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GM32 EX
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SICK GM32 EX Installation Operation & Maintenance

GM32 Ex
In-situ Gas Analyzer Cross-Duct Version
Installation, Operation, Maintenance

O P E R A T I N G I N S T R U C T I O N S

Described product
GM32 Ex
Cross-Duct version
Manufacturer
Production location
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be reserved for SICK AG. Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law. Any modifica‐ tion, shortening or translation of this document is prohibited without the express written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents

CONTENTS
1 About this document........................................................................ 7
1.1 Function of this document....................................................................... 7
1.2 Scope of application................................................................................. 7
1.3 Target groups / qualification requirements............................................ 7
1.4 Further information................................................................................... 7
1.5 Data integrity............................................................................................. 7
1.6 Symbols and document conventions...................................................... 8
1.6.1 Warning symbols...................................................................... 8
1.6.2 Warning levels / Signal words................................................. 8
1.6.3 Information symbols................................................................ 9
2 Safety information............................................................................ 10
2.1 Main operating information..................................................................... 10
2.2 Warnings on the device............................................................................ 12
2.3 Intended use............................................................................................. 12
2.3.1 Purpose of the device.............................................................. 13
2.3.2 Operation in potentially explosive atmosphere...................... 13
2.4 Responsibility of user............................................................................... 14
3 Product description........................................................................... 15
3.1 Product identification............................................................................... 15
3.2 Device version........................................................................................... 15
3.3 Device variants......................................................................................... 16
3.4 Options...................................................................................................... 16
3.5 SOPAS ET (PC program)............................................................................ 16
3.6 Reference cycle......................................................................................... 17
3.7 Check cycle............................................................................................... 17
3.8 Layout and function.................................................................................. 19
3.9 Purge air unit............................................................................................. 20
3.10 Explosion protection in accordance with ATEX....................................... 20
3.10.1 Zone separation GM32 EX ATEX 3G....................................... 20
3.10.2 Pressurized enclosure............................................................. 21
3.10.2.1 ................................................................................. 21
3.11 Connecting hose between SR-unit and junction box.............................. 22
4 Transport and storage....................................................................... 23
4.1 Transport safety device............................................................................ 23
4.2 Storage...................................................................................................... 23
5 Mounting............................................................................................. 24
5.1 Information on installation in potentially explosive atmospheres......... 24
5.2 Preparing the sampling point................................................................... 25
5.3 Scope of delivery....................................................................................... 25
5.3.1 Checking the delivery state..................................................... 26
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CONTENTS
5.4 Installation sequence............................................................................... 26
5.4.1 Overview of the installation steps (duct-side preparation)... 26
5.4.2 Install flanges with tube.......................................................... 26
5.4.3 Installing the connection unit................................................. 28
5.4.3.1 Fitting the FS850S.................................................. 29
5.4.4 Installing the purge air unit..................................................... 30
5.4.4.1 Start-up of the purge air supply............................. 30
6 Electrical installation........................................................................ 32
6.1 Electrical installation safety information................................................. 32
6.2 Connection overview................................................................................ 34
6.2.1 Lines......................................................................................... 35
6.3 Connecting interfaces ............................................................................. 35
6.3.1 Connecting I/O interfaces (option)......................................... 35
6.3.1.1 Connection diagram for variant 3G....................... 36
6.3.1.2 Default values for interfaces.................................. 38
6.4 Connecting the connection hose to the SR-unit on the junction box.... 39
6.5 Connecting pressure, temperature and purge air monitor ................... 40
6.6 Connecting the potential equalization on the purge air fixture............. 40
6.7 Connecting the Ex overpressure control FS850S................................... 41
6.8 Electrical connection of SR-unit............................................................... 42
6.9 Preparing the power supply...................................................................... 43
6.10 Connecting the potential equalization to the SR-unit............................. 44
7 Commissioning.................................................................................. 45
7.1 Safety information for start-up................................................................. 45
7.2 Material required ..................................................................................... 46
7.3 Check before start-up............................................................................... 46
7.4 Overview of start-up steps....................................................................... 46
7.5 Fitting the purge air fixtures on the flange with tube............................. 47
7.6 Installing the device flange on the purge air fixture............................... 47
7.7 Aligning device flanges and purge air fixtures........................................ 49
7.8 Connecting the protective gas on the SR-unit........................................ 50
7.8.1 Feeding protective gas............................................................ 51
7.8.2 Switching the pressurized enclosure on................................. 51
7.9 Installing the SR-unit and reflector unit on the device flange............... 52
7.10 Optical fine alignment of the SR-unit ..................................................... 52
7.11 Fitting the weatherproof cover (option)................................................... 53
8 Operation............................................................................................ 55
8.1 Safety......................................................................................................... 55
8.2 GM32 operator panel............................................................................... 55
8.2.1 LEDs.......................................................................................... 56
8.2.2 Function buttons...................................................................... 57
8.2.3 Setting the display contrast.................................................... 58
8.2.4 Menu tree................................................................................. 58
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8.2.4.1 Diagnosis................................................................. 59
8.2.4.2 Check cycle - results of last check cycle............... 59
8.2.4.3 Alignment check (option) - automatic optical
alignment check..................................................... 60
8.2.4.4 Alignment adjust - manual optical alignment....... 60
8.2.4.5 Maintenance mode - set Maintenance mode ...... 62
9 Maintenance...................................................................................... 64
9.1 Safety ........................................................................................................ 64
9.2 Maintenance plan .................................................................................... 66
9.2.1 Consumable parts, expendable parts and spare parts........ 66
9.3 Preparation work....................................................................................... 67
9.4 Function test of the pressurized enclosure system................................ 67
9.5 Swiveling out and removing the SR-unit or reflector unit....................... 68
9.6 Visual inspection....................................................................................... 69
9.7 Cleaning the window................................................................................. 70
9.8 Check/replace the desiccant cartridge................................................... 70
9.9 Replacing the activated charcoal bag..................................................... 71
9.10 Replacing the sender lamp...................................................................... 72
10 Troubleshooting................................................................................. 75
10.1 Safety......................................................................................................... 75
10.2 Visual inspection....................................................................................... 76
10.3 Device not functioning.............................................................................. 77
10.4 Overpressure monitoring failure.............................................................. 77
10.5 Measured values clearly incorrect........................................................... 78
10.6 Sample gas penetrating........................................................................... 78
10.7 Corrosion on flange.................................................................................. 78
10.8 Measured value blinks............................................................................. 78
10.9 Error messages......................................................................................... 78
10.9.1 Example of an error message................................................. 78
10.9.2 Error messages........................................................................ 80
10.10 Repairing inadequate purge air supply................................................... 84
10.11 Malfunctions on the connection unit ..................................................... 84
11 Decommissioning............................................................................. 85
11.1 Safety information on shutting down...................................................... 85
11.2 Decommissioning of subassemblies with explosion relevance............. 87
11.3 Removing the device................................................................................ 87
11.4 Environmentally compatible disposal ..................................................... 87
12 Technical data.................................................................................... 89
12.1 System: GM32 Ex..................................................................................... 89
12.2 GM32 Ex sender/receiver unit................................................................ 90
12.3 Reflector unit GM32 Ex............................................................................ 90
12.4 Purge air fixture: Sender/receiver unit GM32 Ex................................... 91
12.5 Purge air fixture: Reflector unit GM32 Ex................................................ 91
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CONTENTS
12.6 Connection unit, Ex version I/O module................................................. 91
12.7 Dimension drawings: Sender/receiver unit Ex version.......................... 92
12.8 Dimension drawings: Reflector unit........................................................ 93
12.9 Dimension drawings: Ex purge air fixtures (on SR and reflector side).. 94
12.10 Dimension drawings: Connection unit version 3G................................. 95
12.11 Dimension drawings: Mounting flange DN100....................................... 96
12.12 Dimension drawing, weatherproof cover, SR-unit................................... 96
12.13 Technical data for enclosure pressurization system.............................. 96
12.13.1 Technical data protective gas................................................. 96
12.13.2 Technical data enclosure........................................................ 97
12.13.3 Pressurized enclosure system settings.................................. 97
13 Annex.................................................................................................. 98
13.1 Conformities.............................................................................................. 98
13.2 Electrical protection.................................................................................. 98
13.3 Ex certifications........................................................................................ 98
14 Index.................................................................................................... 100
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ABOUT THIS DOCUMENT 1

