GPro™ 500 TDL Series In-situ sensor convenience with

GPro™ 500 TDL Series
In-situ sensor convenience
with the power of an analyzer
Technical data
Short description
The GPro 500 TDL Series is designed for tough and challenging O2 applications. The series is highly suited
to higher demanding applications where accuracy and fast response is crucial despite a varying background gas composition and a high dust load. The GPro Series can easily be calibrated without interrupting
the process,and the purging keeps the wetted parts clean to minimize maintenance.
GPro 500 TDL
Content
Outstanding features are:
– Interference-free in-situ measurement technology
– Easy calibration without interrupting the process
– 12 month recommended verification interval
– Different probe insertion lengths to suit applications with all types of geometry, incl. DN 100 pipes
– Large selection of materials for the wetted part
– Easy installation with either one flange or, in short path setups, a perpendicular two flange design
– No pre-alignment of flanges required etc.
– Approval for hazardous areas ATEX zone 1, IECEx and FM Class 1 Div 1
– Optional direct current outputs for installation without M400.
Overview / General operation
2
Influences on the measurement / Typical applications
3
Installation examples (drawings)
4
System overview
8
Technical specifications
9
Signal cable connections
11
Wiring diagram (ATEX and US version)
12
TDL configurator sheet
14
Ordering information
15
Overview / General operation
GPro™ 500 TDL Series
Overview
Process gas analyzers are used for continuous determination of the concentration of one or more gases in a gaseous
mixture. The concentration of gases in a process is decisive for the automation and optimization of processes to
ensure product quality.
The fast measurement of gas concentrations directly in the process is the main advantage of in-situ diode laser gas
analyzers. This is because in-situ analytical procedures feature physical measurements directly in the actual
process. In contrast to extractive gas analysis no sample needs to be extracted, conditioned and routed into the analyzer via a sample line. Alternatively the GPro 500 can be installed in a bypass line with respect to process accessibility for manual intervention, process temperature, pressure and/or geometry of the measurement location. An
analyzer carrying out in-situ measurements must always take into account changing process conditions and be able
to automatically compensate for them. Therefore, accurate temperature and pressure compensation is highly recommended. Also, extreme ruggedness of the system is important since it is in direct contact with the process gas.
The GPro 500 gas analyzer offers compact, probe type, service-friendly design with simple operation and exceptional performance data. It is extremely rugged, requires little maintenance and provides high availability. The GPro
500 remains uninfluenced by a wide range of process temperatures and/or varying concentrations of dust (particles)
in the gas. These features, together with fast measurements mean that diode laser gas analysis with the GPro 500
is a very valuabla alternative to established extractive methods.
General operation
GPro Series is a gas analyzer employing a unique, three-line molecular absorption spectroscopy called SpectralD™.
A diode laser emits a beam of near-infrared light, which passes through the process gas and is then reflected back
into the detector by an optical device that is situated and the end of the probe. The wavelength of the laser diode output is tuned to a gas specific absorption line. The laser continuously scans the three discrete absorption lines with a
very high spectral resolution. For analysis, absorption, strength and line shape of the return signal is used. The influence of cross interferences from background gases is negligible, since the wavelength specific laser light is absorbed
very selectively by only one specific molecule. The minimum detectable limit, the accuracy and the resolution is
dependent on the probe length (optical path length), the process temperature and pressure.
2
Influences on the measurement / Typical applications
GPro™ 500 TDL Series
Influences on the measurement
Dust load
As long as the laser beam is able to generate a signal for the detector, the dust load of the process gases does not
influence the analytical result. By amplifying the signal automatically, measurements can be carried out without any
negative impact. The influence from high dust load is complex and is dependent on the optical path length (probe
length), particle size and particle size distribution. At longer path lengths the optical attenuation increases rapidly.
Smaller particles also have a significant impact on the optical attenuation: the smaller the particles are, the more difficult the measurement will be. For high dust load applications, please consult your local METTLER TOLEDO representative.
Temperature
The temperature influence on an absorption line must be compensated for. An external temperature sensor can be
connected to the GPro 500. The signal is then used to correct the measurement results. Without temperature compensation the measurement error caused by process gas temperature changes affects the measurement substantially. Therefore, in most cases an external temperature signal is recommended.
