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5.4

Installation sequence

5.4.1

Installation steps overview

Table 9: Installation steps overview

Step

Procedure

Reference

Install the flange with tube.

see "Installing the flange with tube",
page 25

Fitting the control unit.

see "Installing the control unit",
page 27

5.4.2

Installing the flange with tube

DANGER
Health risk through hot or toxic gases/dusts in the measuring channel

The measuring duct can contain hot or toxic gases or dust deposits which can escape
when opening the duct-side flange. Even if the measuring duct is out of operation
during the installation, escaping gases can lead to severe damage to health.

Always put the measuring duct out of operation for the duration of the installation.

If required, purge the measuring duct with ambient air before starting installation
work.

Always wear suitable or company-specified protective clothing during installation
work.

NOTICE
Device damage through incorrect/missing insulation of the duct when the measuring
channel is hot

When the measuring channel is hot, plan the duct and flange insulation so that
the device is protected against high temperatures.

Installing the flange with tube

NOTE

•

Flange with tube dimensions:

see "Dimension drawing, flange with tube, DN125",

page 96

MOUNTING

8008932/16YT/V4-0/2022-02 | SICK

O P E R A T I N G I N S T R U C T I O N S | GM901-02

Subject to change without notice

Содержание GM901-02

Страница 1: ...O P E R A T I N G I N S T R U C T I O N S GM901 02 Carbon Monoxide Gas Analyzer Probe version...

Страница 2: ...rmissible 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...

Страница 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 poin...

Страница 4: ...2 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 d...

Страница 5: ...ut 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 rece...

Страница 6: ...t 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 u...

Страница 7: ...erated 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 In...

Страница 8: ...gnificance 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 exampl...

Страница 9: ...ory when the power disconnector switch cannot be accessed or only with difficulty after installation of the device connection b Switch off the voltage supply before starting any work on the device b A...

Страница 10: ...itor CO concentrations of gases in industrial plants The GM901 02 measures continuously directly in the gas duct in situ 2 SAFETY INFORMATION 10 O P E R A T I N G I N S T R U C T I O N S GM901 02 8008...

Страница 11: ...emove 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...

Страница 12: ...s 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...

Страница 13: ...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...

Страница 14: ...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...

Страница 15: ...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 xxxx...

Страница 16: ...and power supply Control unit ana lyzer 3 T piece with beam splitter Power supply 115 V 230 V AC 4 Measuring probe Line to temperature sensor PT1000 5 Temperature sensor PT1000 Analog output signals 1...

Страница 17: ...supply via a plug Filter element for filtering dust particles With ceramic filter Dust removal for particles 1 m EPA compliant EPA Guideline CFR 40 Part 60 or Part 75 The measuring cham ber can be fil...

Страница 18: ...t 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...

Страница 19: ...le 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...

Страница 20: ...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 Ou...

Страница 21: ...air supply If the supply of purge air is insufficient hot and corrosive gases can destroy the measuring device within a few minutes Further information on the purge air unit see Operating Instruction...

Страница 22: ...t cells Test cells are available depending on the application specific measuring ranges meas uring paths and test points e g 70 3 PRODUCT DESCRIPTION 22 O P E R A T I N G I N S T R U C T I O N S GM901...

Страница 23: ...der receiver unit and measuring probe from atmos pheric influences preferably with the original transport safety devices b Pack all components for storage or transport Preferably use the original pack...

Страница 24: ...stallation on the stack Unsuitable ambient conditions in the measuring duct can damage the measuring device and make commissioning impossible b First install the measuring device on the stack after co...

Страница 25: ...can lead to severe damage to health b Always put the measuring duct out of operation for the duration of the installation b If required purge the measuring duct with ambient air before starting instal...

Страница 26: ...orcement with junction plates recommended The device has a relatively high weight b Weld junction plates on on site for reinforcement of ducts with thin walls or at fitting locations subject to vibrat...

