................ 51
8.1 Operating and display elements.............................................................. 51
8.1.1 Control unit operating panel................................................... 51
8.1.2 Display...................................................................................... 51
8.1.3 Status LEDs.............................................................................. 52
8.2 Setting the display contrast..................................................................... 52
8.3 Entering the password.............................................................................. 52
9 Menus.................................................................................................. 54
9.1 Safety......................................................................................................... 54
9.2 Measuring mode....................................................................................... 54
9.3 Diagnosis................................................................................................... 54
9.3.1 Viewing error messages.......................................................... 54
9.3.2 Viewing warning messages..................................................... 55
9.3.3 Viewing sensor values............................................................. 55
9.4 Parameter................................................................................................. 55
9.4.1 Changing the physical unit...................................................... 56
9.4.2 Setting the humidity correction.............................................. 57
9.4.3 Changing the response time................................................... 57
CONTENTS
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9.4.4 Changing the measuring range............................................... 58
9.4.5 Changing the limit value.......................................................... 59
9.4.6 Changing the active measuring path...................................... 59
9.4.7 Parameter settings for the external temperature sensor
PT1000..................................................................................... 59
9.4.8 Setting the humidity content in sample gas.......................... 63
9.4.9 Setting the sample gas pressure............................................ 63
9.4.10 Changing the Live Zero value of the analog output (Analog
Out)........................................................................................... 64
9.4.11 Changing the calibration values............................................. 64
9.4.12 Median Filter............................................................................ 65
9.4.13 Device characteristic data (Device)........................................ 66
9.4.14 Service ..................................................................................... 68
9.5 Calibration................................................................................................. 70
9.5.1 Performing zero adjust............................................................ 70
9.5.2 Performing a manual SPAN test............................................. 71
9.5.3 SPAN test according to EPA Guidelines.................................. 72
9.6 Maintenance............................................................................................. 73
9.6.1 Measuring system restart....................................................... 73
9.6.2 Activating/deactivating maintenance mode.......................... 73
9.6.3 Setting the test analog output................................................ 74
9.6.4 Test relay.................................................................................. 74
9.6.5 Reset Parameter...................................................................... 75
10 Maintenance...................................................................................... 76
10.1 Safety......................................................................................................... 76
10.2 Preparatory work....................................................................................... 77
10.3 Visual inspection....................................................................................... 77
10.4 Maintenance plan..................................................................................... 77
10.4.1 Maintenance Table for sender/receiver unit......................... 77
10.4.2 Maintenance Table for GPP measuring probe....................... 78
10.4.3 Maintenance Table for purge air unit..................................... 78
10.4.4 Maintenance Table for GMP measuring probe...................... 78
10.4.5 Final maintenance work.......................................................... 78
11 Troubleshooting................................................................................. 79
11.1 Warning messages................................................................................... 79
11.2 Malfunction messages............................................................................. 80
11.3 Troubleshooting on the sender................................................................ 81
11.4 Troubleshooting on receiver..................................................................... 82
11.5 Troubleshooting on the control unit......................................................... 83
11.6 Communication error between control unit and receiver...................... 84
11.6.1 Sensor values for trouble-free operation............................... 84
11.6.2 Remote Diagnosis, GM901 Sensor Values............................ 85
11.7 Measures after purge air failure (when using the GMP measuring
probe)........................................................................................................ 86
CONTENTS
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12 Decommissioning............................................................................. 87
12.1 Safety information on shutting down...................................................... 87
12.2 Materials and tools required.................................................................... 88
12.3 Disassembling the sender and receiver.................................................. 88
12.4 Storage...................................................................................................... 89
12.5 Disposal..................................................................................................... 89
13 Technical data.................................................................................... 90
13.1 System GM901-02................................................................................... 90
13.2 Sender/receiver unit................................................................................ 90
13.3 Open GMP measuring probe.................................................................... 90
13.4 Gas-testable GPP measuring probe........................................................ 91
13.5 Control unit AWE, standard version (Part No.: 2020428, 2021433)... 91
13.6 Control unit AWE with extended connectivity (Part No.: 2027607,
2084045).................................................................................................. 92
13.7 Dimension drawing, sender-receiver unit with GMP measuring probe. 94
13.8 Dimension drawing, sender/receiver unit with GPP measuring probe. 94
13.9 Dimension drawing, control units............................................................ 95
13.10 Dimension drawing, flange with tube, DN125........................................ 96
13.11 Dimension drawing, weather hoods........................................................ 96
14 Ordering information........................................................................ 97
14.1 Expendable, wearing and spare parts..................................................... 97
14.2 Accessories............................................................................................... 97
15 Annex.................................................................................................. 98
15.1 Dimensional drawing, control unit........................................................... 98
15.2 Overview of AWE control unit electrical connections (cast metal
enclosure).................................................................................................. 98
CONTENTS
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1 About this document
1.1 Function of this document
These Operating Instructions describe:
•System components
•Start-up
•Operation
•Maintenance work required for reliable operation
•Troubleshooting
1.2 Scope of application
These Operating Instructions are only applicable for the measuring device described in
the product identification.
