SICK GM901, Operating Instructions Manual

Page 1: ...MMMI MMMOPERATING INSTRUCTIONS OPERATI NG INSTRUCTIO NS GM901 Carbon Monoxide Gas Analyzer Cross Duct Version Title Page...

Page 2: ...s 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...

Page 3: ...em safety 11 2 7 Protection against hazards through gases 12 2 7 1 Protective measures against escaping gases 12 2 7 2 Noxious gases in device module 12 2 7 3 Hot gases in ambient conditions with over...

Page 4: ...weather protection hood for the GM901 30 5 7 Installing the control unit 31 6 Electrical installation 32 6 1 Project planning 32 6 2 Electrical wiring for the standard version 33 6 3 Electrical wiring...

Page 5: ...etting the sample gas pressure 63 9 3 10 Changing the Live Zero value of the analog output Analog Out 64 9 3 11 Changing the calibration values 65 9 3 12 Median Filter 66 9 3 13 Device characteristic...

Page 6: ...84 13 4 Control unit AWE standard version Part No 2020428 2021433 85 13 5 Control unit AWE with extended connectivity Part No 2027607 2084045 86 13 6 Connection unit 86 13 7 Dimension drawing sender r...

Page 7: ...tions must be observed in their currently valid version 1 3 Target groups This Manual is intended for persons installing operating and maintaining the device Operation The device should be operated ex...

Page 8: ...3 Information symbols 1 6 Data integrity SICK AG uses standardized data interfaces such as standard IP technology in its products The focus here is on the availability of the products and their proper...

Page 9: ...I ON S GM901 Subject to change without notice ABOUT THIS DOCUMENT 1 In all cases the customer is responsible for the implementation of safety measures suitable for the respective situation e g network...

Page 10: ...vice only as described in Intended use The manufacturer bears no responsibility for any other use Carry out the specified maintenance work Do not attempt any work on or repairs to the device unless de...

Page 11: ...and injury to persons Incorrect use or handling of the GM901 CO measuring device can cause personal injury or material damage Therefore in order to prevent damage the relevant safety information and v...

Page 12: ...ally dangerous gases that can escape due to a defect or leak See Table Maximum gas amounts in SICK devices for these gases Should a leakage occur the concentrations inside the closed device could rise...

Page 13: ...re starting the work on the device ensure the power supply can be switched off using a power isolating switch circuit breaker in accordance with DIN EN 61010 Make sure the power isolating switch is ea...

Page 14: ...owing Table 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 accurac...

Page 15: ...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 1 See Section 9 4 8 2 Based on 500 ppm CO the uncertainty is lower for higher concentrations Table 4 Actual process moisture at 2...

Page 16: ...alue entered 1 vol H2O Absolute difference to input value vol H2O Process temperature C Additional relative CO measurement error 2 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...

Page 17: ...PRODUCT DESCRIPTION 3 3 3 Device variants The following device variants are available depending on the measuring task and the application GM901 Standard GM901 Extended calibration Type code GM901 05...

Page 18: ...ut Fig 1 Device component overview 4 6WLYH PVU LY PJL HYUPUN 4HSM UJ PVU Purge air fixture Control unit Sender Receiver Connection unit optional Purge air unit optional Temperature sensor optional Cab...

Page 19: ...S connects the process control level e g central computer host control room to the measuring device Measured values status states and error messages are queried cyclically via the PROFIBUS The GM901 s...

Page 20: ...6 Optional accessories Connection unit for distances longer than 17 m up to 1000 m Purge air unit to protect the optical interfaces from sender and receiver Flanges Optical adjustment device CO test c...

Page 21: ...he measuring device not the optical surfaces with slightly moistened cleaning cloths Use a mild cleaning agent here Protect the openings of the sender receiver unit from atmospheric influences prefera...

Page 22: ...parts when the device tips over or drops Observe the following information to avoid such accidents Do not use protruding parts on the enclosure to carry the device apart from the wall fixture or carr...

Page 23: ...itable reinforcements or support constructions on thin walled steel ducts On easily accessible measuring distances up to 2 m the flanges with tube can be aligned using a suitable auxiliary tube for st...

Page 24: ...flange flange and dimensions for the Top marking of the fitting position Fig 4 Flange with tube standard version To align the flange with tube on site Use a tube Fig 2 or the adjustment device Fig 5 A...

Page 25: ...welding and alignment work make sure the planned flange to flange measuring distance is observed exactly when a zero path has already been ordered or delivered Otherwise the zero path must be adapted...

Page 26: ...e with tube for brick stacks 5 4 4 Assembly variant for thin walled ducts Weld junction plates on on site for reinforcement of ducts with thin walls or at fitting locations subject to vibrations Fig 8...

