SICK gm35 Operating Instructions Manual
I
GM35 Probe
Gas Analyzer for CO, N2O, CO2 and H2O
Version with Measuring Probe
Installation, Operation, Maintenance
MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
MMM
Document ID
Title: Operating Instructions GM35
Part No.: 8009389
Release: 2015-08
Described Product
Product name: GM35
Version: 3-0
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Phone: +49 7641 469-0
Fax: +49 7641 469-1149
E-Mail: info.pa@sick.de
Place of Manufacture
SICK AG
Nimburger Str. 11 · D-79276 Reute · Germany
Legal Information
This work is protected by copyright. All 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 modification, shortening or translation of this document is prohibited without the
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
CONTENTS
1 Safety Information..................................................................................... 9
1.1 Permissible users............................................................................................ 9
1.2 Correct handling.............................................................................................. 9
1.3 Safety............................................................................................................... 9
1.4 Behavior during purge air failure..................................................................10
2 Product Overview .....................................................................................11
2.1 Use and proper application ..........................................................................11
2.1.1 Conformities and certifications ....................................................11
2.1.2 Overview of standard components ..............................................12
2.1.2.1 Measuring probe in detail.........................................14
2.1.2.2 GMP – probe with open measuring gap and vertical
purge air outlet..........................................................14
2.1.3 GM35 options and accessories ...................................................18
2.2 Functional principle ......................................................................................19
2.2.1 Opto-electronic in-situ measuring principle.................................19
2.2.2 Signal evaluation ..........................................................................20
2.2.3 Automatic check cycles ................................................................21
3 Project Planning Information................................................................. 22
3.1 Work steps from system selection to start-up .............................................22
3.2 Project Planning Checklist ............................................................................23
3.3 Initial onsite installation ...............................................................................26
3.3.1 Assembly preparation at the measuring point ............................26
3.3.2 Uncovering the duct......................................................................27
3.3.3 Installing the flange with tube......................................................27
3.3.3.1 Installation steps: Fitting the flange with tube ........28
3.3.4 Installation preparation for the purge air unit .............................29
3.3.5 Duct insulation..............................................................................29
3.3.6 Installation preparation for the evaluation unit ..........................30
3.4 Preparations for electrical installation .........................................................30
3.5 Electrical protection ......................................................................................30
3.6 Specifications on electric isolation of the EvU.............................................30
3.6.1 Electrical installation safety information .....................................30
3.7 Electrical protection ......................................................................................32
3.8 Specifications on electric isolation of the EvU.............................................32
3.9 Laying connection lines ................................................................................33
3.9.1 CAN bus wiring ..............................................................................34
4 Installation ................................................................................................36
4.1 Preparations..................................................................................................36
4.1.1 Checking the scope of delivery ....................................................36
4.1.2 Installation prerequisites..............................................................36
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4.2 Fitting system components .......................................................................... 37
4.2.1 Information on the SR-unit and measuring probe ...................... 37
4.2.2 Installing the purge air unit.......................................................... 37
4.2.3 Terminal box (option) ................................................................... 38
4.3 Installing the evaluation unit........................................................................ 39
4.3.1 Installing the evaluation unit – sheet metal enclosure version. 39
4.3.2 Installing the evaluation unit – cast enclosure version.............. 40
4.4 Electrical connection of system components.............................................. 41
4.4.1 Electrical connection for the purge air unit................................. 41
4.4.2 CAN bus wiring options ................................................................ 42
4.4.3 Electrical connection of the evaluation unit ............................... 44
5 Handling the Evaluation Unit .................................................................47
5.1 User qualifications........................................................................................ 47
5.2 Operating elements ...................................................................................... 47
5.2.1 Function buttons and menu overview ......................................... 48
5.2.2 Display contents........................................................................... 49
5.2.3 Menu structure............................................................................. 49
5.2.3.1 Menu structure Measuring Mode ............................ 49
5.2.3.2 Menu structure Diagnosis ........................................ 50
5.2.3.3 Menu structure Calibration ...................................... 50
5.2.3.4 Menu structure Configuration .................................. 51
5.2.3.5 Menu structure Maintenance Mode (Maint) ........... 52
6 Connecting the System Control Unit - SCU........................................... 53
6.1 SCU connection to the GM35....................................................................... 53
6.1.1 Electrical connection of the SCU to the GM35 ........................... 53
6.1.2 Configuring and operating using SOPAS ..................................... 53
6.1.3 Connecting the GM35 evaluation unit via the SCU operating
unit................................................................................................ 55
6.1.4 Direct serial connection to the GM35 evaluation unit .............. 57
6.1.5 Changing the user level ............................................................... 59
6.1.6 Menu overview (menu tree) ........................................................ 60
6.1.7 Measured values.......................................................................... 60
6.1.8 Menu Parameter .......................................................................... 61
6.1.9 Menu Adjustment ......................................................................... 66
6.1.10 Menu Diagnosis............................................................................ 70
6.1.11 Menu Maintenance ...................................................................... 72
7 Start-up...................................................................................................... 75
7.1 Preparations ................................................................................................. 75
7.1.1 Required qualifications and further prerequisites...................... 75
7.1.2 Start-up procedure overview........................................................ 75
7.2 General preparation ..................................................................................... 75
7.2.1 Required tools and materials for the installation ....................... 76