1 About this document

1.1 Function of this document

These Operating Instructions describe:
Device components
•
Installation
•
Operation
•
Maintenance work required for reliable operation
•

1.2 Scope of application

These Operating Instructions are only valid for the in-situ gas analyzer with the designa‐ tion GM32 Ex Cross-Duct.
They are not valid for other in-situ gas analyzers from SICK.

1.3 Target groups / qualification requirements

Table 1: Qualification requirements
Tasks User groups Qualification
Assembly Operator / system integrator e.g. plant operator, unskilled in measurement
technology
Electrical installation Qualified personnel Authorized electrician (authorized skilled electri‐
cian or person with similar training)
Initial start-up
Returning to operation
Decommissioning
Operation
Maintenance
Troubleshooting
Authorized operator Ü
Operator / system integrator
•
Authorized operator Ü
•
General knowledge in measurement technology, specialist device knowledge (possibly customer training at SICK)
e.g. plant operator, unskilled in measure‐
•
ment technology Authorized electrician (authorized skilled
•
electrician or person with similar training)

1.4 Further information

Operating Instructions of the purge air supply
•
Final inspection record
•
CD-ROM with SOPAS ET
•
Optional: Technical information
•
Optional: Operating Instructions Modular System I/O
•
3G / Zone 2
FS850S Pressurized Enclosure Manual
•
Manual, Purge medium valve SVD.L.2.-AI00
•
NOTE
Observe all supplied documents.
b

1.5 Data integrity

SICK AG uses standardized data interfaces such as, for example, standard IP technol‐ ogy, in its products. The focus here is on product availability and features.
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1 ABOUT THIS DOCUMENT
SICK AG always assumes that the customer is responsible for the integrity and confi‐ dentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures suitable for the respective situation, e.g., network separation, firewalls, virus protection and patch management.