Pressure
The process gas pressure affects the line shape of a molecular absorption line and influences the measurement
results. An external pressure sensor can be connected to the GPro 500. When the correct process gas pressure is
supplied, the GPro 500 uses a special algorithm to adapt the line shape and effectively compensate for the pressure
influence as well as the density effect. Without compensation the measurement error caused by process gas pressure changes is substantial. Therefore, in most cases an external pressure signal is recommended.
Cross interference
Since the GPro 500 derives its signal from one or more fully-resolved molecular absorption lines, cross interference
from other gases is eliminated. The GPro 500 is therefore able to measure the desired gas component very selectively.
Note
Always take great care when choosing the measurement location. Positions where there are fewer particles, the temperature is lower or there is a more suitable process pressure, are recommended. The more optimized the measurement location is, the better the overall performance of the system will be. For advice on the optimal measurement
location, please contact your local METTLER TOLEDO representative.
Typical applications
Industry
Chemical
Petrochemical
Refining
Power
Hazardous waste
Tank farms / Vapor recovery
Safety Control
•
•
•
–
–
•
Process Control
•
•
•
•
•
–
3
Installation examples (drawings)
GPro™ 500 TDL Series
Installation examples
Dimensions of the
290 mm probe
175,5 (6.91")
254 (10")
½" NPT
G ¼"
307 (12,09") 1
290 (11.42") 2
190 (7.48") 3
90 (3.54")
100 (3.94") 4
100 (3.94")
G ¼"
50 (± 0,3 mm)
(19.68 [± 0.01"])
Definition of the lengths:
➊ Nominal path length, the default length when GPro 500 is delivered. It corresponds to the effective path length
without purging.
➋ Probe length, the physical length of the probe.
➌ Insertion length, part of the probe that has to protrude into the pipe for effective purging.
➍ Effective path length, when configuring the GPro 500 with the M400, the double value of the effective
path length must be keyed in (2⫻effective path length).
4
Installation examples (drawings)
GPro™ 500 TDL Series
Installation examples
Dimensions of the
390 mm probe
½" NPT
G ¼"
407 (16.03”) 1
390 (15.35”) 2
290 (11.42”) 3
90 (3.54”)
200 (7.87”) 4
100 (3.94”)
G ¼"
50 (± 0,3 mm)
(19.68 [± 0.01"])
Definition of the lengths:
➊ Nominal path length, the default length when GPro 500 is delivered. It corresponds to the effective path length
without purging.
➋ Probe length, the physical length of the probe.
➌ Insertion length, part of the probe that has to protrude into the pipe for effective purging.
➍ Effective path length, when configuring the GPro 500 with the M400, the double value of the effective
path length must be keyed in (2⫻effective path length).
5
Installation examples (drawings)
GPro™ 500 TDL Series
Installation examples
Dimensions of the
590 mm probe
½" NPT
G ¼"
607 (23.90”) 1
590 (23.23”) 2
490 (19.29”) 3
90 (3.54”)
Definition of the lengths:
➊ Nominal path length, the default
length when GPro 500 is delivered.
It corresponds to the effective path
length without purging.
➋ Probe length, the physical length
of the probe.
➌ Insertion length, part of the probe
that has to protrude into the pipe
for effective purging.
➍ Effective path length, when configuring the GPro 500 with the
M400, the double value of the
effective path length must be keyed
in (2⫻effective path length).