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7.3 Mechanical preparations for the SR-unit and reflector ...............................77
7.3.1 Checking the scope of delivery ....................................................77
7.3.2 Transport safety devices ..............................................................77
7.3.3 Cleaning the optical interface ......................................................78
7.4 Aligning the measuring probe in flow direction ...........................................79
7.4.1 Installing the SR-unit on the measuring probe............................80
7.5 Adjustment work ...........................................................................................82
7.5.1 Prerequisites and location selection for adjustment work .........82
7.5.2 Adjustment preparations..............................................................83
7.5.3 Aligning the optical axis of the measuring probe ........................84
7.5.4 Performing zero adjust .................................................................87
7.6 Starting measuring operation.......................................................................88
7.6.1 Starting up the purge air supply...................................................88
7.6.2 GPP measuring probes: Power supply .........................................89
7.6.3 Installing the GM35 SR-unit and measuring probe on the duct.89
7.6.4 Electrical connections and checking the optical alignment .......90
7.6.5 Weatherproof cover ......................................................................92
7.6.6 Evaluation unit start-up ................................................................93
7.6.7 Setting up the SCU System Control Unit .....................................93
7.6.7 Mapping Table...........................................................93
7.6.7 Measured values on SCU – Measured value (MV) ..93
7.6.7 Control values on SCU – Monitor values (MO).........93
7.6.7 Operating state of the GM35 – State (S) .................94
8 Test Gas Measurement with GPP Measuring Probes.........................96
8.1 One-off preliminary measurement/determining the settings .....................97
8.2 Manual gas test ............................................................................................98
9 Maintenance............................................................................................. 99
9.1 Safety.............................................................................................................99
9.2 Preparation and general preparatory work ............................................... 101
9.3 Maintenance work on SR-unit and measuring probe ............................... 103
9.3.1 Taking the SR-unit with measuring probe off the sample
gas duct...................................................................................... 103
9.3.2 Visual inspection and enclosure cleaning ................................ 104
9.3.3 Cleaning the optical interfaces on the SR-unit......................... 104
9.4 Maintenance work on the purge air supply .............................................. 106
9.4.1 Safety ......................................................................................... 106
9.4.2 General information on maintenance work on the purge
air supply.................................................................................... 106
9.4.3 Preparation and general inspection ......................................... 106
9.4.4 Checking and replacing the purge air filter .............................. 107
9.4.5 Restarting and checking the purge air unit .............................. 109
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9.5 Resuming Measuring mode .......................................................................109
9.5.1 Inserting in the sample gas duct ...............................................109
9.5.2 Electrical connection..................................................................110
9.5.3 Checking and adjusting the optical alignment of GM35 .........111
9.5.4 Completing maintenance work at the measuring point ...........112
9.6 Evaluation unit (EvU) ..................................................................................112
9.7 Box measuring: Checking the measuring ducts for CO or N
and CO
......................................................................................113
2
O
2
9.7.1 Determining the necessary test gas concentration ..................113
9.7.2 Carrying out measurement ........................................................113
9.7.3 Restart Measuring mode ...........................................................115
9.8 Box measuring: Checking the measuring ducts for H
CO
..............................................................................................116
2
O and
2
9.8.1 Setpoint values........................................................................... 116
9.8.2 Carrying out measurement ........................................................116
9.8.3 Restart Measuring mode ...........................................................118
10 Troubleshooting and Clearing Malfunctions......................................119
10.1 Malfunction categories/possible effects................................................... 119
10.2 Purge air failure .......................................................................................... 119
10.3 Integrated monitoring and diagnosis system ............................................120
10.3.1 Troubleshooting and clearing malfunctions, evaluation unit...121
10.3.2 Error messages for the GM35 SR-unit ......................................121
10.3.3 Error messages for the measuring probe .................................124
10.3.4 Warning messages for the GM35 SR-unit.................................124
10.3.5 Warning messages for the measuring probes ..........................126
10.3.6 Further tips on troubleshooting .................................................126
11 Technical Data, Consumables and Spare Parts...............................128
11.1 Data Tables.................................................................................................128
11.1.1 Measuring components and accuracy ......................................128
11.1.2 Stability....................................................................................... 129
11.1.3 GM35-system components
11.2 Dimension drawings ...................................................................................132
11.2.1 GM35 SR-unit dimensions........................................................132
11.2.2 Open measuring probe - GMP, dimensions...............................133
11.2.3 GPP measuring probes dimensions .......................................... 134
11.2.4 Dimension drawing of GM35 evaluation unit, sheet metal
enclosure ....................................................................................135
11.2.5 Dimension drawing for GM35 evaluation unit, cast enclosure136
11.2.6 Purge air unit dimension drawing.............................................. 137
11.2.7 Weatherproof covers dimension drawings................................ 137
11.2.8 Terminal box for CAN bus connection, dimension drawing......139
11.2.9 Flange with tube, dimension drawing and Version Table......... 139
................................................ 130
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11.3 Consumables and spare parts .................................................................. 140
11.3.1 Consumable parts for 2-years operation .................................. 140
11.3.2 Spare parts for the sender/receiver unit.................................. 140
11.3.3 Probe spare parts ...................................................................... 143
11.3.4 Spare parts for the evaluation unit........................................... 144
11.3.5 Spare parts for purge air unit.................................................... 145
11.3.6 Spare parts, miscellaneous....................................................... 145
11.3.7 Fixing accessories...................................................................... 145
11.3.7 Fixing accessories, measuring probe - flange....... 145
11.3.7 Fixing accessories, SR-unit - measuring probe ..... 145
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CONTENTS
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1 Safety Information
The following information and guidelines apply to the Gas Analyzer with Measuring Probe
GM35 described in this “Operating Instructions” document, and are valid for all user
groups performing any work on or using the analyzer.