1.6 Symbols and document conventions

1.6.1 Warning symbols

Table 2: Warning symbols
Symbol Significance
Hazard (general)
Hazard by voltage
Hazard in potentially explosive atmospheres
Hazard by explosive substances/mixtures
Hazard by toxic substances
Hazard by unhealthy substances
Hazard by ultraviolet radiation (UV light)
Hazard by oxidizing substances
Hazard by high temperature
Hazard for the environment/nature/organic life

1.6.2 Warning levels / Signal words

DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
Notice
Hazard which could result in property damage.
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Note
Hints

1.6.3 Information symbols

Table 3: Information symbols
Symbol Significance
ABOUT THIS DOCUMENT 1
Information on consistency of the product relative to Guideline 2014/34/EU (ATEX)
Important technical information for this product
Important information on electric or electronic functions
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2 SAFETY INFORMATION

2 Safety information

2.1 Main operating information

Work on the device
WARNING Risk of explosion
Work on the device assumes an Ex free zone at the installation location otherwise there is an explosion risk.
Ensure the work area is Ex free when working on the device.
b
DANGER Risk for system safety through work on the device not described in these Operating Instructions
Carrying out work on the device not described in these Operating Instructions or associ‐ ated documents can lead to unsafe operation of the measuring system and therefore endanger plant safety.
Only carry out the work on the device described in these Operating Instructions
b
and associated documents.
DANGER Risk of explosion through incorrect performance of maintenance work
Incorrect performance of maintenance work in potentially explosive atmospheres can cause serious injuries to people and damage during operation.
Maintenance work and start-up activities as well as checks must be performed by
•
experienced/trained technicians having knowledge of the relevant rules and regu‐ lations for potentially explosive atmospheres, especially: – Ignition protection types – Installation procedures – Zone classification Standards to be applied:
•
– IEC 60079-14, Annex F: Knowledge, skills and competencies of responsible
persons, operatives and designers – IEC 60079-17: Electrical installations inspection and maintenance – IEC 60079-19: Equipment repair, overhaul and reclamation
Noxious UV radiation
DANGER Damage to eyes and skin by UV radiation
The in-situ gas measuring device GM32 emits UV radiation when the SR-unit or reflec‐ tor unit is opened during operation. Exposure of the unprotected skin and eyes to radia‐ tion is dangerous to health.
10
Disconnect the power supply of the device before opening the device.
b
Wear suitable protective goggles and protective gloves when work on the open
b
device with the power supply connected is performed.
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SAFETY INFORMATION 2
Escaping hot gas
DANGER Risk of fire through hot gas escaping in installations with overpressure conditions
On installations with overpressure, the purge air hose can be severely damaged by escaping hot gas and can catch fire depending on the temperature. On installations with overpressure and gas temperatures over 200°C at the same time:
Regularly check the functionality of the reverse flow safeguard in the purge air fix‐
b
tures.
Potential equalization
CAUTION Device damage through incorrect or non-existing grounding
To avoid device damage, a correctly connected potential equalization is mandatory on all system components with external ground connections in all operating conditions.
Connect a potential equalization on all planned points on the device components.
b
Ensure the potential equalization is connected during all work on the device
b
described in these Operating Instructions.
Contamination caused by purge air failure
CAUTION A faulty purge air supply can damage the measuring system
The measuring system can no longer be protected from contaminated sample gas and is damaged.
When the purge air supply is faulty, immediately perform all actions described in
b
these Operating Instructions.
Responsibility for system safety
ATTENTION Responsibility for the safety of a system
The person setting the system up is responsible for the safety of the system in which the device is integrated.
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1 2
3
4
5
6
7
8
9
1 2 3
2 SAFETY INFORMATION

2.2 Warnings on the device

GM32 Ex SR-unit
Figure 1: Sender/receiver unit from the front, the side and with the intermediate housing open
Sender/receiver unit, front side
1 Warning sign protective gas:
° ° °
2 Warning sign: Pull power plug before opening the device 3 Mandatory sign: Wear eye protection 4 Warning sign: Do not disconnect when live
Sender/receiver unit, right side
5 Type plate GM32 Ex 3G 6 Sampling point designation (optional) 7 Danger sign: UV light
Sender/receiver unit, intermediate housing
8 Type plate GM32 Ex 3G 9 Warning sign: Hot surface
Protective gas outlet Risk of suffocation when using inert gases 20 minutes waiting time before opening the enclosure
GM32 Ex connection unit
Connection unit for GM32 Ex, front side
1 Warning sign protective gas:
Protective gas outlet
°
Risk of suffocation when using inert
°
gases 20 minutes waiting time before open‐
°
ing the enclosure
2 Warning sign: Pull power plug before open‐
ing the device
3 General warning sign: Warning of a danger
area
Figure 2: GM32 Ex connection unit
2.3
12

Intended use

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2.3.1 Purpose of the device

The device serves exclusively for emission and process monitoring of gases in industrial plants.
The device measures continuously directly in the gas duct (in-situ).