400 (15.75”) 4
100 (3.94”)
G ¼"
6
50 (± 0,3 mm)
(19.68 [± 0.01"])
Installation examples (drawings)
GPro™ 500 TDL Series
Installation examples
Required flanges for some typical configurations
➊ Nominal
Pipe size
Number of
➋ Probe
➌ Insertion
➍ Effective
path length
length
length
path length *
DN / SPS
flanges
307 mm / 12.09" 290 mm / 11.42" 190 mm / 7.48" 100 mm / 3.94"
100 mm / 3.94"
2
307 mm / 12.09" 290 mm / 11.42" 190 mm / 7.48" 100 mm / 3.94"
150 mm / 5.91"
2
307 mm / 12.09" 290 mm / 11.42" 190 mm / 7.48" 100 mm / 3.94"
200 mm / 7.87"
1
407 mm / 16.02" 390 mm / 15.35" 290 mm / 11.42" 200 mm / 7.87"
200 mm / 7.87"
2
407 mm / 16.02" 390 mm / 15.35" 290 mm / 11.42" 200 mm / 7.87"
250 mm / 9.84"
2
407 mm / 16.02" 390 mm / 15.35" 290 mm / 11.42" 200 mm / 7.87"
300 mm / 11.81" 1
607 mm / 23.09" 590 mm / 23.23" 490 mm / 19.29" 400 mm / 15.75" 300 mm / 11.81" 2
607 mm / 23.09" 590 mm / 23.23" 490 mm / 19.29" 400 mm / 15.75" 400 mm / 15.75" 2
607 mm / 23.09" 590 mm / 23.23" 490 mm / 19.29" 400 mm / 15.75" 500 mm / 19.69" 2
607 mm / 23.09" 590 mm / 23.23" 490 mm / 19.29" 400 mm / 15.75" 600 mm / 23.62" 1
* When configuring the GPro 500 with the M400, the double value of the effective path length must be keyed in
(2⫻effective path length).
min. clearance: 61,5 mm
(schedule 40)
min. clearance: 77,5 mm
(schedule 80)
100 mm
(4")
100 mm
(4")
DIN 50 or ANSI 2"
Two flange configuration
100 mm
(4'')
100 mm
(4'')
300 mm
(11.81'')
100 mm
(4'')
One flange configuration
DIN 65 or ANSI 2½"
Example of by-pass configuration.
7
System overview
GPro™ 500 TDL Series
System overview
The GPro Series consists of four main components:
(optional)
➊ Sensor head
The combined transmitter and receiver unit is called the sensor head. This part contains the laser, optics and all the
electronics for laser control, signal processing, line locking, detector electronics, etc. The sensor head has an Ethernet interface for high level maintenance by the use of METTLER TOLEDO Process Analytics specific software.
All parts of the sensor head is non-wetted and never gets in contact with the process. If this feature has been selected
when purchasing the analyzer, the GPro 500 can also provide 2x 4…20 mA passive analog outputs directly from
the sensor head.
➋ Insertion probe
The probe exists in several standard versions where both material of construction and insertion length can be customized to particular needs.
Material of construction
Metallic Parts
Glass, Optics
O-rings, Gaskets
1.4404 (comparable to 316L), Hastelloy C22
AR coated Quartz, AR coated Borosilicate
Kalrez® 6375, Graphite
Probe lengths
290 mm / 11.42"
390 mm / 15.35"
590 mm / 23.23"
Other materials of construction as well as different probe lengths are available upon request.
➌ M400 type 3 transmitter
The M400 is the GPro 500 user interface. Using the M400, the user can set the necessary parameters for operation,
and control the alarm and I / O setup. The M400 will also display the measured gas concentration, the process temperature and pressure as well as the transmission (signal quality / strength). It features class 1 Div 2 FM approval
(ATEX zone 2) and four active 4 – 20 mA analog outputs.
➍ Junction box
A junction box is required between the sensor head and the M400. An existing junction box can be used, or one can
be ordered as an accessory. The 4 – 20 mA signals for temperature and pressure compensation are connected to the
sensor's head through the junction box. The Ethernet interface can be accessed through the junction box as well.
8
Technical specifications
GPro™ 500 TDL Series
Technical specifications
Measurement
Effective path length
(EPL)
Detection limit
Display units
Accuracy
Linearity
Resolution
Drift
Sampling rate
Response time (T90)
Repeatability
100, 200, and 400 mm (3.94", 7.87", and 15.75")
When configuring the GPro 500 with the M400, the double value of the effective
path length must be keyed in (2 ⫻ effective path length).
0.01 % Vol (100 ppm-v) with 1 m path length and ambient standard conditions
(no dust load, dry gas, O2 in N2)
ppm-v, % Vol O2
2 % of reading or 100 ppm, whichever is bigger
Better than 1%
< 0.01% Vol O2 (100 ppm-v)
Negligible (< 2 % of measuring range between maintenance intervals)
1s
O2 in N2 21% → 0 % in < 2 s
± 0.25 % of reading or 0.05 % O2, whichever is greater
Electrical inputs & outputs
Communication interface
RS 485 (to transmitter) or direct current outputs (optional)
Service interface
Ethernet (to PC) as direct service interface for FW updates (not using the M400
transmitter), for off-line diagnostics and configuration database up / download
Memory slot interface
SD card reader / writer for data retrieval (measurement & diagnostics), FW update
and remote diagnostics (configuration file up / download) (to be accessed using
Ethernet port). Space for data storage: 4 GB.