Страница 27: ...ts exactly upwards Tilt the tube in the duct or on the retainer plate slightly downwards approx 1 5 Affix in the fitting position Weld on junction plates as reinforcement when possible For ducts made...

Страница 28: ...n mm 1 4 mounting holes 7 2 mm 2 Installation surface 3 Fastening brackets Steps 1 Drill the holes according to the installation drawing 7 2 mm for M8 2 Screw the control unit tight to the four fasten...

Страница 29: ...ave not been adequately observed b Always observe the exact specifications in the Operating Instructions see Techni cal data page 90 for installation of a power line DANGER Electrical accident due to...

Страница 30: ...Malfunction Service Control Unit Figure 12 Electrical wiring of device components 1 Sender receiver connection 2 CAN connection and power supply control unit analyzer 3 Power supply purge air fixture...

Страница 31: ...Test AI1 DO2 DO1 DO3 Contrast Figure 13 Electrical wiring of control unit 1 Connections for wiring 2 Operating voltage selection 115 V or 230 V AC 3 Power supply 115 V 230 V AC 4 Receiver connection 5...

Страница 32: ...ve lines during unin stallation work so that nobody can be injured CAUTION Electrical accident through unsecured switches Switches that should no longer be switched on for safety reasons can lead to s...

Страница 33: ...s can escape during work on the gas duct depending on the plant conditions b Work on the gas duct may only be performed by skilled technicians who based on their technical training and knowledge as we...

Страница 34: ...y through power cable with incorrect rating Electrical accidents can occur when the specifications for installation of a power line have not been adequately observed b Always observe the exact specifi...

Страница 35: ...ioning comprises two main steps 1 Zero adjust The sender receiver unit is prepared for operation with the measuring probe in an atmosphere free from sample gas 2 Installation and commissioning at the...

Страница 36: ...connections to customer data sys tem Configure according to customer specifications see Parameter page 55 11 Fit the weather protection hood optional see Installing the weatherproof cover page 47 7 5...

Страница 37: ...g probe NOTE The measuring probe is normally delivered from the factory already fitted with the T piece Figure 17 Fitting the T piece on the measuring probe 7 7 Aligning transmitter and receiver optic...

Страница 38: ...tioned centered on the focusing screen of the adjustment tube 2 Control the adjustment in both directions 7 8 Fitting the sender and receiver on the T piece Figure 18 Fitting the sender and receiver o...

Страница 39: ...ed calibration page 40 7 10 1 Material required Test tool kit for SPAN test A test cell with a concentration of at least 80 of the highest desired measuring range For example if the desired measuremen...

Страница 40: ...re Input External to No see Setting the use of an external temperature sensor page 60 4 Make sure algorithm coefficients C3 to C6 are set to 1 Do not set these values see Setting the use of an externa...

Страница 41: ...l 2 Menu navigation for zero adjust select zero adjust see Performing zero adjust page 70 The zero point adjustment is running while Zero Measuring is shown in the control unit display 3 When zero adj...

Страница 42: ...PAN test page 71 3 Follow the menu instructions 1 2 Figure 20 GM901 02 with holder for test cell 1 Input compartment for CO cell 2 Holder for test cell 7 11 2 Online SPAN test according to EPA Guideli...

Страница 43: ...of 900 1100 mbar equiv alent to the pressure in the duct Resolution 0 5 mbar 1 8 Swagelok connection P 1 9 8 7 6 4 2 3 5 GM901 Operation Service Warning Malfunction Service Control Unit Figure 21 Equ...

Страница 44: ...rying out a thermal adjustment The cold test gas flow withdraws energy from the measuring probe body as it flows through the device Long purge times can therefore effect a difference between the test...

Страница 45: ...t with different equipment depending on customer requirements NOTICE Valve control as well as triggering a SPAN test must be carried out with an automatic calibration test unit from the customer Equip...

