GREEN INSTRUMENTS G7200 User Manual
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GREEN INSTRUMENTS G7200 User Manual

Multi gas monitoring system
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Multi Gas
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Maritime

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  • Page 1 G7200 Multi Gas Monitoring System User Manual Maritime...
  • Page 2 Email: spares@greeninstruments.com Email: service@greeninstruments.com Website: www.greeninstruments.com For safe and proper use of the G7200 Multi Gas Monitoring System, read this user manual carefully and keep it for future reference. For spare parts information, refer to the G7200 Spare Parts Catalog.

  • Page 3: Table Of Contents

    Contents Contents Introduction ......................... 6 About the System ..............................6 Proposed Field of Application .......................... 6 Technical Specifications ............................ 7 Storage and Handling ............................8 1.4.1 Storage ............................... 8 1.4.2 Handling ..............................8 Delivery Check ............................... 8 Terms and Abbreviations ..........................9 Safety ..........................
  • Page 4 G7200 Multi Gas Monitoring System User Manual 4.4.1 Modbus Map ............................25 4.4.2 Web Viewer (VNC) ..........................31 4.4.3 Remote Connection ..........................31 Commissioning ..............................31 4.5.1 Check Probes ............................32 4.5.2 Check Heated Sample Lines ......................32 4.5.3 Check System Enclosure ........................32 4.5.4...
  • Page 5 Contents MI-7200-002: Replacing the Filter Element and Glass Balls in the Filter Block ........55 MI-7200-003: Replacing Instrument Air Filters ....................58 MI-7200-004: Replacing the Gas Filter in the Sample Probe ................61 MI-7200-007: Replacing the Gas Analyzer 7010 ....................63 MI-7200-014: Checking and Replacing the Condensate Pump Hose ............
  • Page 6 G7200 Multi Gas Monitoring System User Manual List of Figures Figure 3-1 Navigation Bar ..............................13 Figure 3-2 Level 3 Password ............................. 13 Figure 3-3 Log Out ................................14 Figure 3-4 Home Page................................. 14 Figure 3-5 Home Page Example ............................15 Figure 3-6 Component Popup Example........................

  • Page 7: Introduction

    For other applications such as emissions from MGO, LNG, and biofuels the modular system configuration comes into force. By fitting the G7200 MGMS with gas analyzers based on both non- dispersive infrared (NDIR) principle and non-dispersive Ultraviolet (NDUV) principle, the system can detect a wide range of gasses among others SO2, CO2, NO2, NO, CH4, CO, N2O and H20.

  • Page 8: Technical Specifications

    G7200 Multi Gas Monitoring System User Manual 1.3 Technical Specifications NOTE: Specifications are subject to change without notice. G7200 MGMS Type G7200 Function  Monitoring of CO2, SO2, NO2, NO, CH4, CO, N2O, H2O, and other relevant gasses. Equipment including  Analyzer modules, gas cooler, gas pump (s), condensate pump(s), gas filtration system, flow transmitter, solenoid valves, air filter regulator and oil/particle separator, air dryer, HMI, PLC. ...

  • Page 9: Storage And Handling

    Introduction Electrical connection probe end 2 pre-configured plugs for temp. alarm and power Electrical connection monitoring 2 pre-configured connectors on the hose cabinet Ambient temperature Probe 5°C to 55 °C (optional outdoor probe available on request.) Ambient temperature Hose -20°C to 55 °C Humidity RH up to 96% at all relevant temperatures Vibration...

  • Page 10: Terms And Abbreviations

    G7200 Multi Gas Monitoring System User Manual Check for missing parts against the packing list. Any discrepancies or damage should be reported to Green Instruments A/S immediately. 1.6 Terms and Abbreviations The following table lists terms and abbreviations used in this user manual.

