Vaisala MGP260 User manual

M212504EN-A

User Guide

MGP260 Series Multigas Probes for Methane,

Carbon Dioxide, and Humidity Measurement

MGP260

PUBLISHED BY

Vaisala Oyj

Vanha Nurmijärventie 21, FI-01670 Vantaa, Finland

P.O. Box 26, FI-00421 Helsinki, Finland

+358 9 8949 1

Visit our Internet pages at www.vaisala.com.

No part of this document may be

reproduced, published or publicly

displayed in any form or by any means,

electronic or mechanical (including

photocopying), nor may its contents be

modiﬁed, translated, adapted, sold or

disclosed to a third party without prior

written permission of the copyright holder.

Translated documents and translated

portions of multilingual documents are

based on the original English versions. In

ambiguous cases, the English versions are

applicable, not the translations.

The contents of this document are subject

to change without prior notice.

Local rules and regulations may vary and

they shall take precedence over the

information contained in this document.

Vaisala makes no representations on this

document’s compliance with the local

rules and regulations applicable at any

given time, and hereby disclaims any and

all responsibilities related thereto.

This document does not create any legally

binding obligations for Vaisala towards

customers or end users. All legally binding

obligations and agreements are included

exclusively in the applicable supply

contract or the General Conditions of Sale

and General Conditions of Service of

Vaisala.

Table of contents

1. About this document.....................................................................................7

1.1 Version information.......................................................................................... 7

1.2 Related manuals................................................................................................7

1.3 Documentation conventions............................................................................7

1.4 Trademarks........................................................................................................ 8

2. Product overview............................................................................................ 9

2.1 Introduction to MGP260 series....................................................................... 9

2.2 Basic features and options.............................................................................. 9

2.2.1 Hazardous area safety...............................................................................9

2.2.2 Measurement parameters.......................................................................10

2.2.3 Wet basis and dry basis measurement output.................................... 10

2.2.4 Connectivity to Vaisala Insight software................................................11

2.3 Probe parts.......................................................................................................12

2.3.1 Lead-through options and breather plug............................................. 13

2.4 Measurement principle................................................................................... 14

2.5 Using MGP260 series probes in hazardous locations.................................16

2.5.1 Guidelines for safe use in hazardous conditions.................................. 17

3. Installation.......................................................................................................20

3.1 Overview......................................................................................................... 20

3.1.1 NPT 1.5" thread test plug 257525SP..................................................... 20

3.1.2 Installation preparations........................................................................ 20

3.1.3 Installation option: ball valve installation.............................................. 21

3.1.4 Installation option: ﬂow-through adapter installation........................22

3.1.5 MGP260 dimensions...............................................................................24

3.1.6 Recommended installation position on pipeline.................................24

3.1.7 Gas safety during installation................................................................ 25

3.2 Preparing probe for installation....................................................................26

3.3 Inserting probe into process and opening connection box.......................27

3.4 Wiring ..............................................................................................................28

3.4.1 Wiring diagram....................................................................................... 30

3.5 Finalizing installation...................................................................................... 31

3.6 Attaching ﬂow-through adapter to MGP260...............................................31

4. Operating with Insight software............................................................ 34

4.1 Vaisala Insight software................................................................................. 34

4.1.1 Basic and Advanced user modes.......................................................... 34

4.2 Connecting to Insight software.................................................................... 35

4.2.1 Installing the driver for the USB service cable.................................... 36

4.3 Insight main view............................................................................................37

5. Modbus............................................................................................................. 38

5.1 Conﬁguring Modbus communication settings with Insight......................39

Table of contents

1

6. Analog output conﬁguration...................................................................40

6.1 Overview.........................................................................................................40

6.2 Conﬁguring analog outputs with Modbus..................................................40

6.3 Conﬁguring analog outputs with Insight....................................................40

6.4 Changing units in Insight................................................................................41

6.5 Wet basis and dry basis measurement parameters...................................42

7. Environmental compensation................................................................. 43

7.1 Overview......................................................................................................... 43

7.1.1 Temperature compensation...................................................................43

7.1.2 Pressure compensation..........................................................................43

7.1.3 Compensation mode during calibration.............................................. 44

7.2 Conﬁguring environmental compensations with Modbus........................44

7.3 Conﬁguring environmental compensations with Insight..........................44

7.3.1 Conﬁguring setpoint values for compensations with Insight........... 46

7.3.2 Using probe measurement as temperature compensation...............46

7.3.3 Using compensation received from external temperature

or pressure sensor...................................................................................46