Page 27: ...es onto the purge air fixtures and fasten with hose clamps 3 Switch the power supply for the purge air unit on see Electrical connection of the purge air motor page 34 4 Check that purge air is availa...

Page 28: ...es Fig 10 Adjustment device option Fasten the lamp on the sender over the quick release clamps on the purge air fixture Fig 11 Optical adjustment device lamp Fasten the adjustment tube on the receiver...

Page 29: ...device on the purge air fixtures of the sender and or receiver On the sender Tighten the 2 nuts on the horizontal adjustment X and vertical adjustment Y so that the light spot is shown centered on th...

Page 30: ...g the weather protection hood for the GM901 1 Push the base plate onto the side of the flange with tube and screw it to the duct side surface of the flange plate purge air fixture with the threaded bo...

Page 31: ...Based on the control unit dimension drawing ensure enough space is available at the planned installation location for assembly as well as opening the enclosure door Fig 15 Installing the control unit...

Page 32: ...trol unit and purge air motor must be fixed on site Install and secure a separate power supply for the control unit and for the purge air unit Install a dedicated power circuit breaker switch with a m...

Page 33: ...iring for the standard version Fig 16 Electrical connections GM901 standard Connect the system components as shown in Fig 16 GM901 Operation Service Warning Malfunction Control Unit Control unit Sende...

Page 34: ...em components as shown in Fig 17 6 4 Electrical connection of the purge air motor GM 901 Operation Service Warning Malfunction Control unit Cable 15 m CAN bus Cable length 2 m CAN bus Power supply 115...

Page 35: ...n Operation Service Warning Malfunction GM901 Control Unit PE N L1 D H D CA N GN CA GN CA N 24V N L N GN CA GN CA N 24V N Analog in 0 20 mA Analog out 0 20 mA Digital out AC DC 48 V 1 A Digital in 230...

Page 36: ...ND RTS 5 RS232 Power 5V 24V Power CAN 24V H L GND Digital in Analog in 0 20mA 100 100 100 230V or 115V AO1 AO2 AO3 DI1 DI2 DI3 DO1 DO2 DO3 Digital out Analog out 0 20mA Fuse 2 5AT 250 V L1 contrast Po...

Page 37: ...inal strip ST 5 Cable length max 1000 m CAN H CAN L CAN GND Connection on the GM901 receiver terminal strip ST 6 or ST 7 Standard cable 2 m 24 V RS GND GR CAN H YE CAN L GN CAN GND BR Fuse 2 5 AT 230...

Page 38: ...ssioning 7 1 Requirements for commissioning The following work must be completed or checked again before commissioning Check the electric installation Check and function tests fan rotation direction o...

Page 39: ...901 Standard Prerequisite Only for devices with corresponding type code and temperature range see Device variants page 17 Procedure 1 Perform zero adjust see Zero adjust page 41 2 Enter the offset cor...

Page 40: ...the substitute temperature value to the actual ambient temperature see Changing the substitute temperature value page 58 3 Set Temperature Input External to No see Setting the use of an external temp...

Page 41: ...O when a sensitivity test is also planned Adjust the assembly bracket to the flange flange cell holder measure minus 85 mm of the duct measuring distance as shown in Fig 21 Align the purge air fixture...

Page 42: ...m x S m Example Result Test value of the test cell 1050 ppm m Deliverable test cell 1600 ppm m NOTE This test requires the optionally available CO cell and holder see Optional accessories page 20 TW T...

Page 43: ...tart the SPAN test see SPAN Test page 70 and follow the instructions displayed 7 3 Fitting the measuring device on the duct Remove the sender and receiver from the purge air fixtures Remove the holder...

Page 44: ...l Yes Scale Low 0 C Scale High 250 C Input Low 4 0 mA Input High 20 0 mA Humidity Substitute 00 0 Vol Pressure Substitute 1013 hPa Analog Out Live Zero 4 mA Calibration Span 1 00 Zero 000 Median Filte...

Page 45: ...35 Evaluation Uni t CO CO 2 H2O mg m3 236 Ref conditions Hum wet Enter meas diag par cal maint Measuring Enter meas maint cal par diag Operation Service Warning Malfunction 1 2 4 3 CO 564 Measuring T...

Page 46: ...easuring range start value adjustable 2000 Measuring range end value adjustable t Adjustable limit value LED Significance OPERATION Measuring mode Device is switched on Power voltage available SERVICE...

Page 47: ...enus 9 1 Measuring mode The measuring mode display is shown during active measuring operation The Operation Status LED is green Explanations of the measuring mode display see Display page 46 Display A...

