GPro 500 Quick Setup Guide

Transcription

1 GPro 500 Qick Setp Gide

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3 GPro 500 Qick Setp Gide Content 1 Preparation 5 Packing content 5 Site Reqirements 5 Ambient operating conditions 5 What yo also need 5 Optional accesssories Before the installation Flange placement Flange reqirements Flow conditions at measring point Prging 9 Prging with thermal barrier 10 Gronding and wiring (ATEX) 11 Active analog inpts (ATEX Version) 1 Loop powered analog inpts (ATEX) 1 Gronding and wiring (FM) 1 Active analog inpts (FM Version) 15 Loop powered analog inpts (FM Version) 1 GPro 500 cables 1 Cable connections in M00 19 Installation 0 General Setp (applies for all parameters) 0 Channel Selection 0 Calibration 0 TDL Installation 0 Setting the correct process side prging Verification and Maintenance One-point calibration for TDL oxygen sensors Process calibration for TDL oxygen sensors Calibration sing a calibration cell 5 5 Error messages

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5 1 Preparation Packing content Site Reqirements Ambient operating conditions What yo also need GPro 500 Tnable Diode Laser Analyzer 1 Safety Instrction 1 Docmentation CD with Instrction manal and MT-TDL Software Site., 5 W for power spply of the GPro /0 VAC for the power spply of M00 Nitrogen, > 99.% prity (minimm recommended), L /min (any other O free clean and dry gas can be sed, the prity reqirements are: conform to standard set by ISO 5.1, class, analog to instrment air) C ( +11 F) dring operation 1 M00 T Transmitter (p / n 51150) 1 Ethernet cable CAT5 RS 5 cable (< 50 m) 1 Laptop (WinXP / / ) with MT-TDL software installed Flat gasket.1x.5 mm Check valve pcs open-end wrenches (spanners) for M1 bolts 1 pcs Allen key 5 mm for the locking screws on flanges and Tx lid screws 1 pcs Allen key mm for the RS cover screws Flat keys for Swagelok 1 pcs flat screwdriver.5 mm for electrical connections 1 pcs flat ( mm) or cross head (No ) screwdriver for Rx lid screws Adjstable wrench (spanner) for prge connections Torqe wrench for FM version 5

6 Optional accesssories Accessory Order nmber Thermal barrier Jnction box Prging box for M00 Ex d O Calibration kit Kit Flat gasket ST Kit Flat gasket HT (Graphite) Cable GPro 500 ATEX, FM 5 m Cable GPro 500 ATEX, FM 15 m 0 0 Cable GPro 500 ATEX, FM 5 m 0 0

7 Before the installation Flange placement 0 cm (. ) 0 cm (. ) The TDL head shold be easily accessible. A person shold be able to stand in front of it and adjst the M1 fixing bolts sing two standard spanners. There shold be at least 0 cm free space measred from the flange fixed to the stack and otwards as shown below. Flange reqirements min. clearance: 1,5 mm (schedle 0) min. clearance:,5 mm (schedle 0) DIN 50 or ANSI " 100 mm (") DIN 5 or ANSI ½"

8 DIN DN50/PN5 min. Ø 5 mm DN100 min. Ø mm DN5/PN5 DN 50 DN5 100 mm 100 mm ANSI ANSI "/00 lbs " ".5" min..1" min.." ANSI.5"/00 lbs " " Flow conditions at measring point When deciding the placement of the GPro 500 TDL in the process, we recommend a minimm of 5 stack diameters of straight dct before and stack diameters of straight dct after the point of measre. This will lead to laminar flow conditions which is favorable for stable measrement conditions.

9 Prging 0 1 L /min 0 10 L /min Pressre reglator Rotameter 1 Prge gas inlet for instrment side ( mm or ¼" tbe fitting). Prge gas inlet for process side (mst have a check valve). Prge gas otlet for instrment side ( mm or ¼" tbe fitting). Process gas flow. 5 Region that defines the bondaries of the effective path length. WARNING Always start prging at maximm flow before starting the process. WARNING Prging mst always be switched on in order to avoid dst deposition onto the optical srfaces. WARNING Do not remove and / or disassemble the prge gas inlet for processes (). If disassembled, the PED pressre certificate is void. WARNING Do not connect instrment and process side prging in series, otherwise when disassembling the sensor heat the probe prging will stop. 9