  • Page 11: Safety

    This manual uses the following symbols to identify essential information related to the correct and safe operation of the G7200 MGMS. Follow the safety warnings to minimize the risk of electrical shock, burns and equipment damage when operating the system.
  • Page 12 The external switch or circuit breaker must be located near the system and within easy reach of the operator. The G7200 MGMS is equipped with a safety switch located on the top left side of the system. This switch disconnects power to downstream components.
  • Page 13 Safety ATTENTION Gas sampling system. Never block the gas sampling lines to/from the system when the system is operating, as this may damage components. Intentional blockage is only permitted for short periods when carrying out a leakage test in accordance with our instructions. WARNING Harmful components: toxic gas hazard.

  • Page 14: Hmi Structure

    NOTE: The system is case-sensitive and distinguishes between lower- and upper-case letters. ATTENTION Access to Level 3 requires consent and a password from Green Instruments. The admin must contact Green Instruments and share the information shown on the login screen. Green Instruments can then generate a one-time password that will be active for 30 minutes after login.

  • Page 15: Home Page

    HMI Structure Press Yes to log out. Figure 3-3 Log Out 3.2 Home Page Figure 3-4 Home Page On the Home page you can do the following: Get an overview of the system layout and components. ■ View live operational status of components, gas flow, and temperature. ■...

  • Page 16: Figure 3-5 Home Page Example

    G7200 Multi Gas Monitoring System User Manual Figure 3-5 Home Page Example Figure 3-6 Component Popup Example Version 1.1, April 2024 Page of 75...

  • Page 17: Measurements Page

    HMI Structure 3.3 Measurements Page The Measurements page displays live measurements for each parameter and sample point. Figure 3-7 Measurements Page 3.4 Alarm Page Figure 3-8 Alarm Page On the Alarm page you can view both historic alarms and active alarms. Red indicates an active alarm/warning.

  • Page 18: Settings Page

    G7200 Multi Gas Monitoring System User Manual 3.5 Settings Page Figure 3-9 Settings Page Only users with service security access level have access to the Settings page. The page displays relevant system information and enables you to edit system settings and perform zero and span calibration.

  • Page 19: Gas Selection Page

    Before updating the software, make a note of any changes to the system settings and system running hours for future reference. The settings can be overwritten by default values. 1. Copy the HMI software files received from Green Instruments onto an empty and formatted USB stick.

  • Page 20: Log And Data Export

    G7200 Multi Gas Monitoring System User Manual 3. Go to system Settings Page, press the Software Update button, and then follow the instructions in the pop-up window. Figure 3-12 Software Update 3.5.4 Log and Data Export NOTE: IMO resolution MEPC.259(68) and 340(77) stipulates that the logging function must not substitute data recording and processing.
  • Page 21 HMI Structure System state: includes the gas analyzers and components that are not included in the sub-systems ■ such as the flow transmitter and ambient temperature sensor. The system state also controls sampling, flushing, calibration, and shutdown scenarios. Thermo State: covers heating and cooling of the sampling cabinet and heating of the gas analyzer ■...

  • Page 22: Installation

    4.1.1 System Enclosure ATTENTION The G7200 MGMS is designed, developed, and rigorously tested to function efficiently and safely in demanding maritime applications under ambient temperature conditions between 5-55ºC. Failure to comply with recommended maintenance program, service letters and usage instructions can affect the function, lifetime and warranty.

  • Page 23: Probes

    There must be sufficient free space for access to the system enclosure The system enclosure must ■ be mounted in a location with correct circulation of air. Refer to the G7200 MGMS installation layout in the technical drawings for more information and for the dimensions of the system enclosure.

  • Page 24: Electrical Connections For System Enclosure And Probe

    4.2.2 System Enclosure Power Supply Before connecting the external power supply to the system enclosure, make sure that it complies with the power supply rating for the G7200 MGMS. Refer to the electrical drawings that are relevant for the installation.

  • Page 25: Terminals, Cables, And Wires Marking

    Installation 4.2.4 Terminals, Cables, and Wires Marking All terminals, cables and wires are marked with a unique number in accordance with the electrical documentation. 4.3 Heated Hose ATTENTION Before installation, see the Hose Handling and Installation Guide for information about the positioning and protection of the heated sample lines.