2.3.2 Operation in potentially explosive atmosphere

3G / Zone 2: Connection unit and sender/receiver unit
The GM32 Ex corresponds to the ATEX category (according to
•
ATEX 2014/34/EC): X II 3G Ex pzc op is [ia] IIC T3 Gc GM32 Ex meets the following IECEx qualification:
•
Ex pzc op is [ia] IIC T3 Gc
Special conditions (X identification)
•
A measuring function for explosion protection is not part of
°
the EC type approval The duct with sample gas contact must be a non-potentially
°
explosive atmosphere when overpressure against the atmosphere is present in the duct If the duct has underpressure against the atmosphere, this
°
area may correspond to Zone 2
Observe the Ex identification.
•
The Ex identification is on the type plate. Example: SICK GM32-xxx-EX3G (xxx=internal type number) SN: yyyy yyyyy (serial number)
-20 °C ≤ Ta ≤ 55 °C
X
Explosion protection relating to optical radiation in the measur‐
•
ing channel The explosion protection relating to optical radiation in the meas‐ uring channel is satisfied in accordance with the temperature range (-20°... +60 °C) specified by ATX/IECEx. The plant opera‐ tor must evaluate Ex atmospheres possibly present for exhaust gas temperatures exceeding this range separately and take suit‐ able protective measures!
Location of Ex relevant subassemblies, see Chapter “Design
w
and Function”. Do not remove, add or modify any components to or on the
w
device unless described and specified in the official manu‐ facturer information. Otherwise the approval for the device for use in potentially explosive atmospheres becomes void. Adhere to the maintenance intervals, see Chapter “Mainte‐
w
nance plan”. After switching off the main power supply: Wait 20 minutes
w
before opening the enclosure.
SAFETY INFORMATION
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2 SAFETY INFORMATION

2.4 Responsibility of user

Designated users
see "Target groups / qualification requirements", page 7.
Correct project planning
Basis of this Manual is the delivery of the device according to the preceding
•
project planning (e.g., based on the SICK application questionnaire) and the rele‐ vant delivery state of the device (see delivered System Documentation).
Contact SICK Customer Service if you are not sure whether the device corre‐
w
sponds to the state defined during project planning or to the delivered system
documentation.
Special local conditions
In addition to the information in these Operating Instructions, follow all local laws, tech‐ nical rules and company-internal operating directives applicable wherever the device is installed.
Read the Operating Instructions
Read and observe these Operating Instructions.
b
Observe all safety instructions.
b
If anything is not clear: Please contact SICK Customer Service.
b
Retain documents
These Operating Instructions:
Must be available for reference.
b
Must be passed on to new owners.
b
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3 Product description

a*
Ausführung/Device Komponenten/Components
Messlanze/ Measuring probe
Cross-Duct
Ausführung und Kalibierung / calibration
Geräteart 1
Device type 1
Geräteart 2
Device type 2
Dokumentation / Documentation
GM32 -
Ex2G Ex3G
Ex-Gerät 2G (Zone1) Ex-Gerät 3G (Zone2)
Ex-device 2G (Zone1) Ex-device 3G (Zone2)
**** **
*
0
7
6
5
4
3
2
1
9
Sonderausführung SO2 SO2, NO, NOx SO2, NO, NO2, NOx
NO, NOx SO2, NO, NH3, NOx
SO2, NO, NH3, NOx NO, NO2, NOx
SO2, NO, NO2, NH3, NOx
special model

3.1 Product identification

Product name GM32 Ex
Device version Cross-Duct version
Manufacturer SICK AG
Type plates

3.2 Device version

Type code for Ex device versions
PRODUCT DESCRIPTION 3
Erwin-Sick-Str. 1 D-79183 Waldkirch · Germany
Sender/receiver unit: On the right side and on the intermedi‐
•
ate enclosure Connection unit: On the right and inside
•
On the purge air fixture: On the tube
•
On the reflector
•
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Figure 3: Type code for GM32 Ex
Ex version designation
*a
15
Ausführung Device
Anschlusseinheit - Connection unit housing
Anschlusseinheit - Analoge/Digitale Schnittstellen Connection unit - I/Os
Anschlusseinheit - Zusatzbestückung Connection unit - additional assembly
Geräteart Device type
Dokumentation / Documentation
Ex2G Ex3G
Ex-Gerät 2G (Zone1)
Ex-Gerät 3G (Zone2)
Ex-device 2G (Zone1) Ex-device 3G (Zone2)
GM32Gasmessgerät
Typ
Measuring system for gas Type
-A
Anschlusseinheit
Connection unit
a*
GM32 - A
***
*
3 PRODUCT DESCRIPTION
Type code for Ex connection unit
Figure 4: Type code for GM32 Ex connection unit
a*
Ex connection unit designation

