SICK GM901 User manual

GM 901
CO Monitor
Н
О
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05
SICK

GM 901 Introduction Product Information
Introduction
Conformities
^ Conforms to EMC specificationspursuant toEN 50081-1/EN 50082-2
^ CE certificationpursuant toEC Guideline EMC 89/336 EWGand
NSP 72/23/EWG
*• VDE Guidelinespursuant toEN 61010 (IEC 1010-1, VDE 0411), class
of protection 1, degree of protection IP65
^ Prototype tested by TUV, Report No. 502/0741/96-20 081751
*• SICK AG EnvironmentalMonitoring is certified toISO 9001.
Purpose of this Document
This "ProductInformation"describes allofthe proceduresrequired to mount and
install theGM 901.
The document is intended to help you plan your project and prepare the meas-
uringpointbefore the device is delivered.
Among otherthings, the documentcontainsimportantinformation on:
>• Areas of application oftheGM901
^- Features
^ Input and output options
>• Installationinstructions for projectplanning and mounting theGM901atthe
measuringpoint
^- Prerequisites for mounting and connecting the device
>• Overview ofthe installationactivities
^- Calibrating the system (zero calibration)
^- Overview ofthe technical data and dimensioned drawings oftheGM901
components
8008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved

F
GM 901 Contents Product Information
Contents
1 Overview ..................................................... 4
1.1 Benefits ofthe GM 901 ...................................... 4
1.2 Applications ................................................ 4
1.3 Standard Components ....................................... 5
1.4 Accessories/Options ......................................... 6
1.4.1 Accessories fortheGM901 ........................... 7
1.4.2 Options .............................................. 8
2 Instructions for ProjectPlanning ................................ 9
2.1 Checklist ................................................... 9
2.2 InstallationSequence ....................................... 10
3 Preparations for Installation .................................. .11
3.1 Preparations for Mounting .................................. 11
3.1.1 InstallationProposal .................................. 11
3.1.2 Instructions for Mounting the FlangewithPipe ........... 11
3.1.3 Installation on SteelDucts ............................ 12
3.1.4 Installation on BrickDucts ............................. 12
3.1.5 Installation on Thin-WalledDucts ....................... 12
3.1.6 AuxiliaryPipe for Measuring Paths of Less than 2m ...... 13
3.1.7 Aligning the Flangewith the OpticalAlignment Aid ......... 13
3.2 Preparations for ElectricalInstallation ......................... 14
3.2.1 WiringSpecifications/Interfaces tothe Evaluation Unit ..... 14
3.2.2ConnectionUnit(Accessory) ........................... 15
3.2.3Purge-AirUnit(Option) ................................ 16
4 Preparations for Startup ..................................... .17
4.1 Zero Calibration ............................................ 17
4.2 SPAN Test(Option) ......................................... 17
4.2.1Test Cells ........................................... 17
4.2.2Calculating the TestValues ............................ 18
5 TechnicalData ............................................. .19
5.1 DeviceData ............................................... 19
5.1.1 Accessories ......................................... 20
5.1.2 Options ............................................. 20
5.2 DimensionedDrawings ...................................... 21
5.2.1 Transmitter and Receiver ............................. 21
5.2.2EvaluationUnit ...................................... 22
5.2.3 Purge-Air Unit ........................................ 23
5.2.4 Air FilterAssembly ................................... 23
P
8008 876/07-99.HJS.SM • SICK AG• EnvironmentalMonitoring • Germany • All rightsreserved