10 Prging with thermal barrier 1 Prging configration 1 Prge gas inlet for thermal barrier ( mm or ¼ tbe fitting) Prge gas otlet for thermal barrier ( mm or ¼ tbe fitting) Prge gas inlet for process side (Mst have a check valve) Mandatory check valve (to be spplied by the ser) WARNING The prge gas for the thermal barrier mst always be trned on when the process is rnning in order to protect the sensor head from permanent damage. WARNING The failre of the instrment side and thermal barrier prging system mst trigger an alarm. This alarm has to be implemented in th DCS ny the ser. 10

11 Gronding and wiring (ATEX) External earth point for > mm cables (M x 1) Exernal earth point. 11

12 Active analog inpts (ATEX Version) User-provided ACTIVE ANALOG INPUTS + xt Pressre 100 mm (") Temperatre Red Ble Green Yellow Brown Prple Black Pink Grey Red/Ble Grey/Pink White White/Yellow Yellow/Brown White/Green Brown/Green + xt Jnction Box Analog Otpts Ethernet TB M00 Power L N RS-5 A RS-5 B RS-5 +Ain 1 0 ma Ain 1 0 ma +Ain 0 ma Ain 0 ma Aot 1 Aot TX+ TX RX+ RX Power 0. A (5W) M00 TB Temperatre sensor Pressre sensor x 0 ma passive analog otpts Ethernet RS-5 RS-5 B RS-5 A RS VDC or VAC +/ 10% 1

13 Loop powered analog inpts (ATEX) User-provided SENSOR IN xt Pressre Temperatre Red Ble Green Yellow Brown Prple Black Pink Grey Red/Ble Grey/Pink White White/Yellow Yellow/Brown White/Green Brown/Green Jnction Box mm (") SENSOR IN xt Analog Otpts Ethernet TB M00 Power L N RS-5 A RS-5 B RS-5 Sensor In Sensor In Aot 1 Aot TX+ TX RX+ RX Power 0. A (5W) M00 TB Temperatre sensor Pressre sensor x 0 ma passive analog otpts Ethernet RS-5 RS-5 B RS-5 A RS VDC or VAC +/ 10% WARNING All openings have to be closed with certified cable glands or blocking plgs of the same degree of certification as the GPro 500. WARNING It is essential that yo observe all provided information and warnings. The system mst be closed and gronded before switching on the system. 1

14 Gronding and wiring (FM) External earth point for > mm cables (M x 1) Exernal earth point. Protective gronding Material: chromated AISiMg0. Size: Mx1 mm options for inner protective gronding Material: 1.0 (AISI 1L) Size: Mx mm Hex cap screw Connect with mm cable Protective gronding. 1

15 Active analog inpts (FM Version) User-provided ACTIVE ANALOG INPUTS + xt Pressre 100 mm (") Temperatre Red Ble Green Yellow Brown Prple Black Pink Grey Red/Ble Grey/Pink White White/Yellow Yellow/Brown White/Green Brown/Green + xt Jnction Box Analog Otpts Ethernet TB M00 Power L N RS-5 A RS-5 B RS-5 +Ain 1 0 ma Ain 1 0 ma +Ain 0 ma Ain 0 ma Aot 1 Aot TX+ TX RX+ RX Power 0. A (5W) M00 TB Temperatre sensor Pressre sensor x 0 ma passive analog otpts Ethernet RS-5 RS-5 B RS-5 A RS VDC or VAC +/ 10% 15

16 Loop powered analog inpts (FM Version) User-provided SENSOR IN xt Pressre Temperatre Red Ble Green Yellow Brown Prple Black Pink Grey Red/Ble Grey/Pink White White/Yellow Yellow/Brown White/Green Brown/Green Jnction Box mm (") SENSOR IN xt Analog Otpts Ethernet TB M00 Power L N RS-5 A RS-5 B RS-5 Sensor In Sensor In Aot 1 Aot TX+ TX RX+ RX Power 0. A (5W) M00 TB Temperatre sensor Pressre sensor x 0 ma passive analog otpts Ethernet RS-5 RS-5 B RS-5 A RS VDC or VAC +/ 10% 1