3.3 Device variants

“Basic” variant
Reference cycle, see "Reference cycle", page 17: Correction of internal drifts.
•
Zero point check Automatic mirror tracking: Automatic adjustment of optical axis
•
Logbook: System messages are recorded in a logbook
•
Network: Ethernet interface with OPC standard
•
Ethernet: 1 x fiber optics connection on connection unit
•
“Pro” variant
As “Basic” variant. In addition:
TÜV-tested for equipment subject to authorization
•
Check cycle, see "Check cycle", page 17: Reference cycle (as in the “Basic” var‐
•
iant) followed by a cycle to check and output the zero and check point. The check cycle creates the QAL3 values (quality assurance of automated measuring sys‐ tems). The QAL3 values can be displayed with SOPAS ET. Operator panel: Measured values, operational state and malfunction messages
•
are displayed in clear text on a monitor QAL3 Tool (CUSUM chart)
•

3.4 Options

3.5 SOPAS ET (PC program)

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I/O modules (Analog Out, Digital Out, Digital In, Analog In)
•
SCU: Operating unit to control several analyzers with SCU capability (see SCU Oper‐
•
ating Instructions) Super calibration: Several applications/calibrations, e.g., for spare devices
•
Measuring range switch-over (analog outputs). The valid measuring range is sig‐
•
naled via a digital output (configured). Weatherproof cover
•
SOPAS ET enables:
Subject to change without notice
•
•
SOPAS ET runs on an external PC connected via the Ethernet interface, see "Connection
overview", page 34, to the GM32.
NOTE
Further information on SOPAS ET:
•
•

3.6 Reference cycle

Internal drifts correction in an adjustable interval (standard: 1 hour, setting: SOPAS ET) or per command (with SOPAS ET).
Measured value output during the reference cycle: Last valid measured value.

3.7 Check cycle

Check cycle = reference cycle + following check and output of the zero and check points (70% of full scale value).
PRODUCT DESCRIPTION 3
Additional configuration Access to logbook GM32
Technical Information GM32 SOPAS ET Help menu
Start a check cycle via
Set interval (SOPAS ET)
•
Command via SOPAS ET
•
External signal (optional)
•
Purpose of check cycle
Check of the zero point and a reference point for each component without feeding
•
test gases Meets the requirements of EN14181
•
Replaces drift monitoring with test gases according to QAL3
•
Zero point
An internal zero point reflector is swiveled in time-controlled in adjustable intervals. The emitted light is reflected back in the sender/receiver unit to the detector, the zero spec‐ trum is evaluated with the calibration function and thus the zero points of all ducts measured and output.
Signaling of maintenance request: Deviation from zero > ± 2% of the FS.
Check cycle
An internal swivel element with two reference filters and an NO-filled cell is swiveled in during the check cycle in addition to the zero point reflector and the reference value and concentration value measured. These control values are scaled to 70% of the selected measuring range.
Signaling of maintenance request: Deviation from setpoint value > ± 2% of the FS.
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1
2
3
4
7
8
5
6
3 PRODUCT DESCRIPTION
Measuring
1
Zero point
2
Check
3
Data recorder
4
Swivel element
5
Zero point reflector
6
Zero point
7
Figure 5: Measuring principle of check cycle
Check point (70% fsc)
8
Output of measured values during the check cycle Last valid measured value
Signal output during the check cycle (optional digital output or
Not_measuring
OPC interface)
Output of determined zero and reference values on analog outputs
Directly after the check cycle
•
On request via a digital input (option)
•
Signal output during the output Output_control values (optional digital output or OPC inter‐
face) Output sequence:
1 Zero values for 90 s 2 Reference values for 90 s
Display of zero and reference values, the last check cycle as well as QAL3 values in SOPAS ET
Display when check of NO cell failed
Menu: Diagnosis/check values
All interfaces: Results of NO cell
•
All interfaces: “0” is output instead of zero and refer‐
•
ence values Analog output: Live Zero
•
Results of zero and reference measurement are irrele‐
•
vant
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3.8 Layout and function

