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
This work is protected by copyright. Any rights derived from the copyright shall be
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
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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
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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).
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2.2.2 Responsibility of user
Designated users
see "Target groups", page 7.
Correct project planning
•Basis of this Manual is the delivery of the device according to the preceding
project planning (e.g., based on the SICK application questionnaire) and the rele‐
vant delivery state of the device (see delivered system documentation).
bContact SICK Customer Service if you are not sure whether the device corre‐
sponds to the state defined during project planning or to the delivered system
documentation.
Correct use
bUse the device only as described in "Intended use".
The manufacturer bears no responsibility for any other use.
bCarry out the specified maintenance work.
bDo not attempt any work on or repairs to the device unless described in this
Manual.
Do not remove, add or change any components in or on the device unless such
changes are officially allowed and specified by the manufacturer.
Use only original spare parts and expendable parts from SICK.
Failure to observe these precautions could result in:
°Voiding the manufacturer's warranty.
°The device becoming dangerous.
Special local requirements
In addition to the information in these Operating Instructions, follow all local laws, tech‐
nical rules and company-internal operating directives applicable wherever the device is
installed.
Read the Operating Instructions
bRead and observe these Operating Instructions.
bObserve all safety instructions.
bIf anything is not clear: Please contact SICK Customer Service.
Retain documents
These Operating Instructions must be
bAvailable for reference.
bPassed on to new owners.
SAFETY INFORMATION 2
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3 Product description
3.1 Product identification
Product name GM901-02
Device version CO measuring device with probe
Manufacturer SICK AG Erwin-Sick-Str. 1 • D-79183 Waldkirch • Germany
Type plates •Sender and receiver: Under the optics tube
•Measuring probe: On the electronics housing
3.2 Product features
•The in-situ gas analyzer GM901-02 serves for continuous measurement of gas
concentrations in industrial plants.
•The GM901-02 is an in-situ measuring system which means measuring is done
directly in the gas carrying duct.
•Measuring components: CO and reference value temperature.
•Measuring principle: Infrared spectroscopic gas filter correlation.
3.2.1 Cross-sensitivities
Accurate temperature input is a critical factor that may be required to maintain desired
measurement accuracies. The temperature of an external RTD temperature sensor
should be connected to the analog input of the control unit.
The influence of temperature can be assessed in the following Table.
Process temperature Absolute temperature
error
Relative temperature
error
Additional relative %
measurement error
100 °C 5 °C 5% 3%
200 °C 10 °C 5% 4.8%
300 °C 15 °C 5% 6%
400 °C 20°C 5% 6.8%
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The humidity in the process affects measurement accuracy. GM901 does not measure
humidity, but a static humidity default value can be set.
The influence of the humidity on measurement accuracy depends on the process
temperature, the absolute process humidity and the humidity input error. The effect can
be assessed in the following Tables.
Table 3: Actual process moisture at 0 vol.% H2O
Default value
entered1
(Vol.-% H2O)
Absolute differ‐
ence to input
value
(Vol.-% H2O)
Process tempera‐
ture (°C)
Additional rela‐
tive % measure‐
ment error2
5 5 100 -2.5
5 5 200 -6.1
5 5 300 -7.6
5 5 400 -13.9
1See Section 9.4.8
2Based on 500 ppm CO, the uncertainty is lower for higher concentrations
Table 4: Actual process moisture at 10 Vol.-% H2O
Default value
entered1
(Vol.-% H2O)
Absolute differ‐
ence to input
value
(Vol.-% H2O)
Process tempera‐
ture (°C)
Additional rela‐
tive % CO meas‐
urement error2
0 -10 100 3.8
0 -10 200 9.3
0 -10 300 14.2
0 -10 400 22.2
5 -5 100 1.2
5 -5 200 2.9
5 -5 300 4.3
5 -5 400 6.8
15 5 100 -0.9
15 5 200 -2.2
15 5 300 -3.3
15 5 400 -5.2
20 10 100 -1.7
20 10 200 -4.1
20 10 300 -6.2
20 10 400 -9.6
1See Section 9.4.8
2Based on 500 ppm CO, the uncertainty is lower for higher concentrations
Table 5: Actual process moisture at 20 Vol.-% H2O
Default value
entered1
(Vol.-% H2O)
Absolute differ‐
ence to input
value
(Vol.-% H2O)
Process tempera‐
ture (°C)
Additional rela‐
tive % CO meas‐
urement error2
10 -10 100 1.8
10 -10 200 4.2
10 -10 300 7
PRODUCT DESCRIPTION 3
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Default value
entered1
(Vol.-% H2O)
Absolute differ‐
ence to input
value
(Vol.-% H2O)
Process tempera‐
ture (°C)
Additional rela‐
tive % CO meas‐
urement error2
10 -10 400 10
15 -5 100 0.8
15 -5 200 1.9
15 -5 300 3.2
15 -5 400 4.5
25 5 100 -0.7
25 5 200 -1.7
25 5 300 -2.8
25 5 400 -4
30 10 100 -1.4
30 10 200 -3.3
30 10 300 -5.3
30 10 400 -7.6
1See Section 9.4.8
2Based on 500 ppm CO, the uncertainty is lower for higher concentrations
Table 6: Actual process moisture at 30 Vol.-% H2O
Default value
entered1
(Vol.-% H2O)
Absolute differ‐
ence to input
value
(Vol.-% H2O)
Process tempera‐
ture (°C)
Additional rela‐
tive % CO meas‐
urement error2
20 -10 100 1.4
20 -10 200 3.3
20 -10 300 5.9
20 -10 400 7.8
25 -5 100 0.7
25 -5 200 1.6
25 -5 300 2.8
25 -5 400 3.7
35 5 100 -0.6
35 5 200 -1.5
35 5 300 -2.6
35 5 400 -3.4
40 10 100 -1.2
40 10 200 -2.8
40 10 300 -4.9
40 10 400 -6.5
1See Section 9.4.8
2Based on 500 ppm CO, the uncertainty is lower for higher concentrations
The presence of CO2 in the process gas has an effect on CO measurement at high
temperatures. The more the temperature increases at constant CO2 concentration,
the higher the relative CO measurement error becomes. Consider the influence in the
following Table.