17 GPro 500 cables Signal Description Cable no. Color TB1 TB Jnction Box Pin no Pin no Power + V 1 Red 1 Power V, 5 W (Power) Ble RS 5 A Green Interface M00 RS 5 B Yellow (RS 5) RS 5 5 Brown ma pos Crrent inpt Prple...0 ma neg temperatre Black...0 ma pos Crrent inpt Pink...0 ma neg pressre 9 Grey 9 + V Direct anolog otpt 10 Red/Ble 10 Ot 1 (x 0 ma) 11 Grey/Pink 11 Ot (optional) 1 White 1 TX+ 1 White/Yellow 1 Ethernet interface TX 1 Yellow/Brown for commnication RX+ 15 White/Green with PC RX 1 Brown/Green 1

18 TB1 Pin 1 Pin Connections on motherboard in the sensor head. Note: The sensor head cover of ATEX version shold never been opened, as this will invalidate the ATEX certification. TB Pin 1 Pin 1 Connections on IO board in the sensor head. WARNING All openings have to be closed with certified cable glands or blocking plgs of the same degree of certification as the GPro 500. WARNING It is essential that yo observe all provided information and warnings. The system mst be closed and gronded before switching on the system. 1

19 Cable connections in M00 USB TB N L POWER TB TB TB 1 Connection terminal for the power cable TB connection terminal for the GPro 500 TB1 connection terminal for the relays. These can be configred with the M00. 19

20 Installation General Setp (applies for all parameters) (PATH: Men / Qick Setp) MENU Qick Setp 0.9 %V O 5.0 C While in Measrement mode press the [MENU] key to bring p the Men selection. Select Qick Setp and press the [ENTER] key. Display Convention: 1st line on display a nd line on display b rd line on display c th line on display d Select the nits of measrement for a and b. Only lines a and b can be configred in Qick Setp. Go to the Configration Men to configre lines c and d. A.0 ph A 5.0 C Channel Select=ISM Parameter=Ato Channel Selection Please select the type of Sensor: Analog: For conventional analog sensors (will be displayed on channel A ). ISM: For ISM sensors (will be displayed on channel B ). Please select the parameter reqirement: The choice of parameter depends on the level of transmitter. If an ISM sensor is selected, the setting Ato means, all possible ISM sensors will be recognized and accepted. If a special parameter is chosen, only this parameter will be recognized and accepted on the transmitter. Calibration The GPro 500 is calibrated at the factory and does not reqire calibration at installation & Startp. TDL Installation (path: Qick Setp / O TDL / Installation) B 0.9 %Trm MENU Qick Setp B 0.9 %Trm Transmission Signal 01 % While in measrement mode press the key [MENU]. Press the m or. key to select the O TDL and then the Installation men item. In this mode, the crrent live vale of the % transmission is displayed dring 5 mintes ntil it atomatically retrns to the Measrement mode. Use this vale to rotate the ble sensor head attached with a loose clamp connection on to the probe ntil the maximm transmission is fond. In this position, and secre the ble sensor head into position and tighten the clamp. 0

21 B 0.9 %Trm O TDL Commissioning B 0.9 %Trm Pressre=External B 0.9 %Trm Ain ma = 90.0 mbar Ain 0mA = 000. mbar TDL Commissioning (path: Qick Setp / O TDL / Commissioning) While in measrement mode press the key [MENU]. Press the m or. key to select the O TDL and then the Commissioning men item. First, select the type of pressre compensation selected: External: crrent external pressre vale coming from a pressre transdcer of.. 0 ma analog otpt Fixed: pressre compensation ses a fixed vale to be set manally. Note: if this pressre compensation mode is selected, a considerable gas concentration measrement error reslting from a nonrealistic pressre vale can take place. If External compensation is selected, then the minimm ( ma) and maximm (0 ma) analog otpt signals from the pressre transdcer mst be mapped to the corresponding Analog inpt of the TDL. Key in the minimm and maximm vales of the pressre in the following nits: hpa mmhg mbar psi kpa In general, METTLER TOLEDO recommends the se of absolte pressre transdcers for more accrate signal compensation over a broad pressre range. If, however, small pressre variations arond atmospheric pressre are to be expected, relative pressre sensors will prodce better reslts; bt the variations of the nderlying barometric pressre will be ignored. For relative pressre sensors, the minimm and maximm vales mst be mapped so that the TDL can interpret the analog pressre signal as absolte, i.e. a fixed barometric pressre of 101 mbar (for example) has to be added to the mapped vales. B 0.9 %Trm Pressre=fixed If Fixed compensation is selected, the fixed pressre vale with which the measrement signal will be calclated has to be keyed in manally. For the fixed pressre, the following nits can be sed: hpa mmhg mbar psi kpa B 0.9 %Trm Pressre=101. mbar B 0.9 %Trm Temperatre=External If External compensation is selected, then the minimm ( ma) and maximm (0 ma) analog otpt signals from the temperatre transdcer mst be mapped to the corresponding Analog inpt of the TDL. Key in the minimm and maximm vales of the temperatre in C. 1