Страница 46: ...ring the installation escaping gases can lead to severe damage to health b Always put the measuring duct out of operation for the duration of the installation b If required purge the measuring duct wi...

Страница 47: ...3 Fit the measuring probe on the duct side flange Use the supplied mounting kit 7 13 Installing the weatherproof cover The weatherproof cover is installed in two steps 1 Fit the installation plate on...

Страница 48: ...b Place the installation plate on the rubber band of the purge air fixture from the top b Position the mounting ring on the side of the purge air fixture b Screw the lower mounting ring to the upper...

Страница 49: ...e from the top b Engage the locks and close again Figure 25 Placing the weatherproof cover on the installation plate 7 14 Preset parameter values Parameter settings Physical unit mg Nm3 Normalization...

Страница 50: ...lter Size 11 Note The preset value 11 adds 6 seconds to the setting value see Median Filter page 65 Device parameters Serial number Current software version Evaluation unit Current software version Co...

Страница 51: ...eturn button arrow left Enter Confirm set value 4 Function buttons and submenus diag Diagnosis see Diagnosis page 54 par Parameter see Parameter page 55 cal Calibration see Calibration page 70 maint M...

Страница 52: ...lock b Use a 2 mm precision screwdriver to adjust the display contrast setting Figure 26 Rotary potentiometer for display contrast 8 3 Entering the password The password is always prompted for when a...

Страница 53: ...ssword 1 0 0 0 back select Password 2 x Password 1 2 0 0 back select Password Password 1 2 3 4 back select Password Figure 27 Entering the password OPERATION 8 8008932 16YT V4 0 2022 02 SICK O P E R A...

Страница 54: ...splay page 51 The operator can switch directly to the measuring mode display from every menu item b Press meas 9 3 Diagnosis Menu Diagnosis serves to view the following data Malfunction Malfunction me...

Страница 55: ...Sensor values Parameters Malfunction Warning Diagnosis Sensor values back back back Figure 30 Viewing sensor values example NOTE Table of standard sensor values see Sensor values for trouble free oper...

Страница 56: ...urrent parameter setting b Enter the password 8 3 Entering the password page 52 b Press Left arrow after entering the new value Menu Parameter Settings is displayed again 9 4 1 Changing the physical u...

Страница 57: ...3 Changing the response time Submenu item Response Time serves to change the response time NOTE Basic factory setting 24 s Allowable values 5 360 s The actual total response time is 30s because the p...

Страница 58: ...er the changes 4 Confirm value with Enter 5 Press the Left arrow to return to menu item Parameter Settings Parameters back 1000 ppm Measuring Range edit Enter back select Parameters back Range 01000 p...

Страница 59: ...4 6 Changing the active measuring path Submenu item Meas Distance serves to enter or change the value for the active measuring path WARNING Adjusting the value for the active measuring path can lead...

Страница 60: ...ord page 52 3 Enter the changes 4 Confirm value with Enter 5 Press the Left arrow to return to menu item Parameter Settings back Substitute 150 C External Scale Low 0 C Scale High 250 C Edit Enter Tem...

Страница 61: ...e password page 52 3 Enter the changes 4 Confirm value with Enter 5 Press the Left arrow to return to menu item Parameter Settings back Substitute 150 C External Scale Low 0 C Scale High 250 C Edit En...

Страница 62: ...PT1000 page 59 2 Enter the password see Entering the password page 52 3 Enter the changes 4 Confirm value with Enter 5 Press the Left arrow to return to menu item Parameter Settings back External Scal...

Страница 63: ...2 Enter the password see Entering the password page 52 3 Enter the changes 4 Confirm value with Enter 5 Press the Left arrow to return to menu item Parameter Settings back Substitute 0 0 Edit Enter Hu...

Страница 64: ...ter 5 Press the Left arrow to return to menu item Parameter Settings Live Zero 4 mA back Live Zero 4 mA edit Enter Analog Out back Analog Out back Analog Out Select Select Live Zero 3 mA back Analog O...