1.1 Permissible users
All planning, assembly, installation, start-up, maintenance and repair work must be carried
out by adequately instructed personnel only and checked by skilled persons.
Persons responsible for safety must ensure the following:
• All safety-relevant work is carried out by qualified personnel only.
• Qualified persons are those who, based on their training, experience or instruction as
well as their knowledge of relevant standards, regulations, accident prevention rules and
plant conditions, are authorized by those responsible for safety for personnel and the
plant to carry out such work. It is decisive that these persons can recognize and avoid
possible hazards in a timely manner. Skilled persons are persons according to
DIN VDE 0105 or IEC 364 or directly comparable standards such as DIN 0832.
• These persons have access to the documentation supplied with the system as well as the
relevant technical documentation for all work carried out, and these persons adhere to
the information in this documentation in order to prevent danger or damage.
SAFETY INFORMATION
1.2 Correct handling
To ensure safety precautions are observed and the device is used for its intended purpose,
it is important that:
• The system be used in accordance with the technical data and specifications regarding
permissible usage, assembly, connection, ambient, and operating conditions. These
conditions are governed by the order documents, user information (type plates etc.), as
well as the documentation supplied with the system, which includes these
Operating Instructions.
• Users act in accordance with local, system-specific conditions and with due
consideration paid to operational hazards and specifications.
• All measures necessary for conservation of value are observed, e.g. during transport and
storage and/or maintenance and inspection.
1.3 Safety
WARNING: Risk through incorrect use
Equipment-internal protection devices can be impaired when the device is not
used as defined.
▸ Read the Manual before installation, start-up, operation and
maintenance and observe all information on using the equipment.
NOTICE: Responsibility for the safety of a system
The safety of the system in which the equipment is integrated is the
responsibility of the person setting up the system.
Basic measures to prevent property damage and injury to persons
Improper usage or improper handling of Gas Analyzer GM35 can damage health or
material.
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SAFETY INFORMATION
▸ Therefore, in order to prevent damage, the relevant safety information and valid safety
If the GM35 is used as a sensor in combination with a control system, the operator must
ensure that a failure or malfunction on the GM35 cannot lead to unallowed hazardous
operating states or damage.
Protection against hazards through electrical equipment
GM35 system components include electrical equipment designed for use in industrial highvoltage plants where the relevant standards and regulations must be observed.
▸ Disconnect mains lines before working on mains connections or live parts.
Protection against hazards through gases
▸ Wear suitable protective clothing and mask when using hot and/or aggressive sample
▸ Never open the enclosure or switch off the purge air feed without taking appropriate
Troubleshooting precautions
The operator must ensure that:
• Maintenance personnel can be alerted immediately and at any time.
• Maintenance personnel are trained to be able to respond to malfunctions on the GM35
• Suitable protective equipment, tools and auxiliary means are available at all times.
• Malfunctions are analyzed by qualified personnel, faults corrected, and operation
regulations must be observed.
gases resp. with high dust loads.
protective measures when the duct is pressurized.
and correctly clear the operational malfunction involved.
optimized to prevent similar malfunctions in the future.
1.4 Behavior during purge air failure
The GM35 measuring system configurations demand immediate measures to protect the
measuring system should the purge air supply fail.
▸ Measures for purge air supply failure,
see “Purge air failure”, page 119.
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2Product Overview
2.1 Use and proper application
PRODUCT OVERVIEW
The GM35 in-situ gas analyzer continuously measures the concentration of CO
CO or N2O, and in gas ducts – as single or simultaneous measurement depending on the
device variant. As in-situ measuring system, the GM35 determines the measured values
directly in the gas-carrying duct without extracting any samples.
• Emission monitoring
The GM35 determines and quantifies pollutants and reference values in gases reliably,
quickly and precisely.
• Process analysis and control
The reliability, precision, and short response time of the GM35 are decisive advantages in
the efficiency of control circuits in all processing creating CO, N
and drying plants are reliably monitored and efficiently controlled.
2.1.1 Conformities and certifications
Many areas of application require conformity with certain specifications. The Gas Analyzer
with Measuring Probe GM35 complies with the following requirements:
• Guidelines regarding qualification tests for measuring equipment intended for
continuous emission measurements
• Performance testing of ± 2% precision of the measuring range end value (TÜV certified)
• Conformity according to EN 14181 and suitability for emission measurement in plants
according to the 13
components CO, CO
• Conformity with the GOST regulation, Certificate No. DE.C.31.001.A No. 11933
• Conformity with the U.S. EPA regulation CFR 40, Parts 60, 75 and 29 CFR 1310
• KAITEC certified (Korea)
• EMV conformity in accordance with EN 50081-1/EN 50082-2
• CE conformity in accordance with EC Directive EMC 89/336/EWG
• The manufacturer SICK is certified according to ISO 9001
• EC Directive LVD 2006/95/EC
• EU Directive EMC 2004/108/EC
• Applied EN standards:
• EN 61010-1, Safety requirements for electrical equipment for measurement, control and
laboratory use
• EN 61326, Electrical equipment for measurement, control and laboratory use - EMC
requirements
O- and CO2. Incinerating
2
th
, 17th BImSchV and the TI Air, KAITEC certified (Korea) for
and H2O (Cross-Duct and GMP measuring probe versions)
2
2, H2
O and
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PRODUCT OVERVIEW
maintcalpardiag
GM 35
Evaluation Unit
CO
CO
2
H 2 O
mg/
m
3
236
Ref. conditions
Hum: wet
Measuring
Operation
Service
Warnin
Malfunction
Purge air unit SLV4
(not required when
using GPP measuring
probes)
GM35 sender/receiver unit
with GMP measuring probe
Temperature
sensor
Evaluation unit
EvU
CAN bus
CAN
Inputs/outputs
analog, binary
Interfaces to plant
peripherals:
•Host computer
•Sensors
• Measured data
processing
• Status signals
2.1.2 Overview of standard components
Fig. 1: GM35 system overview
• Sender/receiver unit (SR-unit)
Contains the main optical and electronic subassemblies of the measuring system. Records
gas concentrations, calculates measured values, measures components CO or N
and H
O; both singly and simultaneously in combinations.