7.3.4 Conﬁguring input from external analog pressure or

temperature sensor.................................................................................47

8. Calibration.......................................................................................................49

8.1 Calibration recommendations...................................................................... 49

8.2 Calibration overview......................................................................................49

8.2.1 Compensation mode during calibration.............................................. 50

8.2.2 Flow-through adapter............................................................................50

8.3 Calibration and adjustment with Insight PC software............................... 52

8.3.1 Example: 2-point adjustment with zero point adjustment................ 53

8.3.2 Zero point adjustment............................................................................ 53

8.3.3 Calibrating and adjusting methane (CH

4

) measurement...................54

8.3.4 Calibrating and adjusting carbon dioxide (CO

2

) measurement........ 55

8.3.5 Calibrating and adjusting temperature measurement....................... 56

9. Maintenance....................................................................................................58

9.1 Maintenance overview................................................................................... 58

9.2 Filter change................................................................................................... 58

9.3 Removing probe from process..................................................................... 59

9.4 Cleaning the probe........................................................................................ 60

9.5 Sending probe to Vaisala................................................................................61

10. Technical data................................................................................................ 63

10.1 Speciﬁcations..................................................................................................63

10.2 Flow-through adapter dimensions.............................................................. 66

10.3 MGP260 dimensions...................................................................................... 67

10.4 Wetted parts material information.............................................................. 68

10.5 Recycling instructions....................................................................................68

MGP260 User Guide M212504EN-A

2

Appendix A: Modbus reference.................................................................. 70

A.1 Modbus registers............................................................................................70

A.1.1 Measurement data registers.................................................................. 70

A.1.2 Conﬁguration registers........................................................................... 72

A.1.3 Status registers........................................................................................82

A.1.4 Device identiﬁcation objects................................................................. 85

Maintenance and calibration.........................................................................87

Warranty............................................................................................................ 87

Technical support............................................................................................ 87

Recycling........................................................................................................... 87

Table of contents

3

List of ﬁgures

Figure 1 Output parameter selections in Vaisala Insight PC software.............. 10

Figure 2 MGP260 probe parts (closed and opened view)....................................12

Figure 3 Lead-through options and breather plug ................................................ 13

Figure 4 Probe cuvette with mirror and sensor chips............................................ 14

Figure 5 Measurement in the measurement cuvette..............................................15

Figure 6 MGP260 Ga/Gb division.................................................................................17

Figure 7 NPT 1.5" thread test plug.............................................................................. 20

Figure 8 MGP260 installation example with wiring routes and

recommended orientation and depth.......................................................22

Figure 9 MGP260 in ﬂow-through adapter 258877............................................... 23

Figure 10 MGP260 dimensions in millimeters and inches......................................24

Figure 11 Recommended MGP260 installation position on pipeline.................. 24

Figure 12 MGP260 screw terminal markings and cable routes.............................28

Figure 13 MGP260 wiring diagram...............................................................................30

Figure 14 Connecting probe to Insight........................................................................ 35

Figure 15 Insight main menu and settings..................................................................37

Figure 16 Modbus communication settings in Insight PC software.................... 39

Figure 17 Analog output conﬁguration options in insight.....................................40

Figure 18 Unit Selection in Insight................................................................................. 41

Figure 19 Output parameter selections in Vaisala Insight PC software..............42

Figure 20 Measurement menu view in Insight PC software ..................................45

Figure 21 Analog input 1 conﬁguration menu in Insight......................................... 47

Figure 22 Flow-through adapter 258877..................................................................... 51

Figure 23 Calibration menu view in Insight PC software........................................ 52

Figure 24 Zero point adjustment tab........................................................................... 54

Figure 25 Temperature adjustment view in Insight..................................................56