1
ß
9
8
6
6
5
4
3
2
7
ß
PRODUCT DESCRIPTION 3
Figure 6: Components of the GM32 Ex 3G version
Sender/receiver unit GM32-xxxxxxEX3G (SR-unit)
1
Connection unit GM32- A2xxEX3G
2
Control unit FS850S EEx p
3
Metallic connecting hose between sender/receiver unit and connection unit
4
Purge valve SVP3 G 3/8“-300L EEx p
5
Purge air fixture (without electronics)
6
Reflector unit (without electronics)
7
Temperature and pressure measurement
8
Purge air supply
9
Pressure switch for purge air monitor
ß
Function
The device serves for continuous measurement of gas concentrations in industrial
•
plants The device is an in-situ measuring system which means measuring is done directly
•
in the gas carrying duct
erence variables temperature and pressure Measuring principle: Differential Optical Absorption Spectroscopy (DOAS)
•
To maintain measuring reliability, a permanent air flow (optics purge air) protects
•
Measuring components: SO2, NO, NO2 and NH3 (device specific) as well as the ref‐
•
and keeps the optics free from soot and dust particles as well as condensate and moisture condensation Ignition protection type “pressurized enclosure” is applicable when using the
•
GM32 Ex in potentially explosive atmospheres. All relevant enclosures of the sender/receiver unit and connection unit connected together via a pressure-proof metal hose are purged with a protective gas. The protective gas can be air suc‐ tioned in from the non-potentially explosive atmosphere or an inert gas.
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19
DIV 1
DIV 2
Non Ex
1G
2G
Non Ex
3G
Zone 0
Non Ex
Zone 2Zone 1
DI/DOAI
/AO
230 /115 V
GM32 Ex ATEX 3G
Ex p [op is]
p/t
Ex ia
Ex m
Ex p/ Ex i
Ex eb mb [ib]
1
Non Ex
ß
à
9
á
7
6
8
5
3
4
ã ä å
2
9
à
ââ
æ
ç
3 PRODUCT DESCRIPTION

3.9 Purge air unit

The purge air unit supplies filtered ambient air to the purge air fixtures.
•
Protects the window of the SR-unit and the reflector against contamination and
•
high gas temperatures
One purge air unit each for SR-unit and reflector unit
•
The purge air is blown into the gas duct through the “flange with tube”.
•
NOTE
Further information on the purge air unit, see Operating Instructions of the purge air unit.

3.10 Explosion protection in accordance with ATEX

3.10.1 Zone separation GM32 EX ATEX 3G

Figure 7: Zone separation GM32 Ex 3G
Components Control station / measuring station
1
Sender/receiver unit
2
Reflector unit
3
Light source
4
Ex p valve
5
Evaluation unit
6
Overpressure control
7
p/T sensor
8
p sensor
9
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Optics purge air according to plant operator's selection
ß
Lines Purge air hose, optics
à
Connecting hose Ex p
á
Pressure controller, optics purge air Ex i nA
â
Ex p error case signal
ã
Service interface
ä
Feed, Ex p protective gas, provided by operator
å
Feed, optics purge air
æ
Measuring channel
Measuring channel Ex-free; Zone 2 possible with partial vacuum
ç

3.10.2 Pressurized enclosure

Ignition protection type, pressurized enclosure for Zone 2
Purging
All relevant enclosures of the sender/receiver unit and connection unit connected together via a pressure-proof metal hose are purged with a protective gas. This purging before the start of the device ensures any possibly present ignitable mixture is safely removed.
PRODUCT DESCRIPTION 3
Controlling the overpressure in the enclosure
The control FS850P ensures the complete enclosure is held at an overpressure of at least 0.8 mbar against the atmosphere after the purging which in turn ensures no ignit‐ able gas mixture can penetrate the enclosure.
Protective gas types
Instrument air suctioned in from the area outside the potentially explosive atmos‐
•
phere Inert gas
•
More information, see "Technical data protective gas", page 96 and Pressurized Enclosure Operating Instructions.
Alarm signal of the pressurized enclosure when a malfunction occurs
Ex control unit FS850S for category 3G: Ex control unit FS850S will trigger an alarm signal when the pressurized enclosure is not in the correct operating state (malfunction).
WARNING Risk of explosion through incorrect parameter settings
Unauthorized changing of parameters can cause an explosion with fatal consequences.
Never change parameters without authorization.
b
NOTICE
The operating company is responsible for the evaluation of the alarm signal. See the Pressurized Enclosure System Manual.
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3 PRODUCT DESCRIPTION

3.11 Connecting hose between SR-unit and junction box

The connection hose between the sender/receiver unit and the junction box
is part of the pressurized enclosure
•
contains electrical connection lines
•
is under overpressure
•
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4 Transport and storage

1
2

4.1 Transport safety device

Removing the transport safety device of the SR-unit and the reflector unit
1 Open the lock and swivel the flange fixture up 2 Check the transport safety device for damage 3 Remove the transport safety devices (see Figure) 4 Store the transport safety device
TRANSPORT AND STORAGE 4

