SICK GM700 Operating Instructions Manual

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GM700

TDLS Analyzer for NH3, HF or HCI Version with Measuring Probe

Installation, Operation, Maintenance

MMMOPERATING INSTRUCTIONS

OPERATING INSTRUCTIONS

MMM

Document ID

Title: Operating Instructions GM700 Part No.: 8010100/YK22 Release: 2015-12

Described Product

Product name: GM700 Product variant: Measuring probe Version: V4-0

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

Original Documents

The English version 8010100/YK22 of this document is an original document from SICK AG. SICK AG assumes no liability for the correctness of an unauthorized translation. In case of doubt, contact SICK AG or your local representative.

Legal Information

Subject to change without notice.

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IMMEDIATE HAZARD of severe injuries or death

Hazard (general) Please consult the documentation

Hazard by corrosive substances

Hazard by voltage

Hazard by unhealthy substances

Hazard by toxic substances

Hazard by laser radiation

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 personal injury or property damage.

NOTICE

Hazard which could result in property damage.

Information about the use in potentially explosive atmospheres

Important technical information for this product

Important information on electric or electronic functions

Nice to know

Supplementary information

Link to information at another place

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8010100/YK22/V4-0/2015-12 | SICKOPERATING INSTRUCTIONS | GM700

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CONTENTS

1 Safety Information................................................................................... 10

1.1 Main hazards.................................................................................................10

1.1.1 Electrical safety.............................................................................10

1.1.2 Grounding the device ...................................................................10

1.1.3 Protection against hazards through gases .................................11

1.1.4 Protection against laser radiation................................................12

1.1.5 Behavior during purge air failure .................................................14

1.2 Intended use .................................................................................................14

1.2.1 Purpose of the device ...................................................................14

1.3 Responsibility of user....................................................................................14

1.3.1 Disposing of device parts harmful to the environment ..............15

2 Product Overview .....................................................................................16

2.1 Product identification ...................................................................................16

2.2 GM700 system, measuring probe version, layout .......................................17

2.2.1 Measuring probe in detail ............................................................19

2.2.1.1 GMP probe with open measuring gap ......................20

2.2.1.2 GPP gas diffusion probe in dry or wet version .........21

2.2.1.3 GM700 measuring probes in comparison ...............22

2.2.1.4 Special versions ........................................................22

2.3 GM700 options and accessories .................................................................22

2.4 Measuring principle ......................................................................................23

2.4.1 Reference cuvette for wavelength stabilization ..........................23

2.4.2 Signal evaluation ..........................................................................23

3 Project Planning Information................................................................. 24

3.1 Work steps from system selection to start-up .............................................24

3.2 Project Planning Checklist ............................................................................24

3.3 Initial onsite installation ...............................................................................27

3.3.1 Installation preparation at the sampling point ............................27

3.3.2 Uncovering the duct......................................................................28

3.3.3 Installing the flanges with tube ....................................................28

3.3.3.1 Installing the flange with tube ..................................29

3.3.4 Installation preparation for the purge air unit (for GMP probe)..30

3.3.5 Duct insulation..............................................................................30

3.3.6 Installation preparation for the evaluation unit ..........................30

3.4 Preparations for electrical installation .........................................................31

3.4.1 Signal and power supply cables...................................................31

3.4.2 CAN bus wiring ..............................................................................33

4 Installation ................................................................................................ 34

4.1 Preparations ..................................................................................................34

4.1.1 Checking the scope of delivery ....................................................34

4.1.2 Installation prerequisites..............................................................34

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CONTENTS

4.2 Fitting system components .......................................................................... 35

4.2.1 Information on the SR-unit and measuring probe ...................... 35

4.3 Installing the purge air units (for GMP probe) ............................................. 35

4.3.1 Terminal box with 24 V power supply unit (option)..................... 35

4.4 Installing the evaluation unit........................................................................ 36

4.4.1 Installing the evaluation unit – sheet metal enclosure version . 36