Страница 65: ...ction after a reference measure ment Factory setting 0 back Span 1 00 edit Enter Calibration back back select back Zero 0 Calibration Calibration Calibration Span 1 00 Span 1 00 Span 1 00 3 x back Spa...

Страница 66: ...eters back Median Filter Size 11 select Parameters back Median Filter Size 12 select Parameters back Median Filter Size 12 select Parameters back Size 12 Median Filter edit Enter Figure 49 Changing th...

Страница 67: ...he software version Submenu item Software Revision serves to retrieve the software version of the meas uring device and control unit NOTE This value is updated automatically when Service updates the s...

Страница 68: ...he device calibration data 9 4 14 1 Changing the device calibration parameters WARNING Endangerment of system safety through calibration parameters with incorrect settings The calibration values can b...

Страница 69: ...1 000 0712 C2 0 0712 C3 500 1234 C4 20 1234 back Select Calibration Values C2 0 0712 C3 500 1234 C4 20 1234 C1 000 0812 C2 0 0712 C3 500 1234 C4 20 1234 Calibration Values back Edit Enter C1 0 0812 C2...

Страница 70: ...vice temperature stabilizes at 60 C 0 5 C Warming up time depending on ambient conditions 30 60 minutes Press Enter to save the data when the zero adjust has completed back Calibration back Start Ente...

Страница 71: ...Enter the current ambient tempera ture Compare the measured value displayed for CO with that on the test cell setpoint value Correct deviations b The SPAN value to be set measured value displayed Nomi...

Страница 72: ...5 Deviations of the SPAN test value against the expected value can be adjusted in submenu item SPAN Parameter see Changing the calibration values page 64 6 Calculating the SPAN value to be set b Actua...

Страница 73: ...see Maintenance page 73 NOTE A restart cannot be interrupted or terminated The restart takes a few seconds An input is not possible Parameters back Reset System Maint Mode No Maintenance Test Analog O...

Страница 74: ...s to change the mA value for the analog output and then check the value output NOTE Zero Point see Setting the signal Live Zero page 62 Upper output value see Setting the signal Upper output value pag...

Страница 75: ...e parameters to the factory settings The device switches to maintenance mode LED Service goes on Parameters back Maint Mode No Maintenance Test Analog Out Test Relay maint Parameters back Reset Parame...

Страница 76: ...l complying with the safety regulations Noxious gas WARNING Health risk through contact with toxic gases The modules and devices contain enclosed potentially dangerous gases that can escape due to a d...

Страница 77: ...seat Half yearly Check electrical connections and cables Check all cables for damage Pay attention to chafe marks and kinks on cable ducts Check all electric connections for freedom from corrosion an...

Страница 78: ...e Operating Instructions SLV4 Check the hose and hose clamp Task description see Operating Instructions SLV4 Exchange the purge air filter Check fan motor noise Check the purge air heater optional Che...

Страница 79: ...ue page 62 The switching point is at 70 C or half the value of the default temperature depending on which value is lower Check the temperature sensor Sensor low signal Dust content too high outside th...

Страница 80: ...necessary Optical surfaces contaminated Clean the optical interfaces Check for free light path through the duct Receiver unit defective Exchange receiver unit IR source fault Infrared module defective...

Страница 81: ...justment screws Readjustment is only possible at the factory 4 Chopper motor plug 5 Internal plug 6 External plug 7 Receiver cable 8 LED On when voltage connected for motor and logic module 9 LED On w...

Страница 82: ...m control unit RD 5 LED Blinks when the cell disk in the receiver rotates and receives chopper signal 6 LED Blinks when the motor of the cell disk rotates 7 Line to sender 8 Outer plug in connector 9...

Страница 83: ...ply 2 Check operating voltage set 3 Check fuses in control unit 4 Check display for 24 V 5 V supply in the control unit when doing so remove the plug in terminal on the cable to the receiver when nece...