Figure 26 Replacing ﬁlter.................................................................................................58

Figure 27 Flow-through adapter dimensions with MGP260 probe.....................66

Figure 28 Flow-through adapter mounting plate dimensions..............................66

Figure 29 MGP260 dimensions in millimeters and inches......................................67

Figure 30 Removing parts for recycling...................................................................... 69

Figure 31 Probe body and component board: dispose as electrical

and electronic waste......................................................................................69

MGP260 User Guide M212504EN-A

4

List of tables

Table 1 Document versions (English)............................................................................7

Table 2 Related manuals................................................................................................... 7

Table 3 MGP260 measurement parameters.............................................................. 10

Table 4 MGP260 series hazardous area classiﬁcations...........................................16

Table 5 Screw terminal wiring requirements..............................................................18

Table 6 Intrinsic safe IIB output parameters.............................................................. 18

Table 7 Default Modbus serial communication settings........................................ 38

Table 8 Measurement performance.............................................................................63

Table 9 Inputs and outputs............................................................................................ 64

Table 10 Compliance..........................................................................................................64

Table 11 Operating environment....................................................................................65

Table 12 Mechanical speciﬁcation..................................................................................65

Table 13 Options and accessories.................................................................................. 65

Table 14 Modbus measurement data registers (read-only)....................................70

Table 15 Modbus conﬁguration data registers (writable)........................................72

Table 16 Modbus status data registers (read-only)...................................................82

Table 17 Error codes in register 0200

hex

(status code low)................................... 83

Table 18 Error codes in register 0202

hex

(status code high).................................. 84

Table 19 Device identiﬁcation objects.......................................................................... 85

List of tables

5

MGP260 User Guide M212504EN-A

6

1. About this document

1.1 Version information

Table 1 Document versions (English)

Document code Date Description

M212504EN-A October 2020 This manual. First version of the document.

1.2 Related manuals

Table 2 Related manuals

Document code Description

M212481EN MGP260 Series Multilingual Installation and Safety Guide

(languages: English, German, French, Dutch, Spanish, Portuguese,

Italian, Hungarian, Czech, Polish, Finnish, Estonian, Swedish,

Norwegian, Danish)

M212500EN MGP260 Series Multilingual Installation and Safety Guide

(languages: English, Japanese, Chinese)

M212538EN MGP260 Series USB Service Cable 257295 Quick Guide

M212539EN MGP260 Series Flow-through adapter 258877 Quick Guide

M212540EN China ROHS disclosure report

1.3 Documentation conventions

Warning alerts you to a serious hazard. If you do not read and

follow instructions carefully at this point, there is a risk of injury or even death.

WARNING!

Caution warns you of a potential hazard. If you do not read and

follow instructions carefully at this point, the product could be damaged or

important data could be lost.

CAUTION!

Chapter 1 – About this document

7

Note highlights important information on using the product.

1.4 Trademarks

Vaisalaâ and CARBOCAPâ are registered trademarks of Vaisala Oyj.

All other product or company names that may be mentioned in this publication are trade

names, trademarks, or registered trademarks of their respective owners.

MGP260 User Guide M212504EN-A

8

2. Product overview

2.1 Introduction to MGP260 series

Vaisala CARBOCAPâ MGP260 Series Multigas Probes for Methane, Carbon Dioxide, and

Humidity Measurement are compact and durable in situ probes for methane (CH

4

), carbon

dioxide (CO

2

), and humidity (H

2

O vapor) measurements in demanding biogas processing

conditions. MGP260 series probes are Ex certiﬁed for use in Ex Zone 0 (parts inserted into

process) and Ex Zone 1 (parts outside the process).

MGP260 probes can be installed directly into raw process gas, removing the need for sample

treatment. Application areas include anaerobic digestion of industrial and municipal waste and

sludge from waste water treatment, landﬁll gas monitoring, activated carbon ﬁlter monitoring

in biogas treatment process, and CHP engine feed gas monitoring.

The MGP260 series proprietary infrared technology provides superior stability and

repeatability. Thanks to condensation elimination through probe heating and corrosion-

resistant steel and plastic materials, the IP66-rated instruments are highly robust and durable.