4.4.2 Installing the evaluation unit – cast-metal enclosure version ... 37

4.5 Electrical connection of system components.............................................. 38

4.5.1 CAN bus wiring options ................................................................ 38

4.5.2 Electrical connection in the evaluation unit EvU ........................ 40

5 Handling the Evaluation Unit .................................................................42

5.1 User qualifications ........................................................................................ 42

5.2 Operating elements ...................................................................................... 42

5.2.1 Menu overview ............................................................................. 43

6 Start-up...................................................................................................... 46

6.1 Preparations ................................................................................................. 46

6.1.1 Required qualifications and further prerequisites...................... 46

6.2 Start-up steps overview ................................................................................ 46

6.3 Mechanical preparation .............................................................................. 47

6.3.1 Checking the scope of delivery .................................................... 47

6.3.1.1 Transport safety devices .......................................... 47

6.3.2 Fitting the SR-unit on the measuring probe ................................ 48

6.3.3 Electrical connections on the sender/receiver unit.................... 49

6.3.4 Optical alignment ......................................................................... 50

6.3.4.1 Optical alignment for device version for NH3 and

HF measurement ...................................................... 50

6.3.4.2 Optical alignment of device version for HCl

measurement .......................................................... 51

6.3.5 Zero adjust.................................................................................... 52

6.3.5.1 Types of zero point checks ....................................... 52

6.3.6 Fitting the weatherproof cover for the SR-unit............................ 54

6.3.7 Evaluation unit start-up................................................................ 56

6.3.8 Operating states ........................................................................... 57

6.3.8.1 Gas connections on the GPP measuring probe for

zero gas and/or test gas .......................................... 57

6.3.9 Starting operating mode .............................................................. 58

7 Maintenance............................................................................................. 60

7.1 Maintenance intervals.................................................................................. 60

7.1.1 Maintenance protocol .................................................................. 60

7.2 Preparation and general preparatory work ................................................. 60

7.3 Maintenance work on SR-unit ...................................................................... 61

7.3.1 Visual inspection and enclosure cleaning................................... 61

7.3.2 Cleaning the front window on the SR-unit .................................. 61

7.4 Evaluation unit (EvU) .................................................................................... 62

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CONTENTS

7.5 Controlling and tracking the laser working point during measurement .....63

7.5.0.1 Selecting the ambient temperature range ..............63

7.5.1 Filter box measurement to check the measuring channels for NH

, HF or HCl ..............................................................................63

7.5.2 Determining the necessary test gas concentration ....................65

7.5.3 Installing the filter box ..................................................................65

7.5.4 Carry out filter box measurement ................................................66

7.6 Checking the gas analyzer with test cell GMK10 ........................................68

7.6.1 Installation of the GM700 components with the test cell

GMK10 ..........................................................................................69

7.6.2 Carrying out measurement...........................................................70

8 Troubleshooting and Clearing Malfunctions........................................73

8.1 Malfunction categories/possible effects .....................................................73

8.2 Purge air failure.............................................................................................73

8.3 Integrated monitoring and diagnosis system ..............................................73

8.3.1 Display and retrieval of messages on the evaluation unit..........74

8.3.2 Troubleshooting and clearing malfunctions, evaluation unit .....75

8.3.3 Error messages .............................................................................76

8.3.4 Warning messages .......................................................................78

8.3.5 Further tips on troubleshooting ...................................................79

9 Technical Data, Expendable and Spare Parts ..................................... 80

9.1 Technical data GM700 probe system ..........................................................80

9.2 Dimension drawing .......................................................................................85

9.2.1 Dimension drawing sender/receiver unit GM700 (dimensions

in mm) ...........................................................................................85

9.2.2 Dimensions of open measuring probe - GMP ..............................86

9.2.3 Dimensions of GPP measuring probes ........................................87

9.2.4 Dimension drawing evaluation unit GM700: Sheet steel

enclosure (dimensions in mm).....................................................88

9.2.5 Dimension drawing evaluation unit GM700: Cast metal

enclosure (dimensions in mm).....................................................88