  • Page 26: Modbus Map

    G7200 Multi Gas Monitoring System User Manual 4.4.1 Modbus Map The G7200 MGMS communicates via Modbus TCP/IP or optional Modbus RTU. The following table shows details, values, and which Modbus addresses to access for specific parameters. Note the following: Only Modbus holding registers are used. The first holding register is address 0.
  • Page 27 Installation Address Name Function Description Type (Read/Write) Range or (Holding Unit register Function code 03) CALIBRATE_STATUS Calibrate Status uint16 (Read) 0 - 3 0 = Calibration done 1 = Reserved 2 = Calibrate in progress 3 = Calibrate error 12-56 Reserved SYSTEM_HIBERNAT 0 = Hibernate...
  • Page 28 G7200 Multi Gas Monitoring System User Manual Address Name Function Description Type (Read/Write) Range or (Holding Unit register Function code 03) 6 = Reserved 7 - 15 = Reserved According to measuring range in real (Read) According to measuring range in % real (Read)
  • Page 29 Installation Address Name Function Description Type (Read/Write) Range or (Holding Unit register Function code 03) According to measuring range in uint16 (Read) According to measuring range in uint16 (Read) According to measuring range in uint16 (Read) According to measuring range in uint16 (Read) Page of 75...

  • Page 30: Figure 4-2 Modbus Control Flowchart

    User Manual Communication Implementation The following flowchart shows the minimum required implementation for remote control of the G7200 MGMS via the Modbus communication line. The flow chart can be used as a visual aid when implementing the system communication between the G7200 MGMS and the customer control system.
  • Page 31 Installation Table V: Remote (R/W) “REMOTE (R/W)” must be used to determine whether to control the system locally on the HMI or remotely via Modbus TCP/IP. If the user login level is >1 (≠ guest), then the value is automatically forced to 0. REMOTE (R/W) Value Local operation on HMI...

  • Page 32: Web Viewer (Vnc)

    HMI. 4.4.3 Remote Connection The G7200 MGMS allows remote support via an internet connection. The internet connection must be established in accordance with the electrical documentation. To enable this function, contact Green Instruments for further information.

  • Page 33: Check Probes

    Installation 4.5.1 Check Probes Check the following: Probes with the seal plugs have been installed in accordance with the instructions. ■ The electrical connector of the heated hose at the probe end is connected. ■ The sample gas hose (center hose) from the heated hose is connected at the probe end. ■...

  • Page 34: Commissioning Checklist

    NOTE: The commissioning checklist is also included in the documentation package so that you can easily copy and scan it. Send the scanned document to: service@greeninstruments.com ■ the following information in the subject field: G7200 checklist, IMO no., System Serial no. ■ Action Observed criteria Evaluation Note Install cabinet.
  • Page 35 Installation Action Observed criteria Evaluation Note Connect power Power voltage has been verified Accepted Refer to chapter 4 ■ cable to cabinet with multimeter. Installation. Not accepted (X51). Power is ready to be switched Not done ■ Connect ethernet IP address has been configured. Accepted Refer to chapter 4 ■...
  • Page 36 G7200 Multi Gas Monitoring System User Manual Action Observed criteria Evaluation Note switched around. Perform leak test. MI7200-022 has been followed. Accepted Refer to MI7200- Not accepted Not done Implement Verify that all functions have been Accepted Refer to section 4.4 communication implemented by performing a test.

  • Page 37: Operation

    5. Operation 5.1 System Startup After being turned on, the G7200 MGMS typically reaches its operating temperature within 2 hours, depending on the ambient temperature and cooling of the system and probes. Once all the components have reached their operating temperature, sampling from the probes is activated via Modbus and the measured values are displayed on the Measurements Page and send via Modbus to the customer system.

  • Page 38: Figure 5-4 Safe Shut Down

    G7200 Multi Gas Monitoring System User Manual 4. When the flushing is completed, the following popup appears. Figure 5-4 Safe Shut Down 5. Shut down the system by turning the safety switch on the side of the system. Version 1.1, April 2024...