MGP260 series measurement output options include 3 analog current output channels (4 … 20

mA) and Modbus RTU over RS-485. The probes also provide a 4 … 20 mA Ex ia input for

connecting an optional external pressure or temperature sensor.

For easy-to-use access to conﬁguration, diagnostics, and calibration and adjustment

functionalities, MGP260 probes can be connected to Vaisala Insight PC software with a USB

cable accessory.

2.2

Basic features and options

• Available measurement parameters: methane (CH

4

), carbon dioxide (CO

2

), and humidity

(H

2

O vapor)

• Ex classiﬁcation: IECEx and MET certiﬁed for use in Class I Division 2 and Zone 0/1

environments: for full Ex classiﬁcations, see Table 4 (page 16).

• Operating pressure: -500 ... +500 mbar

• 3 analog outputs (4 … 20 mA, scalable, isolated)

• Digital output: Modbus RTU over RS-485

• Optional external temperature or pressure sensor input (4 … 20 mA, Ex ia)

• Power supply input: 18 … 30 VDC

• Direct installation into process: for pipeline ports with 1.5" female NPT thread

• Compatible with Vaisala Insight PC software

2.2.1 Hazardous area safety

Do not install or use MGP260 in a hazardous area before reviewing

the safety information in Using MGP260 series probes in hazardous locations

(page 16).

CAUTION!

Chapter 2 – Product overview

9

2.2.2 Measurement parameters

Table 3 (page 10) shows the units and ranges of the MGP260 measurement parameters. For

further information on the measurement parameters, see Speciﬁcations (page 63).

Table 3 MGP260 measurement parameters

Parameter Unit Measurement range

Methane (CH

4

) Volume-% 0 … 100 vol-%

Carbon dioxide (CO

2

) Volume-% 0 … 100 vol-%

Water vapor (H

2

O) • Volume-%

• Dew point temperature

• Dew point and frost point

temperature

• 0 … 25 vol-%

• -10 … +60 °C (14 … +140 °F)

2.2.3 Wet basis and dry basis measurement output

MGP260 methane, carbon dioxide, and water vapor measurements can be shown either as wet

basis or dry basis values. The wet basis / dry basis measurement output selection is made

when ordering the probe, and can be conﬁgured with Vaisala Insight PC software or Modbus.

Figure 1 Output parameter selections in Vaisala Insight PC software

MGP260 User Guide M212504EN-A

10

More information

‣

Conﬁguring analog outputs with Insight (page 40)

2.2.4 Connectivity to Vaisala Insight software

The probe can be connected to Vaisala Insight software using a Vaisala USB cable (order code:

257295). With the Insight software, you can:

• Calibrate and adjust the measurement.

• See device information and status.

• See real-time measurement.

• Conﬁgure serial communication settings, analog input and output parameters and scaling,

and environmental compensations.

More information

‣

Connecting to Insight software (page 35)

Chapter 2 – Product overview

11

2.3 Probe parts

Figure 2 (page 12) shows the MGP260 main components with the connection box of the

probe closed and opened.

1 2 3

4

5

6

8

9

10

11

7

Figure 2 MGP260 probe parts (closed and opened view)

1

Grounding terminal: use a ≥ 4 mm

2

wire to connect to the grounding rail

2 Breather plug and lead-throughs for wiring: install cable glands as required and seal

unused lead-throughs (see Lead-through options and breather plug (page 13))

3 Tightening ﬂange of the connection box with captive Allen screws. Loosen the captive

screws with a 5 mm (3/16 in) Allen key and open the connection box to access wiring

terminals.

4 Tightening nut: only tighten from the tightening nut when installing (wrench size: 50 mm

(1.97 in))

5 1.5" male NPT thread: never install to any other thread type than 1.5" female NPT thread

6 Probe ﬁlter (user-replaceable)

7 1.5" NPT thread test plug

8 Wiring terminals for optional 4 … 20 mA input from external pressure or temperature

sensor (Ex ia)

9 Barrier separating the intrinsically safe (Ex ia) optional external sensor input terminals

from the analog output, power supply input, and RS-485 terminals

10 Wiring terminals for 4 … 20 mA analog outputs, 18 … 30 VDC power supply input, and

RS-485 communication

11 Measurement cuvette with optics and CARBOCAPâ sensor inside the probe ﬁlter

MGP260 User Guide M212504EN-A

12

2.3.1 Lead-through options and breather plug

Figure 3 (page 13) shows the MGP260 lead-through options and breather plug location.