Analog outputs (on M400) 4 ⫻ 4 – 20 mA (22 mA): process temperature, pressure, % conc, % transmission
Number of direct
2 (optional)
analog outputs
Current outputs
Passive 4…20 mA outputs, galvanically isolated, alarms to 3.6 mA or 22 mA
conform to NAMUR NE43 guidelines
Measurement error
Non-linearity < ± 0.002 mA over the 1 to20 mA range
through analog outputs
Offset error < ± 0.004 mA (zero scale)
Gain error < ± 0.04 mA (full scale)
Analog output configuration Linear
Load
Max 500 Ohms
Hold mode input
Yes, via Ethernet (using the MT-TDL suite)
Analog inputs
2 ⫻ 4 – 20 mA (passive) for pressure and temperature (optional: fixed values)
Display
On M400, see M400 technical datasheet
Relays
4 relays (on M400)
Power supply
24 VDC, 0.2 A, > 5 W
Fuse
1 A slow blow type FC
Calibration
Calibration (factory)
Calibration (user)
Full calibration
One-point and process calibration
9
Technical specifications
GPro™ 500 TDL Series
Operating conditions
Temperature range process
0 … +250 °C (+ 32 … +482 °F)
optional: 0 … +600 °C (+ 32 … 1112 °F) with additional Thermal Barrier
Ambient temperature range – 20 … +55 °C (– 4 … +131 °F) during operation;
– 40 … +70 °C (– 40 … +158 °F) during transport and storage (< 95 % non-condensing humidity)
Pressure
Measuring: 0.8 bar – 5 bar (abs) / 11.6 psi – 72.52 psi (abs)
Design: 25 bar (abs) / 362.6 psi (abs)
Max. dust load @ nom. EPL Application dependent
Temperature & pressure
Using analog 4 … 20 mA input signals or manually set values in M400
compensation
(menu configure / measurement). Automatic plausibility check of analog inputs
Installation
Flange size
Warm up time
Purging
Process side purging
Instrument side purging
Corner cube purging
DN50 / PN25 or ANSI 2"/ 300 lbs
Typically < 1 minute
Nitrogen, > 99.7 % purity (minimum recommended), 0.5 … 5 L / min (any other
”O2 free” clean and dry gas can be used, the purity requirements are: conform to
standard set by ISO 8573.1, class 2–3, analog to instrument air)
Yes, flow < 0.5 L / min
Yes, via process side purging
ISM
ISM diagnostics parameters % Transmission (available as a 4 … 20 mA Analog output)
Window fouling ( TTM: Time to Maintenance)
Laser lifetime ( DLI: Dynamic Lifetime Indicator)
Alarms
Alarm triggers
Too low transmission (min. transmission value to be set in M400 menu Config / ISM
setup)
All alarms (incl SW/HW errors etc) listed into Chapt 8.5.1 of manual M400
Mechanical specifications
Insertion length
Total length
Weight
Insulation / rating
190 – 490 mm / 7.48" – 19.29"
530 – 900 mm / 20.87" – 35.43", depending on probe length
12 – 14 kg / 26 – 30 lbs, depending on probe length
IP 65 / NEMA Type 4X
Data logger
Function
Interval
Format
Logging of all sensor data on SD card
Freely selectable using the METTLER TOLEDO TDL software (on documentation CD)
SPC
Certificates
Quality certificate (final inspection), Material certificate 3.1,
ATEX II 1/2G – Ex op is / [op is T6 Ga] d IIC T6 Ga/Gb,
ATEX II 1/2D – Ex op is / [op is T86°C Da] t b III C T86°C Da/Db,
IECEx, FM, CE, PED, IP 65, NEMA 4X
10
Signal cable connections
GPro™ 500 TDL Series