Page 48: ...s Displays sensor measured values for error diagnosis 9 2 1 Viewing malfunction messages Display Action Note Press diag Display switches to Diagnosis mode Select Malfunction with Arrow down Press Ente...

Page 49: ...ing warning messages Display Action Note Press diag Display switches to Diagnosis mode Select Warning with Arrow down Press Enter Displays warning messages Press Arrow left back Displays possible warn...

Page 50: ...sis mode Select Sensor values with Arrow down Press Enter Displays sensor measured values for error diagnosis Use these data when completing the Diagnosis form Measuring T 150 C Measuring T 150 C 0 20...

Page 51: ...t value page 56 6 Meas Distance see Changing the flange flange measuring distance and the active measuring distance page 57 7 Temperature see Temperature page 58 8 Humidity see Setting the humidity co...

Page 52: ...h Enter Selects the physical unit Press Arrow left back Display returns to selection screen Parameters back back Physical Unit Physical Unit Normalization Normalization Parameter Settings back back Re...

Page 53: ...dry wet Display Action Note Select Normalization Press Enter Measured value normalization Press Enter Basic factory setting Select with Arrow right Press Enter Confirm with Enter to save new mode Pre...

Page 54: ...time by 6 s Select with Arrow right Enter new value with Arrow up or Arrow down Press Enter Confirm with Enter to save new value Press Arrow left back Display returns to selection screen Parameters b...

Page 55: ...up or Arrow down Press Enter Confirm with Enter to save new value Press Arrow left back Display returns to selection screen Parameters back Physical Unit Physical Unit Normalization Parameter Settings...

Page 56: ...right Enter new value with Arrow up or Arrow down Press Enter Confirm with Enter to save new value Press Arrow left back Display returns to selection screen Parameters back Limit Value Limit Value Mea...

Page 57: ...Arrow right Enter new value with Arrow up or Arrow down Press Enter Basic factory setting for the active measuring distance 2000 mm Confirm with Enter to save new value Press Arrow left back Display r...

Page 58: ...erature value Display Action Note Select Temperature Press Enter Exhaust gas temperature Select using Arrow down or Arrow up Press Enter Enter the substitute temperature value Further input options ar...

Page 59: ...ck Limit Value Limit Value Meas Distance Meas Distance Parameter Settings back Temperature Humidity Parameters back Substitute 150 C External AnaIn Temperature Input back Scale Low 0 C Scale High 250...

Page 60: ...up Press Enter Basic factory setting 250 C Max 500 C Select with Arrow right Enter new value with Arrow down or Arrow up Press Enter Parameters back Limit Value Limit Value Meas Distance Meas Distanc...

Page 61: ...r new value with Arrow down or Arrow up Press Enter Confirm with Enter to save new value Parameters back Limit Value Limit Value Meas Distance Meas Distance Parameter Settings back Temperature Humidit...

Page 62: ...setting 0 0 This value is used to perform a gas dryness correction Max 99 9 Select with Arrow right Enter new value with Arrow down or Arrow up Press Enter Confirm with Enter to save new value Paramet...

Page 63: ...th Arrow down or Arrow up Press Enter Confirm with Enter to save new value The pressure correction is made in ppm or Norm in the display using this value Parameters back Humidity Pressure Parameter Se...

Page 64: ...ue Possible values 0 to 4 mA Parameters back Humidity Pressure Parameter Settings back Analog Out Analog Out Calibration Parameters back Live Zero 4 mA Live Zero 4 mA Analog Out back edit Enter edit E...

Page 65: ...rement Select with Arrow right Enter new value with Arrow down or Arrow up Press Enter Confirm with Enter to save new value Press Arrow left back Display returns to selection screen Parameters back Hu...

Page 66: ...Enter The Median Filter adds 1 to 9 seconds to the response time according to the following formula Example Desired response time 20 s When Median Filter 15 15 1 2 8 s extension Enter new value Respo...

Page 67: ...Note Parameters back Number 0000000 Serial Number back edit Enter Parameters back Serial Number Serial Number Configuration Software Revision Software Revision Parameter Device back Parameters back Se...

Page 68: ...Display Action Note Select using Arrow down or Arrow up Press Enter Sensor calibration parameters Caution Changes lead to measured value deviations Press Enter These values may only be changed in spec...

Page 69: ...can be made during the calibration procedure No inputs can be made during the calibration procedure Confirm with Enter Data are saved Calibration back Zero Adjust Zero Adjust Span Test Span Test Passw...

Page 70: ...asured value displayed with the value on the test cell Deviations can be corrected with the SPAN value when necessary see Changing the calibration values page 65 The Span factor to be set is calculate...