Cable glands are not provided by Vaisala. When selecting cable glands for your

application, note the requirements in Guidelines for safe use in hazardous

conditions (page 17).

1

3

2

4

Figure 3 Lead-through options and breather plug

1 Breather plug: do not adjust.

2 M16x1.5 wiring lead-through: used when wiring the optional Ex ia external pressure or

temperature sensor input terminal.

3 M20x1.5 wiring lead-through with removable plastic transport cover (fold sides of

transport cover together and pull out). Wiring option for analog output, power supply

input, and RS-485 terminals, or customer-speciﬁc additional wiring.

4 M20x1.5 wiring lead-through for analog output, power supply input, and RS-485 terminals.

Seal unused lead-throughs. Use only Ex compliant seals on the

MGP260 lead-throughs.

CAUTION!

More information

‣

Preparing probe for installation (page 26)

‣

Wiring (page 28)

Chapter 2 – Product overview

13

2.4 Measurement principle

1

2

3

The Vaisala CARBOCAPâ sensor used in

the probe is a silicon-based, nondispersive

infrared (NDIR) sensor for the

measurement of methane (CH

4

), carbon

dioxide (CO

2

), and humidity (H

2

O).

Figure 4 Probe cuvette with mirror and

sensor chips

1 Mirror

2 Cuvette

3 Sensor chips under TO5 packages

The sensitivity to gases is based on absorption of infrared light at a characteristic wavelength.

During measurement, infrared light is routed through the cuvette that contains the gas to be

measured. A mirror reﬂects the light from the cuvette to thermopile detectors that measure

the light intensity at a wavelength determined by a Fabry–Pérot interferometer (FPI) and a

band pass ﬁlter. One set of optics measures humidity and carbon dioxide, and a second one

measures methane.

The measurement consists of two steps: ﬁrst, the FPI is electrically tuned so that its pass band

coincides with the characteristic absorption wavelength of the measured gas and the signal is

recorded. Second, the pass band is shifted to a wavelength where no absorption occurs in

order to get a reference signal. The ratio of these two signals, one at the absorption

wavelength and the other at the reference wavelength, gives the fraction of light absorption

from which the gas concentration is calculated. Measuring the reference signal compensates

the possible eects of sensor aging and signal attenuation due to dirt on optical surfaces,

making the sensor very stable over time.

MGP260 User Guide M212504EN-A

14

TO5 packages with hermetic windows are used to protect the sensor chips from moisture and

contamination.

1

3

4

5

6

7

8

2

Figure 5 Measurement in the measurement

cuvette

1 Mirror

2 Light absorbed by the measured gases

3 Sensor chips under TO5 packages (see

items 4 … 8)

4 Hermetic window

5 Thermopile detector

6 Hermetic window

7 Fabry–Pérot interferometer

8 Light source (Microglow)

More information

‣

Speciﬁcations (page 63)

Chapter 2 – Product overview

15

2.5 Using MGP260 series probes in hazardous

locations

MGP260 series probes have been designed for use in hazardous

locations as speciﬁed by the product classiﬁcation. The personnel installing,

using, or maintaining MGP260 probes are responsible for determining the

appropriate protection concept for the speciﬁc application the probe is used

in, and that the hazardous area classiﬁcation of the probe meets the

requirements of the application.

WARNING!

If the equipment is used in a manner not speciﬁed by Vaisala, the

protection provided by the equipment may be impaired.

WARNING!