4.2 Storage

Figure 8: Remove the transport safety device
Open the lock and swivel the flange fixture up
1
Remove the transport safety device
2
Clean all components of the measuring system with slightly damp cleaning cloths.
b
Use a mild cleaning agent here.
Check the desiccant cartridges and replace, if necessary.
b
After replacing the desiccant cartridges:
Perform a leak tightness check.
b
Protect the openings of the SR-unit and reflector unit from atmospheric influences,
b
preferably with the original transport safety devices.
Pack all components for storage or transport. Preferably use the original packing.
b
Store all components of the measuring system in a dry, clean room.
b
NOTE
The check of the desiccant cartridges and of the leak tightness of the device is descri‐ bed in the Maintenance Chapter, see "Check/replace the desiccant cartridge",
page 70.
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23

5 MOUNTING

5 Mounting

5.1 Information on installation in potentially explosive atmospheres

Project planning for measuring channel
NOTICE
Observe information in Chapter "Main operating information".
NOTICE
Hazard when exceeding the temperature classes for hot gas ducts The temperature class T4 (max. 135 °C), for which the explosion protection of this
device is designed, can be exceeded on hot gas ducts.
Plan appropriate insulation of the duct and the flange during project planning/
b
assembly. When necessary, ensure adequate ventilation or cooling.
b
Correct installation
DANGER Risk for system safety through work on the device not described in these Operating Instructions
Carrying out work on the device not described in these Operating Instructions or associ‐ ated documents can lead to unsafe operation of the measuring system and therefore endanger plant safety.
Only carry out the work on the device described in these Operating Instructions
b
and associated documents.
DANGER Risk of explosion through incorrect installation
Incorrect assessment of the installation location as well as all further installation work in potentially explosive atmospheres can cause serious injuries to people and damage during operation.
Installation, commissioning, maintenance and inspection may only be carried out
•
by skilled persons having knowledge of the relevant rules and regulations for potentially explosive atmospheres, especially: – Ignition protection types – Installation regulations – Zone classification Standards to be applied:
•
– IEC 60079-14, Annex F: Knowledge, skills and competencies of responsible
persons, operatives and designers – IEC 60079-17: Electrical installations inspection and maintenance – IEC 60079-19: Equipment repair, overhaul and reclamation
24
Local work safety regulations
•
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WARNING Risk of injury when the device drops down
The weight of the device can cause it to drop down and cause injuries during the work described in this Chapter.
Carry out assembly work on parts of the device together with another person when
b
necessary.
Purge air
DANGER Risk of explosion through suctioning optics purge air from an Ex zone
Zone separation is no longer ensured when the purge air supply to purge the optics is suctioned in within the Ex zone. This can lead to an explosion.
Always make sure the air for the purge air supply is suctioned in from an Ex free
b
zone.

5.2 Preparing the sampling point

MOUNTING 5
The operator is responsible for preparing the sampling point
NOTICE
Basis for determining the sampling point:
Preceding project planning (e.g., based on the SICK application questionnaire)
•
Regulations of the local authorities
•
Responsibility of the operator
Determine sampling point
•
Preparing the sampling point
•
Feed and drain for protective gas
•
DANGER Risk of explosion through suctioning optics purge air from an Ex zone
Zone separation is no longer ensured when the purge air supply to purge the optics is suctioned in within the Ex zone. This can lead to an explosion.
Always make sure the air for the purge air supply is suctioned in from an Ex free
b
zone.
NOTICE
Observe zone separation, see "Zone separation GM700 EX ATEX 3G".

5.3 Scope of delivery

NOTICE
Check the scope of delivery according to the order confirmation/delivery note.
b
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25
5 MOUNTING

5.3.1 Checking the delivery state

NOTICE
Check all components have no exterior damage.
b
Ensure the supply voltages on the type plates match the plant conditions.
b

5.4 Installation sequence

5.4.1 Overview of the installation steps (duct-side preparation)

Step Procedure Reference
1 Installing the flange with tube. see "Install flanges with tube",
2 Installing the connection unit. see "Installing the connection unit",
3 Fitting the purge air unit or units. see "Installing the purge air unit",
4 Observing protective gas discharge line (con‐
nection unit).
5 Connecting pressure, temperature and purge
air monitor.
6 Connecting protective gas feed to SR-unit. see "Connecting the protective gas on
page 26.
page 28.
page 30.
see "Fitting the FS850S", page 29.
see "Connecting pressure, temperature and purge air monitor ", page 40.
the SR-unit", page 50.