GM 901 Overview Product Information
тттттнвияяитвтттяятшттвнияаятш£: _____________тт!т1штттшпттттттттттмтяштттттишшят
1 Overview
l.± Benefits ofthe GM 9O1
^- CO analyzer: GM901 measures theCO contentdirectly inthegas duct.
^ Bus capability:using a CAN bus, the evaluationunit canbe mounted ata
distance ofupto 1000 m from the measuringpoint,e.g. inthe controlroom.
^- Easy to mount and connect.
> Shortstartuptime - to install the opticalunits and switch onthe powersupply.
^- User-friendly operation by means of function buttons onthe evaluation unit:
-for settings the display and outputfunctions
-for configuring the deviceparameters
^ Low maintenance requirements, no test gases required.
*• Variablemeasurementvalueoutput: ppm, mg/m3, or mg/Nm3.
^ Measurementvalue,measuringrange, and limitvalues are visible onthe
display. Additionaltemperaturedisplay and plaintextinformation onthe
operatingmode.
> Integrateddiagnosisfunction.Diagnosisdata canbe called upfor warnings
and errormessages.
±.2 Applications
The GM901is designed for instant and no-contactmonitoring oftheCO concen-
tration, for example, for processcontrolpurposes inthe followingareas:
^- Powerstations
> Coal processingplants
^- Refuseincinerationplants
^ Plants inthe cementindustry
>• Paperindustry
^- Pharmaceuticalindustry
> Melting/steel industry
^ Glassindustry
^ Chemicalindustry
^ Foodindustry
8008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved

GM901
Overview
Product Information
In plants operating with
a partial vacuum
±.3 StandardComponents
>• 1 transmitter
^ 1 receiver
^ 1 evaluationunitwithconnectioncable (2 m)
> 1 cable for connecting the transmitter and receiver (15m)
^- 2 flanges withpipe
Note Depending onthe ambient conditions, air filters maybe required to clean the
ambientair. See 1.4.2"Options".
Gas duct
Connection
cable (2m)
Connectioncable (15m)
©
Fig. 1: GM 901 - standard components
Flangewithpipe
L
Purge-airattachment
Л
Transmitter
Evaluationunit
Analogsignals:
1 input,
1 output
Status signals:
1 input,
2 outputs
115/230 VAC
8008 876/07-99.HJS.SM • SICK AG• EnvironmentalMonitoring • Germany • All rightsreserved

GM901
Overview
Product Information
In pressurizedplants ata
distance ofupto ±OOO m
from the evaluationunit
±.4 Accessories/Options
Purge-air attachment
Receiver
A
У
г
Purge-air attachment
A
Transmitter
Hose 5 m
Cabel max. 2 m
(CAN bus, power
supply)
Connec-
tionunit
(accessory)"
115/230 VAC
Purge-airunit
(option)
Cabel max.
1000m
(CAN bus),
provided by
the customer
©
Control room
Evaluation unit
f
Fig. 2: GM 901 with purge-air unit (for pressurized plants) at a distance of up
to 1000 m (e.g. in a control room) from the evaluation unit.
8008 876/07-99.HJS.SM • SICK AG • EnvironmentalMonitoring • Germany • All rightsreserved

GM901
Overview
Product Informatior
1.4.1
Accessories forthe GM 9O1
Connectionunitwithpowersupply for transmitter/receiver for distances ofup
to 1000 m from the evaluation unit
Alignment unit
Mounting bracket for zero calibration
8008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved

GM901
Overview
Product Information
f
Cover platewithseal for covering the ductapertureswhen the transmitter and
receiver are replaced
CO test cellwithbracket in transportcase
Weatherproof covers for mounting the deviceoutdoors
Dimensioned Drawings,
Page 21
1.4.2
Options
Purge-air unit for protecting the opticalboundaryareas onthe transmitter and
receiver fromdirt(includingconnectionhose)
- Air filter assembly for cleaning the ambient airin plantsoperatingwith a partial
vacuum
PT 100 temperaturesensorincludingmeasuringtransducer
f
8008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved

GM901
Instructions for
Project Planning
Product Informatior
2
Instructions for Project Planning
2.±
Checklist
See alsoChapter 3 "Preparations for Installation".
Check the followingconditions by ticking theboxinthe thirdcolumn.
I Check
Measuring point selection
Field service
! conditions
Flange mounting
(see 3.1 "Preparations for
Mounting")
! Mounting location
Transmitter and receiver
Ductwalls
Evaluation unit
(see 3.1.1. "Installation
Proposal")
Duct aperture
selection
Installation site
Tab. 1: Checklist
(contd. on Page 10)
Measure
The gasflowinthe vicinity ofthe measuringpoint
should be homogeneous.
Measuring gas temperature: s 300 °C;
highertemperatures on request.
Dustconcentration: < 1 g/m3 x m
A highdustcontent inthegas duct can impair the
measurement.
Duct pressure:
•A purge-air unit isnot required if there isa
constantpartialvacuum inthe duct. Air filter
set recommended.
•A purge-airunit is required in pressurized
plants.Pleaseconsult the SICK Customer
Servicedepartmentwithregard tothe correct
fan type.
Steelducts: the device is designed for installation
in steel ducts.
Brick or thick-walledducts:modified flange with
pipe required. Canbe provided bythe customer
or designed by SICK.
Suitablereinforcements or supportconstructions
must be provided on thin-walledducts to ensure
that the transmitter and receiver are permanently
aligned.
The size and position ofthe aperturemust be sel-
ected in such a way thatsufficientspace is pro-
vided forthe transmitter and receiver.
Some ofthe ductinsulationmust be removed
and sufficientspaceprovided for installation and
maintenanceactivities.
Ifthe device is mountedoutdoors,sufficientspace
should be provided forthe weatherproof cover.
The unit should be installed ata position that is
freelyaccessible.Max.distancefromtransmitter
and receiver:
- standard: 2 m
- withextensioncable: 17m
- For cable lengths upto 1000 m:
with connectionunit(accessory)
The unitshould be mounted ona flat surface.
п
п
In
8008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved

GM901
Instructions for
Project Plannmg
Product Information
Purge-air unit (option)
Mounting platform
Check Measure
Installationsite
! Ambientconditions
Installation
Accident prevention
Tab. 1: Checklist
The purge-airsupplymust be installed atan
equal distance from the transmitter and receiver
to ensurethat theairflows uniformly.
Sufficientspaceshould be provided for replacing
thefiltersetand dustcollector.
If the unit is mountedoutdoors,sufficientspace
should be provided for installing/removing the
weatherproof cover.
The temperature ofthe purge air entering the
duct must not fallbelow thedew point. If neces-
sary, the purge air must be heated (SICK heaters
are recommended).
"temperature"of the intake air:"6~°C"<~T < 55 °C.
If Т < О °С, heat the purgeair.
The intakepurge air should be free of dust.
П
- Height of platform:approx. 1.5 m below the inten-
ded location forthe transmitter and receiver.
- Lighting anda powersupplyshould be installed at
the measuringpoint to facilitateservicing.
All ofthe device components should be safely
accessible.
Always observe the nationalaccidentprevention
regulations!
П
2.2 Installation Sequence
1. Step: Carry outallofthe planning activities (see 2.1 "Checklist")
2. Step: Mount theflangeforthe transmitter and receiver atthe measuring
point
3. Step: Check the wiring atthe siteusing the wiringspecifications(see
3.2.1"WiringSpecifications/Interfaces tothe Evaluation Unit")
4. Step: Laythe cables and signalleads
5. Step: Check allthe connections(see 3.2 "Preparations for Electrical In-
stallation")
6. Step: In pressurizedplants:mount the (optional)purge-airunit and check
whether itis functioningcorrectly
7. Step: Mount the evaluationunit
8. Step: Mount the transmitter and receiver
9. Step: Ifthe cablebetween the receiver and evaluationunit is longerthan
17m: install the connectionunit(accessory)
10. Step: Ifthe devices are installedoutdoors:mount the weatherproof
covers
f
10
8008 876/07-99.HJS.SM • SICK AG• EnvironmentalMonitoring • Germany • All rightsreserved