2
O, CO2
2
• Measuring probe
Measuring probes are available in open design versions with integrated purge air guidance
system (GMP) as well as versions with a gas-permeable diaphragm not requiring purge air
(GPP: G
as Permeable Probe). Both versions are described from page 14 onwards.
• Purge air unit
Provides purge air supply for the SR-unit with a GMP measuring probe (open design) and
protects against contamination and high gas temperatures. The blower types for the
SR-unit resp. reflector are designed differently depending on the application.
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PRODUCT OVERVIEW
• Evaluation unit
The evaluation unit in the GM35 measuring systems serves as user interface and
prepares and outputs the measured values and performs control and monitoring
functions. The EvU can be installed near the SR-unit; if necessary, however, it can also
be installed up to 1000 m from the measuring point, e.g. in a central control/monitoring
room in an industrial plant.
The evaluation unit carries out the following tasks, for example:
– Output of measured values, computed data and operating states
– Communication with the peripheral equipment
– Output of error messages and other status signals
– Control of automatic test functions and access during service (diagnosis)
• Connection cables
Cable type Part No.
Cable*) (CAN bus), SR-unit – measuring probe, length 1.0 m 2023704
[1]
Cable
Cable
(CAN bus), SR-unit – evaluation unit, length 4 m
*)
, measuring probe – filter monitor for purge air unit, length
5m
*)
2 cables
, measuring probe – filter monitor for purge air unit, length
2 m as extension
Cable, measuring probe – filter monitor for purge air unit, length 3 m
as extension
Scope of
delivery
2032143
6025923
6028663
[1]Included in scope of delivery
• Flanges with tube
To install the SR-unit with measuring probe on the gas duct.
The purge air fixtures onto which the SR-unit and reflector are
later mounted are secured to the flanges. Dimension drawing
and order data,
page 139. ANSI or DIN flanges provided by the
customer can be used alternatively to the flanges supplied.
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PRODUCT OVERVIEW
2.1.2.1 Measuring probe in detail
EPA conformity When using a GPP probe, an audit measurement in compliance with EPA CFR 40 Part 60 or
Part 75 can be performed with the device mounted.
2.1.2.2 GMP – probe with open measuring gap and vertical purge air outlet
Shortest response times and resistance against high temperatures characterize measuring
probes of the GMP series. A continuous purge air supply is required for operation. In the
current GMP probe series, the air is outlet into the duct at 90° to the gas flow (directed
purge air).
The GMP probe has a closing device towards the opening for sample gas and is operated
using the lever on the probe flange.
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PRODUCT OVERVIEW
Tempera ture sensor
PT 1000
Purge air outlet
Open measuring path
(measuring gap)
Lever position
Lever and closing
device: Open
Fig. 2: GMP measuring probe (with open measuring gap)
GPP – gas diffusion probe as dry or wet version
These GPP probe versions are more suitable for higher dust contents than GMP probes
because the GMP probes separate dust particles at the filter element which keeps the dust
away from the measuring path. The GPP (G
as Permeable Probe) is also the best measuring
probe choice for audit measurements according to EPA specifications as well as for low
flow rates or irregular flow profiles.
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PRODUCT OVERVIEW
Temperature sensor PT 1000
Ceramic filter or Teflon/
ceramic filter, gas permeable
Fig. 3: Measuring gap for GPP measuring probe
The two versions of the GPP differ with regard to the respective filter making them suitable
for different applications,
see page 17.
Advantages of GPP
probes
GPP probes do not require a purge air supply and are easy to maintain. They are fitted with
an automatic heater for reliable prevention of condensate on the optical interfaces. The
electronic components for the heater regulator, and temperature and pressure
measurements, are located protected in a stable cast housing which forms the measuring
probe section between the duct flange and the SR-unit.
The Figure below shows this housing fitted with the electrical connections for the CAN bus
and power supply as well as the test gas connection which supports audit measurement
according to EPA Directive CFR 40, Part 60 or Part 75.
16
Fig. 4: Electronic connections on the GPP probe
GM35 measuring probes in comparison
This Table shows an overview of the features of the different measuring probes. All
measuring probe versions are compatible with all SR-units. The SR-unit is calibrated to the
respective probe length on delivery.