22 B 0.9 %Trm Ain ma = C Ain 0mA = 50_0 C B 0.9 %Trm Temperatre=Fixed If Fixed compensation is selected, the fixed temperatre vale with which the measrement signal will be calclated has to be keyed in manally. For the fixed temperatre, only C can be sed. B 0.9 %Trm Temperatre=0.0 C B 0.9 %Trm Pathlenght=0000 mm Last, select the initial optical path length corresponding to the probe length installed: 90 mm probe: 00 mm 90 mm probe: 00 mm 590 mm probe: 00 mm This initial vale is valid when instrment prging on the instrment and on the process side is rnning. Depending on the process conditions and after the optimm of the process prging flow has been fond (see next chapter), this vale may have to be slightly adapted.

23 Setting the correct process side prging The flow rate of the prging will affect the effective path length and conseqently the measrement vale. Therefore the following procedre shold be sed. Start with a very high flow rate and gradally decrease it. The measrement vale will then start at a low vale and increase with decreasing prge flow. At some point it will level ot and stay constant for a while and then again start increasing. Choose a prge flow in the middle of the constant region. Inecreased reading 1 Decreasing prge flow Optimizing the prge flow On the x-axis there is prge flow and on the y-axis there is the instrment concentration reading. 1 Concentration reading with high prge flow. The path length is now shorter than the effective path length since the prge tbes is completely filled with prging gas and some of the prging gas is flowing into the measrement path. Concentration reading with optimized prge flow. The path length is now eqal to the effective path length since the prge tbes are completely filled with prge gas. See the illstration below. Concentration reading with no prge flow. The path length is now eqal to the nominal path length since the probe is completely filled with process gas. The optimized prge flow. WARNING Always start prging at maximm flow before starting the process. WARNING Prging mst always be switched on in order to avoid dst deposition onto the optical srfaces.

24 Verification and Maintenance One-point calibration for TDL oxygen sensors B 5.0 C Calibrate Sensor Channel B TDL H 5.0 C TDL Calibration Type = 1 Point 5.0 C Pressre = 101 hpa Temperatre =.00 C 5.0 C Press ENTER when Sensor is in Gas Enter Oxygen calibration mode as described in section.1 Enter Calibration Mode. A one-point calibration of oxygen sensors is always a slope (i.e. with air) calibration. A one point slope calibration is done in air or any other calibration gas with defined oxygen concentration. Select 1 point as calibration type. Press [ENTER]. Enter vales for the effective temperatre and pressre vales of the gas sed for calibration. When sing the calibration tbe for calibration, se vales measred manally for the gas present in the calibration tbe. Adjst the optical path length for yor individal system (). Place the sensor in the calibration gas (e.g. air). Press [ENTER]. Depending on the sed drift control (see chapter...5) one of the two following modes is active. Process calibration for TDL oxygen sensors B 1.1 %V O B 5.0 C Calibrate Sensor Channel B Oxygen B 1.1 %V O 5.0 C TDL Calibration Type = Process B 1.1 %V O B 5.0 C Press ENTER to Captre B O= V% O Enter Oxygen calibration mode as described in section.1 Enter Calibration Mode. A process calibration of oxygen sensors is always a slope calibration. Select Process as the calibration type. Press [ENTER] Take a sample and press the [ENTER] key again to store the crrent measring vale. To show the ongoing calibration process, A or B (depending on the channel) is blinking in the display. After determining the O vale of the sample press the c key again to proceed with the calibration.