GM901
Preparations
for Installation
Product Informatior
3
Preparations for Installation
3.1 Preparations for Mounting
3.±.1 Installation Proposal
HI——Measuring distance-—
Flange-flange
Flange with
pipe
ArrangementX ~|ч
of studbolts
x«4Fi
(shown rota-
ted through
45°)
Steel pipe 50x5
DIN 2391
(Mounting position
marking
Fig. 3: Installation proposal for GM 901 with mounting flange and purge-air unit
(optional)
3.1.2 Instructions for Mounting the Flange with Pipe
In the descriptionthat follows, the term "flange" is used to refer totheflange with pipe
The standard flange supplied by SICK hasa totallength of130mmandan oute
diameter of76mm.
> Mount theflangein such a way that the axes are aligned. The angulardis-
placementmust be lessthan 1°. Suitablereinforcements or support construe
tionsmust be provided on thin-walledducts.
> The pipestubs ontheflange shouldprotrudeinto the duct by approx. 30mm
The pipestubsmustalso be adapted if necessary.
^ A suitableauxiliarypipe canbe used to align the flange for measuringdis-
tancesthat are easilyaccessible (upto2 m). (Theinnerdiameter of standarc
flanges is 70.2 ± 1 mm.)
> The opticalalignment aid (accessory)must be used for longermeasuring patl
or measuringpathsthat are difficult to access.
8008 876/07-99.HJS.SM • SICK AG• EnvironmentalMonitoring • Germany • All rightsreserved
11

GM901
Preparations
for Installation
Product Information
3.1_3
Installation on Steel Ducts
1=130,240, or
500mm
Mounting positionmarking
Arrangement of
stud bolts
(shown rotated
through45°)
Fig. 4: Steel duct
30
3.1.4 Installation on Brick Ducts
On brickducts, the flangemust be welded toa suitableretainingplate(provided
by the customer)mounted onthe duct.
500mm
Mountingpositionmarking ^Т^ТоГ^ч.
j^ 1 "*") ^^.
/^Ж^^^^^У\ У'~"
<-<_v>
/
/
Arrangement of \
studbolts \
(shown rotated Vati
through 45°) *ЦЩ
$~
k
J
1
— i
h
E3
^
-
-^
\
у
у
Q «. ^ С
Sl^
X™
aua'i
30
(0
5: Brick duct
3.±.5 Installation on Thin-Walled Ducts
On thin-walledducts orat locationssubject to vibrations,reinforcementmust be
provided inthe form of junctionplates.
Mounting positionmarking
12
Fig. 6: Junctionplates
8 008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved

GM901
Preparations
for Installation
Product Information
3.3-6 AuxiliaryPipe for Measuring Paths of Lessthan 2 m
An auxiliarypipeshould be used to helpmount the standardflange.
I
Fig. 7: Mounting the flange with an auxiliary pipe
* Arrangement of stud bolts (shown rotated through45°)
3.1.7
Aligning the Flange with the Optical Alignment Aid
A suitableauxiliarypipe canbe used to align theflangefor measuringpathsthat
are easilyaccessible (upto2 m). (Theinsidediameter of standard flangesis
70.2 ± 1 mm.)Whenusing the opticalalignmentaid,align the lightsource and
the adjustment tube as shown inthefigure below.
I
Light source Flange 1
О
Flange 2 Adjustmenttube
Fig. 8: Mounting the flange with the optical alignment aid
* Arrangement of studbolts (shown rotated through45°)
Note Whencarrying outthe zerocalibration,makesurethat the mountingbracket is
installed ata distanceequal tothe (flange-flange) measuringpath.
^- Align flange1 in such a way that the lightspotfrom the lightsource is centered
on the target ofthe adjustmenttube.Tack-weld flange1.
^- Place the adjustment aidonflange2.
*• Align and tack-weld flange2.
8008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved 13