  • Page 39: Calibration

    Ready or Sample. 6.1 Auto Calibration The G7200 MGMS automatically performs a zero calibration of all available analyzers every 24 hours using instrument air as reference. The G7010 analyzer module can automatically perform both a zero and span calibration by means of built-in calibration cells together with instrument air every 24 hour.

  • Page 40: Perform Span Gas Calibration

    G7200 Multi Gas Monitoring System User Manual NOTE: Bottled zero reference gas is used for troubleshooting purposes only. 3. Zero calibration starts and the following popup appears. Figure 6-2 Zero Calibration Start 4. When the zero calibration is complete, you can perform the span gas calibration.

  • Page 41: Figure 6-5 Span Calibration Connect Gas Bottle

    Calibration 6. When the following popup appears, use a hose to connect the span gas bottle to the calibration gas inlet port found on the bottom of the cabinet, and then open the valve on the bottle. Figure 6-5 Span Calibration Connect Gas Bottle Figure 6-6 Gas Bottle 7.

  • Page 42: Figure 6-8 Span Calibration Complete

    G7200 Multi Gas Monitoring System User Manual 9. The span calibration is complete when the Calibration successful message appears. Figure 6-8 Span Calibration Complete NOTE: If zero or span calibration has not been successfully after 3 attempts, then consult the trouble shooting section of this manual.

  • Page 43: Maintenance

    Maintenance 7. Maintenance 7.1 Planned Maintenance Program ATTENTION Specific conditions can affect how often maintenance must be carried out. For example: The sample flow is above the recommended setpoint. ■ Soot blowing occurs frequently. ■ The system, spares, or components are not handled properly. ■...

  • Page 44: Lifetime Considerations

    G7200 Multi Gas Monitoring System User Manual Action Maintenance Instruction Secondary water trap replacement MI7200-001 (for analyzer type G7010) Instrument Air Instrument air filter elements MI7200-003 replacement Cabinet Ventilation filter replacement Heated Hose Heated Hose Refer to the replacement installation drawing...
  • Page 45 Maintenance Regardless of application, the lifetime will be reduced by various operational factors of which the most common are: Excessive sampling flow. ■ Exposure to liquids such as condensate, aerosols, acids, or similar. ■ All mechanical forces including vibration, shock, drop, impact, and bends. ■...

  • Page 46: Services

    To find out more about our service offerings, contact our service department at service@greeninstruments.com. 8.1 Spare Parts Place your original spare parts order directly with Green Instruments. Our dedicated spare parts team ensures effective handling of your order, and we offer fast worldwide delivery to stock or directly to vessel. Contact spares@greeninstruments.com.

  • Page 47: Troubleshooting

    Troubleshooting 9. Troubleshooting For troubleshooting of the system, refer to the PI diagram of each system. Troubleshooting must always be carried out by trained professional personnel. Carry out the suggested actions for each issue in the listed prioritized order. Issue Possible Causes Action Gas cooler temperature...
  • Page 48 G7200 Multi Gas Monitoring System User Manual Issue Possible Causes Action Malfunction in solenoid If pressure and filters are OK, then valve V3, V4, V5, or V6. troubleshoot on solenoid valve V3, V4, V5, or Broken or leaking hose or Inspect gas path.
  • Page 49 Troubleshooting Issue Possible Causes Action loss to exhaust gas pipe or Reduce probe heat loss to exhaust gas ■ insulation is missing. pipe. Broken Check/improve insulation. ■ ■ cable/wire/connection Replace defective probe. ■ Defective relay or probe. ■ Heated hose temperature Fuse is tripped.
  • Page 50 G7200 Multi Gas Monitoring System User Manual Issue Possible Causes Action Ethernet port(s). High temperature can ■ cause I/O card error. Defective I/O card. ■ PLC errors Multiple reasons could be Refer to section below. the cause. DC consumers are all AC mains supply is Measure AC supply voltage.