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PRODUCT OVERVIEW
Measuring probe GMP (open probe) GPP (dry)
Measuring path open in flow
Version
direction; purge air guidance
with outlet aligned 90° to
gas flow
[1]
Max. gas temperature
430 °C
N20 measurement up to
180 °C
Gas check according to EPA
specification possible
–Yes
Purge air supply required Yes –
Heating on optical interfaces
in the probe
– Yes, with integrated control
Flow rate of sample gas 1...40 m/s < 40 m/s
Suitable for wet sample gas Yes –
Maximum duct pressure
Measurable components
System-response time (T
Duct diameter
[3]
Dust concentration < 2 g/m
±120 hPa, depending on
purge air supply
[2]
CO or N20, CO2, H2OCO or N
) ≥ 5s ≥ 120 s
90
> 360 mm > 300 mm
3
act < 30 g/m3 act
Probe lengths available [m] 1.0/1.5/2.0 / 2.5 1.0/ 1.5/2.0
Active measuring paths
available [mm]
**
250/500/750/1000/1250 250/500/750/1000
Gas diffusion probe with
ceramic filter, for dry
sample gas
430 °C
N20 measurement up to
180 °C
±120 hPa
0, CO2, H2O
2
Table 1: Comparison Table for GM35 measuring probes (dimension
drawings,
[1] The maximum temperature used for the measurement depends on the application.
[2] Probes are fitted with gold-plated hollow triples when CO or N20 is measured as component or with other
components, otherwise probes with quartz glass are used.
[3] Probes with shorter active measuring paths are available on request (may be required for higher concentrations
or smaller duct diameters)
see page 128)
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PRODUCT OVERVIEW
Special versions Apart from the standard probes shown above, other versions made from materials
especially resistant to acid are available (1.4539 and PVDF). Special versions can be
manufactured according to customer demands on request.
2.1.3 GM35 options and accessories
• Automatic beam tracking
Ensures exact alignment of the measuring path to the probe (open and GPP version) under
difficult and changing measurement conditions, such as, for example, large temperature
fluctuations.
• CAN bus extension cable 15 m
A 15 m extension cable, ready for connection, is available when the evaluation unit is to be
installed more than 2 m away from the SR-unit.
• Terminal box for CAN bus
For even greater distances between SR-unit and EvU, an optional terminal box can be used
for the connection via the CAN bus cable provided by the customer. The total length of the
CAN bus connections in the GM35 measuring system can be up to 1000 m in this case.
However, the EvU is normally installed close to the SR-unit for easy operating at the
measuring point. Section
to use the terminal box.
• Angle flange for zero point measurement
Some adjustments must be made outside the duct in an atmosphere free from sample
gas. A suitable angle flange that can be screwed to the mounting flange is available to
enable carrying out these adjustments easily and directly at the measuring point. The duct
is sealed and the SR-unit with measuring probe is mounted in front of the duct opening, at
a right angle to the duct, using this bracket.
“Preparations for electrical installation”, page 30 describes how
• Weatherproof covers for SR-unit and purge air unit
Required for outdoor installation – dimension drawings,
see page 128.
• Line writer, single or multi-duct
For measured value recording. Protocol(s) can of course be produced using customer
systems.
• Air heater for purge air supply
For special application conditions to prevent condensate. An air heater is required when
the difference between gas temperature and dew point temperature is too low. The
following practical rule of thumb serves as guideline:
An air heater is required when :
Gas temperature [°C] – dew point temperature [°C] < abs. humidity [%]
Values are compared without considering the units of measure.
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2.2 Functional principle
Reflector of
the measuring
probe
Front window of the SR-unit
Measuring path in the gas
duct (Measuring gap or
diffusion filter depending on
the probe)
Deflection mirror
Filter wheel and detector for
CO2 and H2O
CO detector
Cell wheel CO/N
2
Filter for CO measurement
Visor with opto-electronic adjustment tool
IR transmitter
lamp
Chopper
Lens mirror Reference filter pivot segment
Beam splitter
Zero point reflector
and blanking
diaphragm
2.2.1 Opto-electronic in-situ measuring principle
The Gas Analyzer with Measuring Probe GM35 is based on in-situ technology with optoelectronic direct measurement. Measured values are recorded through no-contact
measurement directly in the gas flow across the entire duct cross-section (cross-duct). The
GM35 SR-unit determines the concentration of the respective gas component based on
wavelength-specific light absorption by the gas mixture in the active measuring path.
PRODUCT OVERVIEW
Fig. 5: Optics layout of the GM35
The beam from the sender/receiver unit (SR-unit) passes lengthwise through the active
measuring path (
see page 26) and is reflected by the reflector at the other end. The
reflected light from the beam splitter then passes through a filter or cell wheel to detectors
configured optionally to measure CO or N
received into its spectral components, the receiver elements record the absorption of the
gas molecules at characteristic points of the spectrum in the IR range of 1.6 to 4.9 µm.
0 as well as CO2 and H2O. By filtering the light
2
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PRODUCT OVERVIEW
CO
CO
2
H2O
2000 2500 3000 3500 4000
λ
[nm]
4500 50001500
18001600 2000 2200
Ref. 2 H2OCO2Ref. 1
Absorpti
H2OCO
2
46004400 4800 5000
CO
N
2
CO
4600 4800 4600 4800
CO2 and H2O measurement in the
range of 1600– 2200 nm
CO or N
2
O measurement
in the range of
approx. 4500–4900 nm
Cell wheel
N
2
/CO
Absorption CO
≈ measured value
Absorption CO
= 100%
Filter wheel for
CO
2
and H2O
Reference filter for determining the
background absorption, free of crosssensitivities with other gas components
The CO or N
2
O- measured values are
determined from the signals at the detector with
absorption by the sample gas and with a cell
filled with the component to be measured.