GM901
Preparations
for installation
Product Information
SICK
О Operation 1 —————
О Service
GM 901
O Warning ' —————
О Malfunction
3.2 Preparations for ElectricalInstallation
All installation and finalwiringactivitiesmust be carried outbythe customer, un-
lessotherwiseagreedwithSICK.
3.2.1WiringSpecifications/Interfaces
tothe EvaluationUnit
The conductor and jacketmaterial as well asthe insulatingcoveringsmust be
selected in accordancewith the conditions atthe site.
Analog out Digital out
0...20 mA48V AC/DC
100
Digital in 30VA.1A
max. 5 V/2mA
CAN bus Temp.Maintenance CO MalfunctionLimitvalue
Power supplyInputs
and outputs
CAN bus interface
Power supply
Temperatureinput
3 wires;cross-section: 0.75 to2.5 mm2
Cable diameter: 6 to12mm
Conduit thread 13.5
CAN bus interface
Inputs and outputs
Max. bus length: 1000 m
Wires: 2x2 plusshield;cross-section:
up to500m > 0.25 mm2, upto 1000 m > 0.75 mm2
Cable diameter: 6 to10mm
Conduit thread 12
Digitalinput,active <; 500 Q, relay
Analogoutput 0 to20mA, max. load 500 Q
Outside diameter of cable: 6 to12mm
Conduitthread 13.5
Temperatureinput
Analog input 0 to20mA; senseresistor 100 Q
2 wiresplusshield
Outside diameter of cable: 4 to8 mm
Conduit thread 9
Fig. 9: Cable specifications and interfaces to the evaluation unit
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GM901
Preparations
for Installation
Product Information
,
t
3.2.2 Connection Unit (Accessory)
The connectionunit is required to connect the evaluationunit and receiver over
distances > 17 m. The unitprovides the powersupply tothe sensors and con-
nects theCAN bus.
The connectionunit is mounted atthe receiverwith a standard 2 m cable.
Wheninstalling the connectionunit,disconnect the powersupply tothe receiver
at the evaluationunit and connect ittothe connectionunit.
Operating voltage
setting
115 V/230 V
230 V=
or
P^/N/LL
Fuse
2.5 ДГ
1
' 250V
Connection to Connection to
evaluation unit GM901 receiver
Power supply
CAN bus interface
it
Power supply
115 V/230 VAC
Conduitthread13.5
CAN bus interface(Connection
to evaluationunit)
Max. bus length1000 m
Wires: 2x2 plus shield, cross-section:
up to500m a 0.25 mm2, upto 1000 m
Cable diameter: 6 to10mm
Conduitthread13.5
0.75 mm2
t
Fig. 10: Connection unit
8008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved 15

GM901
Preparations
for Installation
Product Information
Power supply
3.2.3Purge-Air Unit (Option)
The three-phasea.c.motor ofthe type 2BH1300 fanis connected tothe3 L-
conductors LI, L2,andL3.The ratedvoltage ofthe motor inthe runningconnec-
tion must be equal to that ofthe phase-to-phase voltage ofthe system (oper-
ating voltage).
Motorswith a windingconstruction for230V (A)/400 V (Y) canbe used if they
are starteddirectly andifa suitablecircuit is provided onthe terminalboard for
230V or400V.
U2
V1
W2 W1
V
IE
/2 U2V
I ft,
1
Ivi ?PE
Low pressuremonitor
W2 U2V2
q~
_n
n
U1
О
V1
о
W1
о
РЕ
L1 L2 L3 РЕ
L.
Й
24V
Fig. 11: Electrical connections of the purge-air unit
16 8008 876/07-99.HJS.SM • SICK AG• EnvironmentalMonitoring • Germany • All rightsreserved

GM 901
.___ _ Preparations for Startup
Product Information
4
Preparations for Startup
•
4.1 Zero Calibration
A zerocalibrationmust be carried outontheGM901 before the device isput
intooperation forthe first time or before it resumesoperation.
A СО-freeenvironment is required forthe zerocalibration. The calibration can
also be carried out directly atthe measuring point ifthe plant is shut down and
the duct is free ofCO.
Ifa zerocalibration isnot possible atthe measuringpoint, it must be carried out
with the transmitter and receiver atthe mountingbrackets.
Optical
axis
Reveiver
Mounting
bracket
Transmitter
Mounting
bracket
-Level surface
:„
Fig. 12: Mounting bracket (accessory) for zero calibration
Note If purge-airattachments are alsoused onthe mountingbrackets, the transmitter
and receivershould be attachedusing the quick-releaselocks.
i •
4.2 SPANTest(Option)
4.2.1 Test Cells
The following test cells are available
^ 250 ppm x m
^ 750ppmxm
^ 4000 ppmx m
^ 10000 ppm x m
Otherconcentrations can also be supplied on request.
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GM 901 Preparations *or Startup ProductInformation
4.2.2 Calculating the Test Values
The test concentration(testcellvalue) is calculatedusing the following formula*:
TV [ppm x m] = MR [ppm] x x x S [m]
TV = Testvalue
MR = Uppermeasurementrangelimit
x = Position ofthe test point
S = Measuringdistance
Example:
Upper measuringrangelimit MR = 1500 ppm
Measuringdistance S= 4m
Testpoint at70%ofMRx=0.7
TV [ppm x m]= MR [ppm] x x x S [m]
TV [ppm x m]= 1500[ppm] x 0.7x 4 [m]
TV [ppm x m]= 4200 [ppm x m]
The test cellvalueshould be 4200 ppmx m.
The nearest test cell hasthe test value 4000 ppmx m.
*Ifthe concentrationvalues arein mg/m3, they must be convertedaccordingly.
188 008 876/07-99.HJS.SM • SICK AG• EnvironmentalMonitoring • Germany • All rights reserved