5.4.2 Install flanges with tube

DANGER Hazard through hot, explosive or toxic flue gases
Hot and/or noxious gases can escape during assembly work on the gas duct depending on the plant conditions.
Work on the gas duct may only be performed by skilled persons who, based on
b
their technical training and knowledge as well as knowledge of the relevant regula‐ tions, can assess the tasks given and recognize the hazards involved.
DANGER Hazard through hot, toxic and corrosive flue gases
Hot and/or noxious gases can escape during assembly work on the gas duct depending on the plant conditions.
Switch the plant off when working on the gas duct
b
or the operator determines the safety measures to be observed during work on the
b
plant when switched on.
CAUTION Device damage through incorrect/missing insulation of the duct when the measuring channel is hot
26
When the measuring channel is hot, plan the duct and flange insulation so that
b
the device is protected against high temperatures.
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Installing the flange with tube on the gas duct
1
200
18
4
5
°
1
2
1 Cut openings on the gas duct for the flange with tube. 2 Insert the flange with tube. Pay attention to the following:
°
The "Top" marking must point upwards vertically, irrespective of the gas duct
angle.
°
The tube must project at least 30 mm into the gas duct.
Figure 9: "Top" marking on flange with tube
"Top" marking
1
3 Attach the flange with tube.
MOUNTING 5
NOTE
Make sure other devices or installations do not intersect or interrupt the beam path of the measuring device.
4 Cut the flange opening for the reflector unit accordingly. Caution: Deviation of tube
axis between SR-unit and reflector unit: Max. 1°.
Figure 10: Define the measuring path
Active measuring path
1
Active measuring path "flange - flange"
2
4 Align the flange visually
Remove the protective cap from the adjustment tube.
w
Install the adjustment device (light source on SR-unit side, adjustment tube
w
on reflector side) onto the flanges.
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27
2
1
5 MOUNTING
Light source
1
Adjustment tube
2
NOTE
The alignment is performed on the flange where the adjustment tube is located.
– Look in the window of the adjustment tube and focus the light spot of the light
source by shifting the optical beam tube.
– Alignment: The light spot must be shown centrally in the target of the adjustment
tube.
Not aligned correctly
1
Aligned correctly
2
5 Attach the flanges with tube on the gas duct.
NOTICE
In doing so, the alignment of the flanges may not be changed!
6 Perform the check:
– Active measuring path dimension – Flange - flange dimension – Alignment
7 Remove the adjustment device again. 8 If necessary, attach duct insulation to protect the measuring device from heat.

5.4.3 Installing the connection unit

The lengths of the lines to the sender/receiver unit match the project planning.
Install the connection unit using the 4 threaded bolts according to project plan‐
b
ning.
NOTE
Dimension drawings of the connection unit and specifications on screw fittings for the lines, see "Dimension drawings: Connection unit version 3G", page 95.
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5.4.3.1 Fitting the FS850S
1
2
Information on fitting
When setting up outdoors, it is recommended to protect the explosion-proof device against direct atmospheric influences, e.g, with a protective roof.
The fitting position is independent of the location but it should be ensured that the pro‐ tective gas inlet and outlet are in a horizontal axis
MOUNTING 5
Figure 11: Protective gas outlet
Protective gas outlet: Thread G 1"
1
Reference opening (M5 inner thread)
2
Protective gas quality
Instrument air or inert gas
•
Compressed air, class 533 according to ISO 8573-1
•
Solid matter 40 µm (class 1)
•
Pressure dew point ≤ 20 °C (class 3)
•
Oil quality ≤ 0.01 mg/m3 (class 1)
•
The air quality may possibly have to be better depending on the requirements of the devices fitted in the pressurized enclosure.
Protective gas outlet
It is important that protective gas can flow out of the protective gas outlet against the atmospheric pressure.
Ensure the unhindered flow of the protective gas.
b
Reference opening
The reference opening must be located in the Ex area.
Make sure the opening is always clear.
b
Line lengths for protective gas supply
Large pressure losses occur during the purge phase (high purge medium throughput) depending on the supply line diameter. Consider this when dimensioning the supply line:
Reference values: With 4 mm line diameter (inner diameter), a pressure loss of 500 mbar per meter must be calculated during purging with 2 l/s.
Pressure losses are apparent due to the purge medium throughput being too low and lead to a longer or never-ending purge phase.
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5 MOUNTING
NOTE
More information on protective gas,
see "Connecting the Ex overpressure control FS850S", page 41.
•
see "Technical data protective gas", page 96.
•

5.4.4 Installing the purge air unit

NOTE
Purge air hose to the device according to project planning.
NOTE
For information on installing the purge air unit, see the Operating Instructions of the purge air unit.
5.4.4.1 Start-up of the purge air supply
CAUTION Risk of device damage caused by inadequate purge air pressure
The purge air supply protects the measuring system from contamination and overheat‐ ing. If the purge air pressure is inadequate, the purge air can not enter the gas duct. This can result in inadequate provision with purge air and therefore a device failure.
Ensure the purge air pressure is adequate to force the purge air into the gas duct.
b
If you have questions concerning the purge air pressure, contact SICK Customer
b
Service or your local SICK representative.
CAUTION Risk of device damage through accidentally switching off the power supply
The purge air supply may not be switched off while the measuring system is on the gas duct.
Attach clearly visible warnings against accidental switching-off to all switching devi‐
b
ces where the purge air supply can be switched off.
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