Interference is eliminated
Tra nsmi ssi on
characteristic
line of the CO
measurement
filter
Absorption
Cross-sensitivities with gases other than those to be measured are avoided by selecting
these evaluation ranges within the IR spectrum in conjunction with the evaluation
algorithms used (see
2.2.2 Signal evaluation
The optimized algorithms of the GM35 evaluation electronics process the measurement
signals of the receiver elements together with the associated parameters in accordance
with the correlation procedure with optical filters for CO
gas for CO or N
O.
2
page 20).
and H2O and with cells filled with
2
Fig. 6: Evaluation of absorption spectrums for sample gases with the GM35
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2.2.3 Automatic check cycles
Measure
Zero point
Check
Zero point
Check point
(70% fsc)
Zero point reflector
Swivel element
Data recorder
To ensure a consistently high level of measuring precision, the GM35 SR-unit performs a
regular automatic check cycle in an adjustable interval (standard: Every 2 hours). In this
check cycle, the zero point is first determined by swiveling a zero point reflector into the
beam path. Reference filters are then moved into position to control the check point. The
spectral properties of the device are checked using a test gas cell. If a check cycle reveals
that the system is not functioning in accordance with the operation specifications, the
GM35 measuring system outputs appropriate error or warning messages.
Triggering options
1 Di 1 (falling edge): The check cycle can also be suppressed with this function.
2 Time interval, adjustable via the menu of the EvU.
Sequence
1 Check cycle is started.
2 Internal reference measurement is executed. Signal: Relay 3 (function check)
3 The zero point and check point are output on the EvU display and the assigned analog
outputs for 90 seconds each. Relay 3 remains active.
PRODUCT OVERVIEW
Observe the following for connecting to an emission computer: Measure the
time from the start to the output to compensate differences in the device
settings.
Fig. 7: Determining the check point
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PROJECT PLANNING INFORMATION
3 Project Planning Information
3.1 Work steps from system selection to start-up
Application changes
If the information regarding your application submitted with your purchase order has
changed, or if a device is to be used for an application other than the one that was
originally intended, please contact your local sales representative or our project planning
department to determine whether the device(s) can be used under the new conditions, and
whether readjustment or reparametrization is necessary.
The following steps are generally carried out before the measuring system is started up:
The version of the TCU-MS operating unit is selected according to the external signals to be
processed or output.
• Project planning
See planning checklist below
• Initial onsite installation
Following preparatory work normally carried out by the customer is described on
page 26:
• Flange assembly,
– Preparation for assembling the purge air unit, see page 29.
– Laying the signal and power supply cables to the measuring point, see Chapter 3.9 ,
page -33.
– Preparations for installing the EvU, see “Installation preparation for the evaluation unit”,
page 30
.
– Possibly preparation of signal cables for the interface to peripheral equipment, see
“Preparations for electrical installation”, page 30
• Device installation
To allow speedy start-up, the following components are normally installed ready for
operation before the start-up date;
see page 27.
see “Installation”, page 36.
– Purge air unit
– Evaluation unit
• Start-up
The actual start-up procedure is carried out by trained personnel or SICK Customer
Service. This work is described on
page 53. The main activities are adjustment tasks on
the GM35 system related to the application.
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PROJECT PLANNING INFORMATION
3.2 Project Planning Checklist
The following Checklist simplifies performing and controlling project planning measures
required before start-up in the correct sequence. Technical data and dimensional drawings
of system components,
Topic Task Measure/determination
Determination of
measuring point
Observe national
regulations such as
VDI 3950
Provide for unhindered inlet and outlet paths:
▸ For round duct cross-sections: 3 times the duct diameter
▸ For rectangular cross-sections: Hydraulic diameter
page 128 and following.
▸ If these specifications cannot be met: Inlet path > outlet path,
2
/3 : 1/3; uniform concentration spread whenever possible
e.g.
▸ Obtain official approval for emission measuring point.
Emission measuring
point
Application conditions
▸ Provide for calibration openings at easily accessible places.
▸ Ensure the GM35 and calibration probe do not influence
each other; the calibration gland should be located at a
minimum distance of 0.5 m away from the measuring device.
▸ Observe Technical Data for duct/ambient conditions!
▸ Gas temperature above/below dew point (dry/wet)
▸ Acc. to FGD wet :
Installation location
Pressure conditions
at the measuring
point
Select a version with active measuring path ≤ 500 mm when
a GMP probe is used.
▸ A fitting location with partial vacuum in the duct is ideal.
▸ For duct pressures > 10 mbar, please contact SICK to select
the correct purge air blower type.
4F (Cross-sectional area)
-------------------------------------------------------------------------------------=
D
U (Circumference)
Table 2: Project planning checklist
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PROJECT PLANNING INFORMATION
Topic Task Measure/determination
SR-unit, probe
See 3.3.1 “Assembly preparation at the measuring
point”, page 26
Select suitable flange
with tube
▸ Flange fitting is planned in steel ducts as standard;
corresponding flanges with tube are normally included in the
GM35 scope of delivery.
▸ Brick stacks or thick-walled ducts require a holding plate, to
be provided by the customer, and, if necessary, a longer
flange with tube, see Chapter 3.3.3 , page -27.
▸ If some of the components have not yet been delivered, you
may need to arrange an advance delivery of the flanges with
tube so that you can mount these as part of the preparations
for installation onsite.Alternatively, you can use a suitable
flange prepared onsite (or ANSI flange, check the Technical
Data, see page 128).
▸ Determine the alignment of the measuring gap of the GM35
measuring probe in gas flow direction.
▸ Provide a suitably sized opening for the tube of the mounting
flange.
▸ Install the flange with tube tilted slightly downwards (> 1°) to
prevent condensate deposits and therefore corrosion.