Страница 84: ...Calling up the sensor values see Viewing sensor values page 55 Table 19 Sensor values Unit Description Min value Typical value Max value V1 Signal voltage 1 0 5 V Depending on the current condi tions...

Страница 85: ...ure Substitute ______________ External ______________ Scale Low ______________ Scale High ______________ Scale High ______________ Input High ______________ Humidity Substitute ______________ Pressure...

Страница 86: ...easures 1 Open the quick release fasteners on the sender receiver unit and remove the device 2 As protective measure especially with overpressure close off the flange opening with heat resistant mater...

Страница 87: ...trolled have been taken DANGER Health hazard through contamination Depending on the composition of the gas in the measuring duct the measuring device components could be contaminated with substances w...

Страница 88: ...is recommended for longer plant standstills NOTE The analyzer must be removed from the gas duct when The optional purge air unit is taken out of operation on device versions with GMP measuring probe...

Страница 89: ...ly 1 Clean the outside of all housings the measuring probe and all other components with slightly moistened cleaning cloths A mild cleaning agent can be used 2 Protect the openings on the SR unit and...

Страница 90: ...C 55 C Conformities T V type examination Cross Duct GPP measuring probe U S EPA compliant Electrical safety EC Degree of protection IP 65 NEMA 4 Dimensions W x H x D 367 mm x 418 mm x 1 414 mm details...

Страница 91: ...with test gas Measuring distance see Dimension drawing Accuracy Pressure sensor 1 Temperature sensor 1 Process temperature 430 C Process pressure 120 200 hPa Dust load 30 g m3 Degree of protection IP6...

Страница 92: ...nu guided operation via LC display and membrane key board Version Sheet steel enclosure Dimensions W H D 200 mm 300 mm 90 mm Weight 4 3 kg Power supply Voltage 115 V 230 V AC plus 10 tolerance Frequen...

Страница 93: ...erial Type of field bus integration RS 232 Function Proprietary Service Interface PROFIBUS DP Only for AWE 2027607 CAN bus Function Internal System bus Display LC Display Status LEDs Operation Service...

Страница 94: ...probe all specifica tions in mm 13 8 Dimension drawing sender receiver unit with GPP measuring probe Figure 69 Dimensions GM901 02 sender receiver unit with GMP measuring probe all specifica tions in...

Страница 95: ...l enclosure version 210 160 381 4 345 4 300 108 102 90 Figure 70 Control unit AWE sheet steel enclosure version dimensions in mm TECHNICAL DATA 13 8008932 16YT V4 0 2022 02 SICK O P E R A T I N G I N...

Страница 96: ...imensions in mm 13 11 Dimension drawing weather hoods Weatherproof cover for sender receiver unit 532 4 5 86 450 325 282 5 12 5 170 160 Figure 72 Weather hood for sender receiver unit dimensions in mm...

Страница 97: ...air hose Per meter 5304683 Weatherproof cover for purge air unit 1 5306108 Weatherproof cover for GM901 sender receiver 2 2702407 Weather protection hood for GM901 control unit 1 4029146 Operating In...

Страница 98: ...322 300 160 200 8 Figure 73 Fitting the control unit AWE sheet steel enclosure version dimensions in mm 15 2 Overview of AWE control unit electrical connections cast metal enclosure NOTE This control...

Страница 99: ...230 V 2 Power supply 115 V 230 V 3 Potential equalization connection 4 Screw cap for power supply cable 5 Measuring transducer for PT1000 20mA 6 Terminals for wiring by customer Connect new measuring...

Страница 100: ...80 7425 E Mail enquiry my sick com Mexico Phone 52 472 748 9451 E Mail mexico sick com Netherlands Phone 31 0 30 229 25 44 E Mail info sick nl New Zealand Phone 64 9 415 0459 0800 222 278 tollfree E M...

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