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Max. CO2 concentration for 1 m Max. temperature Relative CO measurement
error
10 Vol.-% 370 °C 2%
400 °C 3%
410 °C 4%
15 Vol.-% 390 °C 2%
380 °C 3%
360 °C 4%
20 Vol.-% 340 °C 2%
360 °C 3%
380 °C 4%
25 Vol.-% 370 °C 2%
350 °C 3%
330 °C 4%
3.3 Device variants
The following device variants are available depending on the measuring task and
application:
GM901 Standard GM901 Extended calibration
Type code GM901-02-xxxx1 or xxxx3 GM901-02-xxxx2 or xxxx4
Temperature range Applications up to 250 °C Applications up to 430 °C
PRODUCT DESCRIPTION 3
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3.4 Layout
ã
â
á
à
ß
9
8
7
6
5
4
3
2
1
G
M901
Operation
Service
Warning
Malfunction
Service Control Unit
Figure 1: Device component overview
Table 7: Device components legend
System components Line
1GM901-02 sender 8Sender-receiver connection
2GM901-02 receiver 9CAN connection and power supply Control unit - ana‐
lyzer
3T-piece with beam splitter ßPower supply 115 V / 230 V AC
4Measuring probe àLine to temperature sensor PT1000
5Temperature sensor PT1000 á•Analog output signals: 1 input, 1 output
•Status signals: 1 input, 3 outputs
6Control unit âPower supply 115 V / 230 V AC
7Service PC ãRS232 interface (Service)
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3.5 Measuring probes
3.5.1 Gas-testable GPP measuring probe
Figure 2: GPP measuring probe with ceramic filter
Characteristics:
•Suitable for applications with dry process gas
•Measuring probe material:
– Standard: Stainless steel (1.4571/316 Ti)
– On request: 1.4539
•No moving parts
•Active elements: Optical surface heaters and their controls
•PT1000 temperature sensor with SPU for gas temperature measurement
•Power supply via a plug
•Filter element for filtering dust particles
°With ceramic filter: Dust removal for particles > 1 μm
•EPA compliant (EPA Guideline CFR 40, Part 60 or Part 75): The measuring cham‐
ber can be filled with known concentrations of test gases
•SPAN and zero point test possible: Usage as "zero path" by purging the measuring
chamber with air or N2 possible
•Pressure-resistant up to 200 mbar differential pressure to duct
•No special flow conditions in duct necessary
PRODUCT DESCRIPTION 3
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3.5.2 Open GMP measuring probe
Figure 3: Measuring probe with open measuring gap and PT1000 tempera‐
ture sensor
Characteristics:
•Very short response times
•High temperature stability
•Continuous purge air necessary
•Air outlet in the duct 90° to gas flow
•PT1000 temperature sensor with SPU for gas temperature measurement
Gas inlet and outlet with the GMP measuring probe
The measuring probe has a closing device for the opening towards sample gas and is
operated using the lever on the probe flange. This ensures a correct purge air function
without an analyzer.
1
2
3
4
Figure 4: Closing device on the GMP measuring probe
1Purge air outlet
2Open measuring path (measuring gap)
3Closing device lever
4Closing device set to position "open"
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GM901-02 with GMP measuring probe and purge air unit
1
2
3
4
6
5
7
Figure 5: GMP measuring probe with purge air unit on the duct
1GM901-02 sender
2GM901-02 receiver
3T-piece with beam splitter
4Lever for closing device of the sample gas opening
5GMP measuring probe
6Purge air hose
7Purge air unit SLV4
3.5.3 Measuring probes in comparison
Table 8: Measuring probes: Characteristics and usage
Characteristic Open GMP measuring probe Gas-testable GPP measuring
probe
Type Measuring path in flow direc‐
tion open; Purge air supply
with outlet aligned 90° to gas
flow
Gas-testable measuring probe
with ceramic filter, for dry sam‐
ple gas
Max. process temperature ≤+430 °C ≤+430 °C
Gas check according to EPA
specification possible
No Yes
Purge air supply required Yes No
Optical surface heating in
measuring probe
No Yes, with integrated control
Suitable for wet sample gas Yes No
Measurable components CO CO
Response time (t90) ≥ 5 s ≥ 120 s
Duct diameter > 360 mm > 300 mm
PRODUCT DESCRIPTION 3
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Characteristic Open GMP measuring probe Gas-testable GPP measuring
probe
Dust load ≤ 3 g/m3
Relative to 1 m measuring dis‐
tance, depending on applica‐
tion
≤ 30 g/m3
Probe lengths available [m] 1,1 1,1
Active measuring paths availa‐
ble [mm]
250/500 250/500
3.6 Control unit
Control unit with connection line (4 m)
The control unit AWE serves in the measuring system as user interface and prepares
and outputs the measured values and performs control and monitoring functions.
The control unit can be located in the vicinity of the sender/receiver unit. It can also be
located up to about 1000 meters from the sampling point, e.g., installed in the switch
center or monitoring center of the industrial plant.
Functions:
•Output of measured values, computed data and operating states
•Communication with the peripheral equipment
•Output of error messages and other status signals
•Access during service (diagnosis)
3.7 Accessories
Weather protection hood
The weatherproof cover is used when the measuring system is operated outdoors. It is
available as an accessory.
Figure 6: Weatherproof cover
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