Signal cable connections
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
2
Signal
Power + 24 V
GND (Power)
RS 485 A
RS 485 B
RS 485 GND
4 … 20 mA pos
4 … 20 mA neg
4 … 20 mA pos
4 … 20 mA neg
+ 24 V
Out 1
Out 2
TX+
TX–
RX+
RX–
3
4
5
6
Description
Power 24 V, 5 W
Interface M400 (RS 485)
Current input temperature
Current input pressure
Passive analog outputs
Ethernet
1
7
Cable no.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Connections in the junction box
➊ Connections to the GPro 500 –
Cable numbers below
➋ Power from an external source or
optionally from the M400
➌ RS 485 from the M400
➍ 4 … 20 mA from temperature
sensor
➎ 4 … 20 mA from pressure sensor
➏ Direct analog outputs (optional)
➐ Ethernet
Color
Red
Blue
Green
Yellow
Brown
Purple
Black
Pink
Grey
Red / blue
Grey / pink
White
White / yellow
Yellow / brown
White / green
Brown / green
11
Wiring diagram (ATEX and US version)
GPro™ 500 TDL Series
Active analog inputs (ATEX and US version)
ACTIVE ANALOG INPUTS
GND
24 VDC
User-provided
Pressure
GND
24 VDC
Brown/Green
BROWN/GREEN
White/Green
WHITE/GREEN
Yellow/Brown
YELLOW/BROWN
White/Yellow
WHITE/YELLOW
White
WHITE
Grey/Pink
GREY/PINK
Red/Blue
RED/BLUE
Grey
GREY
Pink
PINK
Black
BLACK
Purple
PURPLE
Brown
BROWN
Yellow
YELLOW
Green
GREEN
24 VDC
GND
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Junction Box
Red
RED
Blue
BLUE
Temperature
Ethernet
Analog
1WVRWVU|||
Power
1
24 VDC
2
3
4
5
6
7
8
GND
RS-485 A
RS-485 B
RS-485 GND
+Ain 1 4…20 mA
–Ain 1 4…20 mA
+Ain 2 4…20 mA
–Ain 2 4…20 mA
24 VDC
Aout 1
Aout 2
TX+
TX–
RX+
RX–
9
10
11
GND
12
13
14
15
16
RS-485
20 – 30 VDC or
100 – 230 VAC +/– 10%
Wiring diagram with active analog outputs (ATEX and US version).
12
24 VDC Power 0.2 A (5W)
M400 TB4
6GORGTCVWTGUGPUQT||
2TGUUWTGUGPUQT||||
2x 4…20 mA
passive analog outputs
Ethernet
RS-485 GND
RS-485 B
RS-485 A
Wiring diagram (ATEX and US version)
GPro™ 500 TDL Series
Loop-powered analog inputs (ATEX and US version)
Wiring diagram with loop-powered analog inputs (ATEX and US version).
13
Gas analyzer GPro product key
GPro™ 500 TDL Series
Gas analyzer GPro product key
Gas Analyzer
GPro™ 500 – Y Y Y Y Y Y Y Y Y Y Y Y
* Other configurations upon request
Hazardous Area Approvals
ATEX Ex d, IECEx
A T
U S
FM Class 1 Div 1
Process Windows*
Standard (AR-coated Borosilicate)
B
High temperature (AR-coated Quartz)
Q
Process O-rings*
Standard (Kalrez)
K A
High temperature (Graphite)
G R
Wetted Materials*
1.4404 (comparable to 316L)
4 4 0 4
Hastelloy
C 2 2 –
Probe length*
290 mm / 11.42"
2 9 0
390 mm / 15.35"
3 9 0
590 mm / 23.23"
5 9 0
Process connection*
ANSI 2''/300 lbs
DIN DN50/PN25
Thermal Barrier*
No thermal barrier (for temperatures
up to 250 ºC / 482°F)
With thermal barrier (for temperatures
up to 600 ºC / 1112°F)
Gas to measure
Oxygen
Interface
RS 485 (for M400)
RS 485 and direct analog outputs
14
Y Y Y Y Y Y – Y Y
–
–
–
A 0 3
D 1 2
S T
H T
A
X
A
Ordering information
GPro™ 500 TDL Series
Ordering information
Accessories
Thermal barrier
Junction box
Purging box for M400 Ex d
O2 Calibration kit
Gasket for process flange
Check valve
Order no.