  • Page 51: Plc Error Codes

    Troubleshooting 9.2 PLC error codes The following figure shows the status LEDs. These indicators show the current status of the system. The following table describes the system status LEDs: Label Function Color Status Description Type Power Green Power is applied. Power is removed.
  • Page 52 G7200 Multi Gas Monitoring System User Manual Label Function Color Status Description Type 4 flashes The IP address is already in use. 5 flashes The module is waiting for BOOTP or DHCP sequence. 6 flashes The configured IP address is not valid.

  • Page 53: System Hibernation

    System Hibernation 10. System Hibernation To ensure optimal system performance, you must enable the hibernation function via the external Modbus TCP/IP interface if the system is taken out of operation for extended periods (>30 days). Using the hibernation function benefits system lifetime and minimizes electrical power consumption during the out-of-operation period.

  • Page 54: Maintenance Instructions

    G7200 Multi Gas Monitoring System User Manual 11. Maintenance Instructions The following is a list of G7200 Maintenance Instructions (MI) available. For more information about the spare parts listed in the maintenance instructions, refer to the Spare Parts Catalog. Number...

  • Page 55: Mi-7200-001: Replacement Of The Secondary Water Trap

    Difficulty 1-5 Overhaul interval Estimated time Every 12 months 15 min. Spare parts Part no. GI-G7200-104778 Maintenance Kit 1-year G7200 (1-stack) ■ Part no. GI-G7200-104779 Maintenance Kit 1-year G7200 (2-stack) ■ Part no. GI-G7200-104678 Secondary Water Trap ver. 2 ■...
  • Page 56 Part no. GI-G7200-104763 Gas Adsorber Set ■ Procedure 1. Perform a safe shutdown of the G7200 system. Press the ON/OFF button in the right corner of the HMI, and then follow the instructions on the screen. 2. Pull out the locking ring on the filter block.
  • Page 57 Maintenance Instructions 3. Pull down the filter glass carefully to release it, and then replace the O-ring on the filter glass. 4. Unscrew the filter screw counterclockwise. 5. Carefully insert a new filter element. 6. Refit the filter glass, and then reinsert the locking ring. 7.
  • Page 58 G7200 Multi Gas Monitoring System User Manual 3. Replace the container (with glass balls) and filter glass and then reinsert them. Version 1.1, April 2024 Page of 75...
  • Page 59 Part no. GI-G7200-104978 Filter Elements Particle/Oil Separator ■ Procedure 1. Perform a safe shutdown of the G7200 system. Press the ON/OFF button in the right corner of the HMI, and then follow the instructions on the screen. 2. Turn off the Air Treatment Unit switch by turning it to EXH.
  • Page 60 G7200 Multi Gas Monitoring System User Manual 3. Confirm that the unit is pressureless, and then disconnect the two hoses for the Instruments condensate drain. 4. Unscrew the filter glasses. Version 1.1, April 2024 Page of 75...
  • Page 61 Water Particle Separator. 7. Remount the filter glasses 8. Turn on the Air Treatment Unit switch by turning it to SUP, and verify that the pressure is high. 9. Power ON the G7200 System Page of 75...
  • Page 62 Shut down the MGMS, scrubber and engine during filter change to avoid unfiltered exhaust gas in ■ the MGMS and the surroundings. 1. Perform a safe shutdown of the G7200 system. Press the ON/OFF button in the right corner of the HMI, and then follow the instructions on the screen.
  • Page 63 Maintenance Instructions 2. Loosen the 2 bottom thumb screws. You can then pivot the probe cover up to gain access to the probe handle and filter. 3. Loosen the handle by rotating it 90°and then pull out the handle. 4. Remove the old filter and O-ring from the handle. 5.
  • Page 64 MI-7200-007: Replacing the Gas System Analyzer G7010 Description This procedure describes how to replace the Gas Analyzer in the G7200 MGMS The operation must be carried out by a skilled technician. Chemical hazard. Wear personal protective equipment. Difficulty 1-5 Overhaul interval...