Duct openings
selection
▸ Provide for adequate clearance for installation and
maintenance activities for the duct insulation cutout.
▸ Plan sufficient clearance for pivoting the GM35 SR-unit,
removing the cable connector from the device, and pulling
the measuring probe out of the duct.
▸ Ensure the ambient temperature for the GM35 SR-unit is
between -20 and +55 °C (–40 °C during continuous
operation).
▸ For installation outdoors, plan a weatherproof cover.
▸ If adjustments are to be made at the measuring point
(prerequisites: clean, atmosphere free from sample gas;
protected from weather): order the angle flange for zero point
measurement (Part No. 2 017 833); when necessary, plan a
longer version of the flange with tube to ensure sufficient
distance from the duct.
▸ Plan installation location on the duct in immediate vicinity
(5 m) of the GM35 SR-unit.
▸ Keep the purge air hose to the measuring probe as short as
possible (approx. 1.2 mbar pressure loss per meter).
▸ Ensure secure cable laying.
▸ Ensure dry and, whenever possible, dust-free intake air on
the purge air unit, use a preliminary filter when necessary.
Purge air unit
● Only relevant when
using a purge air unit,
i.e. not on systems
using a GPP probe
● See Section 3.3.1:
Assembly preparation
at the measuring point
Tools for start-up and
maintenance
Fitting location
selection
▸ The intake air temperature should be between 0 and 55 °C.
For T < 0 °C, heat the purge air.
▸ Provide sufficient clearance for exchanging the filter element.
▸ Plan a weatherproof cover for installation outdoors as well as
sufficient clearance for fitting (and removing) the cover.
24
Table 2: Project planning checklist
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PROJECT PLANNING INFORMATION
Topic Task Measure/determination
Evaluation unit
• See 3.3.6 “Installation
preparation for the
evaluation unit”, page
30
Determine the fitting
location
▸ Install the evaluation unit at an easily accessible location,
preferably at the measuring point. If necessary, install it at a
distance from the measuring point, whereby the total length
of all CAN bus connections in the GM35 measuring system
must not exceed 1000 m.
▸ Ambient temperature between –20 °C and +55 °C.
▸ During continuous operation –40 °C.
▸ Is the 4 m CAN bus cable sufficient for the connection
between EvU and SR-unit at the selected installation
location?
Options for CAN bus
wiring
Assembly platform
Specify the assembly
platform
If not, select a suitable cable (see page 13):
If the distance is less than 19 m: Plan a 15 m prefabricated CAN
bus cable with plug-in connectors.
For larger distances: Use a CAN bus terminal box and the cable
provided by the customer (see page 43).
▸ Provide a suitable working platform for installation on the
outside of a duct/stack.
▸ The fitting location of the GM35 SR-unit should be about 1.3
to 1.5 m above the platform.
▸ The platform must be large enough, secured and positioned
so that all device parts can be accessed without danger. This
is especially important when fitting and removing the SR-unit.
Accident prevention ▸ Applicable (national) regulations on accident prevention must be observed.
▸ Always observe and follow the relevant safety information provided for the
corresponding texts in these Instructions.
Table 2: Project planning checklist
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PROJECT PLANNING INFORMATION
30
L
50
470
M10
Ø133
1
°
FL. 60x8x60
DIN 174
min. 700
Stahlrohr
50 x 5
DIN 2391
▴
: Markierung für Einbaulage
in Strömungsrichtung zeigend
Befestigung der Spüllufteinheit
1,3 – 1,5 m
50 mm Überstand bei kreisförmigem Kanalquerschnitt
Arbeitsbühne/Plattform
470
Duct wall (steel)
Duct insulation
Flange with tube,
standard: L = 240 mm
▴ : Marking for fitting position,
pointing in flow direction
Steel pipe
50 x 5
DIN 2391
Purge air unit fastening
Platform
50 mm protrusion for circular duct cross-section
3.3 Initial onsite installation
The following work can be carried out by the customer's technicians. Requirement: The
project planning checklist has been processed beforehand.
3.3.1 Assembly preparation at the measuring point
This Section describes the welding work on the duct including making fixing elements
onsite.
Already completed? If you have already used the separate document “Product Information and Planning Guide”
to complete the work described here prior to delivery of the device, please check that the
work done corresponds to the following instructions.
26
Fig. 8: Installation recommendation: Mounting flange and purge air unit (duct diameter not representative)
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CAUTION: Protective measures at the measuring point
Duct wall (steel)
Reinforcing sheets (onsite)
Flange with tube
▸ Always shut down the installation before any work on the duct!
▸ Secure parts to be separated with, for example, wire binding, to prevent
damage by falling objects.
▸ Take appropriate protective measures against hot, explosive gases or toxic
gases that could possibly escape from the duct.
▸ Always take all necessary safety precautions during welding work to prevent
explosions or fire in the duct atmosphere and on the duct insulation.
▸ If necessary, seal off the mounting flange with a cover securely until device
assembly (e.g. for overpressure in duct).
3.3.2 Uncovering the duct
▸ If necessary, remove approx. 800 x 1500 mm (W x H) of the duct insulation to be able to
access the duct during subsequent work.
▸ Keep the insulation material removed for later refitting resp. provide new suitable
insulation material.
3.3.3 Installing the flange with tube
PROJECT PLANNING INFORMATION
Notes on flange
installation
• Standard flanges and special versions
SICK delivers one flange with tube with 240 mm total length and 125 mm inner diameter
as standard. A version with 500 mm total length is available for installation locations with
thicker insulation or for stone stacks.