25 B 1.1 %V O B 5.0 C B Point1 = 5.90 %sat B O = 5.1 %air B 1.1 %V O B 5.0 C O S= 0.00nA Z=0.0000nA Save Adjst Enter the O vale of the sample then press the [ENTER] key to start the calclation of the calibration reslts. After the calibration the slope S is displayed. In case of a sccessfl calibration, the calibration vales are stored in the cal history* and taken over (Adjst), stored in the cal history* and not taken over (Calibrate) or discarded (Abort). If Adjst or Calibrate are chosen, the message Calibration sccessfl is displayed. The M00 retrns to the measring mode. Calibration sing a calibration cell For a more accrate calibration the calibration cell can be sed. Doing this the TDL (the nits head) needs to be removed from the probe. Then it has to be monted on the calibration cell according to the illstration below. Before calibration is started new vales for path length, temperatre and pressre have to be entered on M00. Then the calibration gas is flowed throgh the calibration cell and the calibration is done in the calibration men of M00. Dring calibration with the calibration cell the process is still sealed and no extra precations need to be taken. 150 (5.91 ) EPL x100 (.9 ) 10, (.1 ) Calibration cell. 5

26 5 Error messages Message No sensor on channel Comment The M00 is nable to detect any of the ISM sensor(s) it can identify. If no sensor is fond it will disply the message NO SENSOR DETECTED Signal Processing Failed Laser Sorce Error Bad Signal Qality Fitting of the line profiles failed. The laser wavelength has shifted. Readjstment of the laser temperatre necessary Transmission lower than 5% threshold Flashcard Error Missing or bad calibration and/or database data Pressre Inpt Error Temperatre Inpt Error Configration Mode Pressre reading ot of extended range: 0. bara<p< bara 0 ma inpt error: ma>p>0 ma Pressre reading ot of extended range: 0 C<T<1000 C 0 ma inpt error: ma>p>0 ma Ethernet port in se: diagnostic or configration in progress The GPro 500 error messages can be fond in the M00 nder the following path: Men Service Diagnostics TDL Messages

27 Action Sorce Relay State Mapping This is the initial message after Power on. M00 Falt B disconnected Wait for the GPro 500 to flly boot. Check if the GPro 500 is powered and wait ntil the system is flly started. Check the RS5 wiring of the GPro 500 to the M00 Check with the MT-TDL software and the Ethernet port if the system is rnning correctly. If timeot still occrs after 0s, send nit back to METTLER TOLEDO. Send nit back to METTLER TOLEDO TDL Falt Software error Send nit back to METTLER TOLEDO TDL Falt System error Clean corner cbe and process window. TDL Falt System error Check the gasket between TDL and probe. Rotate TDL on the probe to maximize Transmission. Redce the dstload in the process. Perform a calibration with the calibration TDL Falt Software error tbe. If still not sccessfl, send nit back to METTLER TOLEDO for Flashcard exchange. Check external pressre sensor and mapping TDL Maintenance reqest System error Check external temperatre sensor and mapping TDL Maintenance reqest Disconnect Ethernet cable TDL Maintenance reqest System error Software error

28 A BR CH CN D E F J KO UK USA Mettler-Toledo Ges.m.b.H., Südrandstrasse 1, A-10 Wien Phone , Fax Mettler-Toledo Ind. e Com. Ltda., Avenida Tamboré, 1, Tamboré, BR Bareri / SP Phone , Fax Mettler-Toledo (Schweiz) GmbH, Im Langacher, Postfach, CH-0 Greifensee Phone , Fax Mettler-Toledo Instrments (Shanghai) Co. Ltd., 59 Gi Ping Road, Cao He Jing CN-00 Shanghai. Phone , Fax Mettler-Toledo GmbH, Prozeßanalytik, Ockerweg, D-59 Gießen Phone , Fax Mettler-Toledo S.A.E., C / Migel Hernández, 9-1, ES-090 L Hospitalet de Llobregat (Barcelona) Phone , Fax Mettler-Toledo, Analyse Indstrielle S.A.S., 0, Bolevard Doamont, F-501 Paris Phone , Fax + 1 Mettler-Toledo K.K., Process Division, F Ikenohata Nisshok Bldg., -9-, Ikenohata, Taito-k JP Tokyo. Phone , Fax Mettler-Toledo (Korea) Ltd., Yeil Bilding 1 & F, 1-5, YangJe-Dong, SeCho-K, KR Seol Phone , Fax Mettler-Toledo LTD, Boston Road, Beamont Leys, GB-Leicester LE 1AW Phone , Fax Mettler-Toledo, Process Analytics, Inc., Middlesex Trnpike, Bedford, MA 010, USA Phone , Fax Mettler-Toledo AG, Process Analytics Im Hackacker 15, CH-90 Urdorf, Switzerland Phone , Fax +1 9 Sbject to technical changes. Mettler-Toledo AG 05 / 01. Printed in Switzerland / pro