  • Page 65 Maintenance Instructions 3. Loosen the three Allen bolts on both sides of the analyzer bracket (you don’t have to unmount them completely.) Lift and remove the analyzer bracket from the backplate. 4. Loosen the two Allen bolts on both sides of the analyzer bracket and remove the analyzer.
  • Page 66 Part no. GI-G7200-03386 Tube for Condensate Pump ■ Procedure 1. Perform a safe shutdown of the G7200 system. Press the ON/OFF button in the right corner of the HMI, and then follow the instructions on the screen. 2. Check the state of the condensate hose. Ensure that the hose is not bent, folded, or ruptured.
  • Page 67 Spare parts Part no. GI-G7200-104637 Condensate Pump w. Connector Procedure 1. Perform a safe shutdown of the G7200 system. Press the ON/OFF button in the right corner of the HMI, and then follow the instructions on the screen. 2. Disconnect the cable of the condensate pump. To identify the correct cable and connector, refer to the electric drawing.
  • Page 68 G7200 Multi Gas Monitoring System User Manual System type G7200 Multi Gas Monitoring MI-7200-022: Performing a Leak Test System Description This procedure describes how to perform a leak test. The operation must be carried out by a skilled technician. Chemical hazard: Wear personal protective equipment.
  • Page 69 Maintenance Instructions 2. Click the M3 pump icon on the HMI display. 3. In the pop-up window, click the Off button, and then click Close. For two-stack systems do this for both gas pumps. 4. Click the Selector valve icon on the HMI display. In the pop-up window, click the Off button, and then click Close.
  • Page 70 G7200 Multi Gas Monitoring System User Manual 6. Ensure that the plug is fitted during the leak test. 7. NOTE: The following steps describe the leak test for one-stack systems. For two-stack systems repeat steps 7-14 for the second probe and heated hose.
  • Page 71 Maintenance Instructions 10. Wait 10-20 sec, and then submerge the air hose into the glass of water. Count the number of bubbles in the water. Up to 40 bubbles/minute is allowed. 11. If the number of bubbles is less than 40 pcs/minute, the system is airtight and the system has passed the leak test.
  • Page 72 Part no. GI-G7200-104585 Gas Pump 24V w. Connector ■ Procedure 1. Perform a safe shutdown of the G7200 system. Press the ON/OFF button in the right corner of the HMI, and then follow the instructions on the screen. 2. Disconnect the wire connector (1).
  • Page 73 GI-G7200-102745 Sample Gas Hose Service Set 40 m ■ Procedure 1. Perform a safe shutdown of the G7200 system. Press the ON/OFF button in the right corner of the HMI, and then follow the instructions on the screen. 2. Disconnect the sample gas hose from the connector inside the cabinet.
  • Page 74 G7200 Multi Gas Monitoring System User Manual 3. Remove the sample gas hose from the probe. 4. Unplug the power and alarm connectors from the probe. 5. Remove the heated hose from the probe bracket. 6. While holding the sample gas hose end with one hand, use your other hand to cut off the stainless-steel fittings at the end of the hose.
  • Page 75 Maintenance Instructions 7. Use the hose connector to join the new hose and the old hose. The part of the connector that is fitted inside the hoses must be of the same length. First, use your hands to insert the hose connector, and the use the spanner.
  • Page 76 G7200 Multi Gas Monitoring System User Manual 15. Reconnect the power and alarm connector. 16. Connect the sample hose with the gas cooler adapter. 17. Connect the PTFE hose named Calibration Gas to the fitting named Test Gas. Version 1.1, April 2024...
  • Page 77 EUROPE Green Instruments A/S Erhvervsparken 29 9700 Brønderslev, Denmark Tel: +45 96 45 45 00 sales@greeninstruments.com AMERICA Green Instruments USA, Inc. 6750 N. Andrews Avenue Suit 200 Fort Lauderdale, FL-33309, USA Tel: +1 954 613 0400 usa@greeninstruments.com ASIA Green Instruments (S) Pte. Ltd. 4008 Ang Mo Kio Avenue 10 #01-09/10 Techplace I, Singapore 569625 Tel: +65 3100 0577 sales.sg@greeninstruments.com...

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