Special versions can be manufactured on request. Onsite flanges, including ANSI
flanges, can also be used.
• Reinforcement with junction plates recommended
Due to the weight of the GM35 sender/receiver unit, it is recommended to reinforce the
flange tube onsite with junction plates.
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Fig. 9: Reinforcing with junction plates
• Gas-carrying duct made of brick/concrete
An additional retaining plate with suitable opening should be manufactured for ducts not
made of steel and the flange with tube then welded into the opening.
27
PROJECT PLANNING INFORMATION
Wall of the gas-carrying duct (brick/concrete)
Retaining plate (onsite)
Flange with tube
(example: Version 500 mm long)
Reinforcement plates (recommended, onsite)
Fig. 10: Installation on a brick/concrete duct
• Using the angle flange for zero point measurement
To use the angle flange (Part No. 2 017 833) for zero point measurement, make sure the
SR-unit with mounted measuring probe can be attached without hindrance to the duct
using the angle flange. Avoid obstacles in the vicinity of the flange with tube, such as, for
example, protruding duct insulation. A longer flange with tube or an angle flange with
spacer (to be provided by the customer) may be required to ensure the distance from the
duct wall is sufficient.
3.3.3.1 Installation steps: Fitting the flange with tube
1 For brick/concrete ducts: Cut the duct opening approx. 2 cm larger than the flange tube
outer diameter.
2 Cut an opening matching the outer flange tube diameter (standard Ø
the duct wall resp. retainer plate.
3 Position the flange tube so that the marking points exactly in gas flow direction
(compare
plate (approx. 1°, see page 26) to prevent condensate deposits later between tube and
probe. Affix in the fitting position.
4 Weld the flange tube on.
5 Weld on with junction plates as reinforcement when possible; see
NOTICE: Observe the safety information on page 26 at all times!
= 133 mm) out of
a
page 26). Incline the tube slightly downwards in the duct resp. on the retainer
page 27 or page 28.
28
NOTICE: Brick/concrete ducts: Anchor the holding plate with the welded flange
with tube to the duct as shown on
page 28.
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3.3.4 Installation preparation for the purge air unit
Steel pipe 50 x 5
DIN 2391
Purge air unit fastening
50 mm protrusion for circular duct cross-section
Flange 60 x 8 60
DIN 174
PROJECT PLANNING INFORMATION
Is a purge air unit to
be used?
This step is only relevant for device configurations containing a purge air unit. GM35
configurations with GPP measuring probes do not require purge air.
1 Make brackets from steel pipes (e.g. 50 x 5) with flanges (e.g. FL 60 x 8 x 60) for the
four fixing points of the purge air unit ; bore M10 threads in the mounting holes.
2 Weld the brackets on as shown when using steel ducts.
For stone stacks, fit retainer plates to each steel pipe or use a different, suitable mounting
for the purge air unit.
3.3.5 Duct insulation
3
Fitting recommendation for purge air units (duct diameter not representative)
▸ Refit the thermal duct insulation; reinforce the insulation when necessary.
CAUTION: Device failure due to high ambient temperatures
The SR-unit of the GM35 is designed for a maximum ambient temperature of
+55 °C. Radiant heat on the enclosure surface can, under certain
circumstances, lead to temperatures higher than the measured air
temperature.
▸ Therefore, design insulation and radiation shielding so that temperature
limits are reliably maintained.
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PROJECT PLANNING INFORMATION
3.3.6 Installation preparation for the evaluation unit
Requirements The installation location for the evaluation unit was determined during project planning.
The maximum total cable length of all CAN bus connections in the GM35 measuring
system of 1000 m was taken into account, bearing in mind that the closer the device is to
the measuring point, the easier it is to use.
Installation location preparation
The evaluation unit is fitted with clips which enable it to be mounted easily using 4 screws,
even on an uneven surface.
▸ Based on the dimension drawing of the EvU according to
space is available at the planned installation location to fit and wire the EvU as well as to
pivot the enclosure door.
▸ Drill suitable openings as assembly points as required.
3.4 Preparations for electrical installation
The onsite supply and signal cables are laid beforehand to facilitate subsequent
installation and start-up of the GM35 system components. Suitable cable ducts or
conduits are installed for the prefabricated cables and delivered with the GM35 system
(marked with * in
“Cable routing diagram”).
page 135, make sure sufficient
The prepared cables are connected to the devices during installation or start-up by suitably
qualified personnel or by SICK Customer Service.
Already completed? If you have already used the separate document “Product Information and Planning Guide”
to complete the work described here prior to delivery of the device, please check that the
work done corresponds to the following instructions.
3.5 Electrical protection
Evaluation units of GM35, Power Supply 24 V; SCU I/O
• Insulation: Protection class 1 in accordance with EN 61140
• Insulation coordination: Overvoltage category II in accordance with EN61010-1
• Contamination: Degree of contamination II in accordance with DIN EN 61010-1
3.6 Specifications on electric isolation of the EvU
Connections SCU I/O
Relay contact <-> PE 860 V AC
Relay contact <-> relay contact 860 V AC
Relay contact <-> actuation 1376 V AC
Table 3: Characteristic data for electric isolation
3.6.1 Electrical installation safety information
WARNING: Hazard by voltage.
▸ Only allow an authorized electrician to work on the electric system.
▸ Observe the relevant safety regulations during all installation work.
▸ Take suitable protective measures against local risks and those arising
from the plant.
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