They are not applicable for other SICK measuring devices.
The standards referred to in these Operating Instructions are to be observed in the
respective valid version.
1.3 Target groups
This Manual is intended for persons installing, operating and maintaining the device.
Operation
The device may only be operated by qualified persons who, based on their device-spe‐
cific training and knowledge as well as knowledge of the relevant regulations, can
assess the tasks given and recognize the hazards involved.
Installation and maintenance
Installation and maintenance may only be carried out by trained specialists familiar
with the installation conditions.
Please observe the information at the beginning of the respective Sections.
1.4 Further information
•Purge air unit Operating Instructions
•Final inspection record
NOTE
bObserve all documents provided.
1.5 Symbols and document conventions
1.5.1 Warning symbols
Table 1: Warning symbols
Symbol Significance
Hazard (general)
Hazard through electrical voltage
ABOUT THIS DOCUMENT 1
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Symbol Significance
Hauard through toxic substances
Hazard through noxious substances
Hazard through high temperature
Hazard for the environment/nature/organic life
1.5.2 Warning levels / Signal words
DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
Notice
Hazard which could result in property damage.
Note
Hints
1.5.3 Information symbols
Table 2: Information symbols
Symbol Significance
Important technical information for this product
Important information for electrical or electronic functions
1.6 Data integrity
SICK AG uses standardized data interfaces such as, for example, standard IP technol‐
ogy, in its products. The focus here is on product availability and features.
SICK AG always assumes that the customer is responsible for the integrity and confi‐
dentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures
suitable for the respective situation, e.g., network separation, firewalls, virus protection
and patch management.
1 ABOUT THIS DOCUMENT
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2 Safety information
2.1 Basic safety information
NOTICE
Responsibility of the operator in case of device malfunctions or failure
If the GM901-02 is used as a sensor in combination with control technology, the
operator must ensure that a failure or malfunction on the GM901-02 cannot lead to
unallowed damage or hazardous operating states.
NOTICE
Responsibility for system safety
The person setting the system up is responsible for the safety of the system in which
the device is integrated.
Electrical safety
DANGER
Danger to life through electric shock
There is a risk of electric shock when working on the device with the voltage supply
switched on.
bBefore starting work on the device, ensure the voltage supply can be switched
off in accordance with the valid Standard using a power isolating switch/circuit
breaker.
bMake sure the disconnector switch is easily accessible.
bAn additional disconnecting device is mandatory when the power disconnector
switch cannot be accessed or only with difficulty after installation of the device
connection.
bSwitch off the voltage supply before starting any work on the device.
bAfter completion of the work or for test purposes, calibration of the power supply
may only be activated again by authorized personnel complying with the safety
regulations.
WARNING
Endangerment of electrical safety through power cable with incorrect rating
Electrical accidents can occur when the specifications for installation of a power line
have not been adequately observed.
bAlways observe the exact specifications in the Operating Instructions (see "Techni‐
cal data", page 90) for installation of a power line.
Grounding the device
NOTICE
Device damage through incorrect or non-existing grounding
During installation and maintenance work, it must be ensured that the protective
grounding to the devices and/or lines involved is effective in accordance with EN
61010-1.
2.2 Intended use
SAFETY INFORMATION 2
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2.2.1 Purpose of the device
The GM901-02 only serves to monitor CO concentrations of gases in industrial plants.
The GM901-02 measures continuously directly in the gas duct (in-situ).
2 SAFETY INFORMATION
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