Page 71: ...ult setting 9 5 1 Reset System Display Action Note Selectusing Arrowdown or Arrow up Press Enter Restarts the device Press Enter No input possible on the device Device is restarted Maintenance back Re...

Page 72: ...mode when Yes is selected Output relay drops out Analog output retains last value Maintenance back Reset System Reset System Test Analog Out Test Analog Out Maint Mode No Maint Mode No Test Relay Tes...

Page 73: ...down or Arrow up Press Enter NOTE Analog In can be tested using the displayed sample gas temperature Maintenance back Reset System Reset System Test Analog Out Test Analog Out Maint Mode No Maint Mod...

Page 74: ...rrow down or Arrow up Press Enter Select with Arrow right Press Enter Maintenance back Reset System Reset System Test Analog Out Test Analog Out Maint Mode No Maint Mode No Test Relay Test Relay Test...

Page 75: ...ress and acknowledge Activate Maintenance mode maint and call up the Profibus menu Perform menu item Cold Start This initializes the PROFIBUS software with the new addresses The device master file GSD...

Page 76: ...because the influences are also individual This is why the maintenance interval is typically determined based on experience 10 2 Maintenance interval of individual components of GM901 CO systems GM90...

Page 77: ...perature sensor Check parameterization see Temperature page 58 The switching point is at 70 C or half the value of the substitute temperature depending on which value is lower No action required when...

Page 78: ...ck for free light path Sensor no signal Erroneous device adjustment Optical surfaces contaminated Light path interrupted Receiver unit defective Check device alignment Clean optical surfaces Check for...

Page 79: ...s the sender to be adjusted incorrectly New adjustment only possible at the factory IR source Plug connection IR source Risk of burns The infrared lamp becomes extremely hot during operation Adjustmen...

Page 80: ...On when operation is uninterrupted LED as status indicator for optics heating On continuously Ambient temperature too high Blinks Normal operation Off Ambient temperature too low LED Communication to...

Page 81: ...in the control unit when doing so remove the plug in terminal on the cable to the receiver when necessary Check the cables first when these displays are only on when the plug connections are disconne...

Page 82: ...ol unit Cable to receiver External plug connection on receiver Internal plug connections in receiver Sensor values The sensor values shown in the Table are valid for uninterrupted steady state operati...

Page 83: ...ation Observe safety information according to VDE and national guidelines During deinstallation make sure no live lines are accessible unsecured Always insulate open cable ends with suitable auxiliary...

Page 84: ...n Sender unit of measuring system Measuring distance 0 5 m 8 0 m Process temperature 250 C standard 430 C with extended calibration Process pressure 30 hPa Depending on purge air supply Process gas hu...

Page 85: ...48 V DC 1 A 30 W Relay 1 NO contact normally open for device malfunction potential free Relay 2 NO contact normally open for limit value overrun potential free Digital inputs 1 input 24 V Serial m Typ...

Page 86: ...lly closed for limit value overrun potential free Digital inputs 3 inputs 24 V Serial m Type of field bus integration RS 232 Function Proprietary Service Interface PROFIBUS DP m Only for AWE 2027607 T...

Page 87: ...S TR UC TI ON S GM901 Subject to change without notice TECHNICAL DATA 13 13 7 Dimension drawing sender receiver unit Fig 27 Sender or receiver unit dimensions in mm 150 150 240 7 404 7 298 462 157 19...

Page 88: ...O P ERA TI N G I NS TRU CT IO N S GM901 Subject to change without notice 13 TECHNICAL DATA 13 8 Dimensional drawing control unit Fig 28 Control unit AWE sheet steel enclosure version dimensions in mm...

Page 89: ...ge without notice TECHNICAL DATA 13 13 9 Dimension drawing connection unit Fig 29 Connection unit dimensions in mm 13 10 Dimension drawing flange with tube DN125 Fig 30 Flange with tube DN125 dimensio...

Page 90: ...S TRU CT IO N S GM901 Subject to change without notice 13 TECHNICAL DATA 13 11 Dimension drawing weather protection hood sender receiver unit Fig 31 Weather protection hood for sender receiver unit di...

Page 91: ...38 Battery for real time clock in the control unit Type CR2032 Designation Quantity Part No Optical adjustment device 1 2 020 436 Assembly bracket for zero path 2 2 020 445 Purge air unit with distrib...

Page 92: ...version of the control unit complies with the following EC directives and EN standards EC Directive LVD 2006 95 EC EC Directive EMC 2004 108 EC Applied EN standards EN 61010 1 Safety requirements for...

Page 93: ...93 8008250 1F7Y V4 0 2022 06 SICK OP E RAT IN G I N S TR UC TI ON S GM901 Subject to change without notice CONFORMITIES 15...

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