MGP260 probes are certiﬁed for use in hazardous areas as deﬁned by the following

classiﬁcations:

Table 4 MGP260 series hazardous area classiﬁcations

Certiﬁcation MGP260 classiﬁcation

IECEx (international)

ATEX (EU)

Ex II 1/2 (1) G Ex eb mb [ia] IIB T3 Ga/Gb -40 °C ≤ Tamb ≤ +60 °C

MET (US/CAN) NEC 500: Class I, Division 2, Groups C & D; T3

NEC 505: Class I, Zone 0, AEx eb mb [ia] IIB T3 Ga/Gb

CSA 60079: Ex eb mb [ia] IIB T3 Ga/Gb

The personnel installing, operating, and maintaining MGP260

probes must have the required competencies for working in the hazardous

location, as deﬁned by the applicable standards.

CAUTION!

For information on the standards that apply to using MGP260 probes based on the

classiﬁcation of the device, see MGP260 certiﬁcation documentation and the declarations of

conformity related to MGP260 probes at www.vaisala.com/declarationofconformity.

MGP260 User Guide M212504EN-A

16

2.5.1 Guidelines for safe use in hazardous conditions

Process connection and partition wall

Gb Ga

1

2

Figure 6 MGP260 Ga/Gb division

1 The part outside of the process (up until to the NPT 1.5" connection thread) complies with

the Gb E

quipment Protection Level (EPL).

2 The part inside the process (starting from the NPT 1.5" thread) complies with the Ga EPL.

The partition wall is made of stainless steel, sapphire glass, and silicone adhesive. The

stress limit temperature range of the silicone adhesive is -40 … +60 °C (-40 ... +140 °F).

While installing or uninstalling the device, there is a risk of

ﬂammable gas r

elease or ﬂame entrance.

WARNING!

Wiring requirements

• The wiring of the optional intrinsically safe (Ex ia) external pressure or temperature sensor

input terminal must be kept separate from the analog output, power supply input, and

RS-485 wiring.

• See the wiring instructions in the installation section.

• The cable glands and cables used for wiring the device must not impair the Ex protection.

• US/CAN: The cables used for wiring must have a flammability rating of UL 2556 VW-1

or equivalent.

• Unused lead-throughs must be sealed using Ex compliant plugs.

• See Table 5 (page 18) for screw terminal requirements.

• Use an 18 … 30 VDC power supply with the probe.

• Permitted supply short-circuit current (I

k

): 50 A.

• US/CAN: only use a UL listed 18 … 30 VDC (min. 6 W) power supply. The power supply

must be UL/CSA 60950-1 certified.

• MGP260 analog outputs must be externally powered.

Chapter 2 – Product overview

17

Connect only de-energized wires. Never switch on the power supply

input before completing the wiring and closing the connection box.

CAUTION!

Table 5 Screw terminal wiring requirements

Property Speciﬁcation

Connection torque 0.5 Nm ... 0.6 Nm

Wire cross section / connection capacity (solid

and ﬂexible)

0.2 mm

2

... 2.5 mm

2

(AWG 24 ... 12)

Stripping length 7 mm (0.27 in)

Intrinsic safety

The overvoltage category of MGP260 series probes is I (non-mains equipment), as deﬁned in

IEC 60664-1.

MGP260 probes are in conformance with the IEC 60079-11 dielectric strength requirement. For

the intrinsic safe IIB output parameters, see Table 6 (page 18).

Table 6 Intrinsic safe IIB output parameters

Parameter Value

U

o

25.2 V

I

o

78 mA

P

o

0.5 W

U

m

40 V

C

o

820 nF

L

o

20 mH

The parameters listed in Table 6 (page 18) apply when one of the two conditions below is

given:

• the total L

i

of the external circuit (excluding the cable) is < 1% of the L

o

value; or

• the total C

i

of the external circuit (excluding the cable) is < 1% of the C

o

value.

The parameters are reduced to 50% when both of the two conditions below are given:

• the total L

i

of the external circuit (excluding the cable) is ≥1% of the L

o

value; and

• the total C

i

of the external circuit (excluding the cable) is ≥1% of the C

o

value.

Note: the reduced capacitance of the external circuit (including cable) shall not be greater

than 1μF for Groups I, IIA, IIB & IIIC, and 600nF for Group IIC.

MGP260 User Guide M212504EN-A

18

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