GM901
Technical Data
Product Information
5
Technical Data
5.1
Device Data
Basic device
Transmitter
Receiver
Evaluation unit
I•
Measurementrange
Measuring distance
Gas temperature
Linearity
Resolution
Adjustmenttime
Ambient temperature
Degree of protection
Voltage supply
Line frequency
100ppmto 20000 ppm*________
0.5mto8 m
300 °C; higher temperatures on request
±5%of uppermeasurementrangelimit
approx. 10ppm
~5 to 360s ~
^20 °C to +55 °C
IP 65
115/230 V
~50/60'Hz
75 VA
Max. powerconsumption
Dimensions incl. purge-air
attachment
Weightincl.purge-airattachment 3 kg
Lamp servicelife
Dimensionsincl.purge-air
attachment
240mmx 150mmx 150mm(Lx W xH)
approx. 20000 hours
240mmx 150mmx 150mm(Lx W xH)
Weight incl.purge-airattachment 3 kg
Analog input
Analog output
electrically isolated
Relay 1
0to20 mA; inputresistor 100 Q
~0 to~20~mA; maxJoad 500 Q
Break contact for devicemalfunction,floating,
makecontact
Max. switchingcurrent: 1 A
Max. switchingvoltage: 125VDC
150VAC
Max. switchingcapacity: 30VADC
60VAAC
Relay 2
Make contact for limitvalueviolation
Max. switchingcurrent: 1 A
Max. switchingvoltage: 125VDC
150VAC
Max. switchingcapacity: 30VADC
60VAAC
Status input
Serial interface
Dimensionsincl.purge-air
attachment
Status input for maintenance
Max. contact load: 5 V/2mA
~RS 232for service
CAN bus (option)
Profi-bus (option)
200mmx 90mmx 300mm(Lx W xH)
Weight incl.purge-airattachment 4.3kg
Tab. 2: Technical data
* Depending onthe measurement distance
8008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved
19

GM901
Technical Data
Product Information
5.1_± Accessories
Part
Optical alignment aid
Mountingbracket for zero-point adjustment
Connectionunitwith 230 V/24 V powersupply for
transmitter and receiver
5m extensioncable
10m extensioncable
15m extensioncable
Weatherproofcover for purge-airunit
Weatherproofcover forGM901 transmitter/receiver
Weatherproofcover forGM901 evaluationunit
Cover plate withseal
Air filterassembly
Testcase for SPAN test withcell
Quantity
1
2
1
1
2
1
2
1
1
Order number
2020436
2020445
2020440
2020437
2020438
2020439
5306108
2702407
4029146
2020435
2020442
2019639
Tab. 3: Accessories
5.1.2
Part
Options
Quantity Order number
Purge-air unit with distributor and5 m hose
Flangewithpipe 130mm,ST37
Flangewithpipe 240mm,ST37
Flange withpipe 500mm,ST37
Flangewithpipe 130mm, 1.4571
Flangewithpipe 240mm, 1.4571
Flangewithpipe 500mm, 1.4571
Temperaturesensor PT100 incl. measuringtransducer
Tab. 4: Options
1
1
1
1
1
1
1
1
1012424
2017845
2017847
2017849
2017846
2017848
2017850
6007585
20
8008 876/07-99.HJS.SM • SICK AG• Environmental Monitoring • Germany • All rights reserved