30 034 138
30 034 149
30 034 148
30 034 139
To be provided by the user (82.14 ⫻ 3.53 mm)
To be provided by the user
Spare parts
Window Module Q GR 4404 D12
Window Module Q GR 4404 A03
Window Module B KA 4404 D12
Window Module B KA 4404 A03
Window Module Q GR C22 D12
Window Module Q GR C22 A03
Window Module B KA C22 D12
Window Module B KA C22 A03
Order no.
30 032 364
30 032 365
30 032 366
30 032 367
on request
on request
on request
on request
Spare parts
O2 Corner Cube Module B 4404
O2 Corner Cube Module Q 4404
O2 Corner Cube Module B C22
O2 Corner Cube Module Q C22
Kit Flat gasket ST
Kit Flat gasket HT (Graphite)
Cable GPro 500 ATEX, FM 5 m
Cable GPro 500 ATEX, FM 15 m
Cable GPro 500 ATEX, FM 25 m
Order no.
30 038 091
30 038 092
on request
on request
30 080 914
30 080 915
30 077 735
30 077 736
30 077 737
15
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Russia
Mettler-Toledo Vostok ZAO
Sretenskij Bulvar 6/1
Office 6
RU -101000 Moscow
Phone +7 495 621 56 66
Fax
+7 495 621 63 53
e-mail inforus@mt.com
Singapore
Mettler-Toledo (S) Pte. Ltd.
Block 28
Ayer Rajah Crescent # 05-01
SG -139959 Singapore
Phone +65 6890 00 11
Fax
+65 6890 00 12
+65 6890 00 13
e-mail precision@mt.com
Slovakia
Mettler-Toledo s.r.o.
Hattalova 12 / A
SK - 831 03 Bratislava
Phone +421 2 4444 12 20-2
Fax
+421 2 4444 12 23
e-mail predaj@mt.com
Slovenia
Mettler-Toledo d.o.o.
Pot heroja Trtnika 26
SI -1261 Ljubljana-Dobrunje
Phone +386 1 530 80 50
Fax
+386 1 562 17 89
e-mail keith.racman@mt.com
South Korea
Mettler-Toledo (Korea) Ltd.
Yeil Building 1 & 2 F
124-5, YangJe-Dong
SeCho-Ku
KR -137-130 Seoul
Phone +82 2 3498 3500
Fax
+82 2 3498 3555
e-mail Sales_MTKR@mt.com
Spain
Mettler-Toledo S.A.E.
C / Miguel Hernández, 69-71
ES - 08908 L’Hospitalet de Llobregat
(Barcelona)
Phone +34 902 32 00 23
Fax
+34 902 32 00 24
e-mail mtemkt@mt.com
Sweden
Mettler-Toledo AB
Virkesvägen 10
Box 92161
SE -12008 Stockholm
Phone +46 8 702 50 00
Fax
+46 8 642 45 62
e-mail sales.mts@mt.com
Switzerland
Mettler-Toledo (Schweiz) GmbH
Im Langacher
Postfach
CH - 8606 Greifensee
Phone +41 44 944 45 45
Fax
+41 44 944 45 10
e-mail salesola.ch@mt.com
Thailand
Mettler-Toledo (Thailand) Ltd.
272 Soi Soonvijai 4
Rama 9 Rd., Bangkapi
Huay Kwang
TH -10320 Bangkok
Phone +66 2 723 03 00
Fax
+66 2 719 64 79
e-mail
MT-TH.CustomerSupport@mt.com
USA / Canada
Mettler-Toledo Ingold, Inc.
36 Middlesex Turnpike
Bedford, MA 01730, USA
Phone
+1 781 301 8800
Freephone +1 800 352 8763
Fax
+1 781 271 0681
e-mail
mtprous@mt.com
certified
Management System
certified according to
ISO 9001 / ISO 14001
Subject to technical changes.
03/2013. © Mettler-Toledo AG
Printed in Switzerland. 30 031 663
Mettler-Toledo AG, Process Analytics
Im Hackacker 15, CH - 8902 Urdorf, Switzerland
Phone + 41 44 729 62 11, Fax +41 44 729 66 36
www.mt.com/pro