9.2.6 Connection unit GM700 (Can bus option) (dimensions in mm) .88

9.2.7 Dimensions of weatherproof cover for GM700 SR-unit .............89

9.2.8 Dimension drawings of flange with tube ....................................89

9.3 Accessories, expendable and spare parts ...................................................90

9.3.1 Consumable parts for 2-years operation .....................................90

9.3.2 Spare parts for the sender/receiver unit.....................................90

9.3.3 Spare parts for the measuring probe ..........................................90

9.3.4 Spare parts for the evaluation unit ..............................................92

9.3.5 Fixing accessories.........................................................................92

9.3.6 Spare parts assignment for sender/receiver unit .......................93

10 Annex ......................................................................................................... 97

10.1 User information “Laser safety” ...................................................................97

10.2 Positioning the probe reflector when the probe must be realigned ...........99

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1 SAFETY INFORMATION

1 Safety Information

1.1 Main hazards

Important safety information in short form.

Operational safety

DANGER: Hazards through defective device

The GM700 is likely to be unsafe when it:

● Has been penetrated by moisture.

● Has been stored or operated under irregular conditions.

When safe operation is no longer possible:

▸ Put the GM700 out of operation, separate all connections from the power supply

WARNING: Hot surfaces when enclosure open

Pay attention to hot surfaces on the measuring cell when opening the GM700 enclosure.

1.1.1 Electrical safety

and secure against unauthorized start-up.

WARNING: Hazard by voltage

▸ Pay careful attention to power supply connections. ▸ Do not interrupt protective conductor connections.

WARNING: Endangerment of electrical safety by not switching the power supply off during installation and maintenance work.

An electrical accident can occur when the power supply to the equipment or the lines is not switched off using a power isolating switch/circuit breaker for installation and maintenance work.

▸ Before starting work on the equipment, ensure the power supply can be

switched off using a power isolating switch/circuit breaker in accordance with DIN EN 61010.

▸ Make sure the power isolating switch is easily accessible. ▸ An additional disconnecting device is mandatory when the power isolating

switch is difficult to access or cannot be accessed when connecting the equipment after installation.

▸ After completion of the work or for test purposes, the power supply may

only be activated again by authorized personnel complying with the safety regulations.

WARNING: Endangerment of electrical safety through power cable with incorrect rating

When a removable power cable is used, electrical accidents can occur when the specifications are not fully observed.

▸ Always observe the exact specifications in the Operating Instructions

(Technical Data Section) when replacing a removable power cable.

1.1.2 Grounding the device

CAUTION: Equipment damage through erroneous or missing grounding

Ensure the protective grounding of the equipment and/or lines involved during installation and maintenance work in accordance with EN 61010-1.

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1.1.3 Protection against hazards through gases

WARNING: Hot and/or aggressive sample gases

▸ Wear suitable protective clothing and mask when using hot and/or aggressive

sample gases and/or with high dust loads.

▸ Never open the enclosure or switch off the purge air feed without taking appropriate

protective measures when the duct is pressurized.

WARNING: Toxic and caustic substances in parts in contact with sample gas

● Depending on the sample gas composition, parts of the GM700 in contact with

sample gas can contain toxic or caustic substances.

● When fitted in the measuring device, the reference cuvette contains the respective

gases to be measured. These gases must not escape. Special care must be taken with the GME700-2 (HF) because this cell not only contains gaseous HF but also a certain amount of liquid (max. 0.1 g HF for 8 cm cell). HF / hydrofluoric acid is extremely toxic and caustic. It is imperative to avoid inhaling or skin contact at all times. Particularly when there are indications of leaks or defects, wear protective clothing (protective goggles, latex gloves) and carry out work in a well ventilated room/area. Never open the cuvette under any circumstances. Check replacement cuvettes for any possible transport damage.

● Handle with care when test gases are used:

▸ When handling HF, keep an HF emergency set (including calcium gluconate gel)

available.

▸ Before working on the gas path, ask the operator which gases have been applied to

the GM700.

▸ Ask the operator whether, and how, the gas path of the GM700 has been cleaned. ▸ If necessary, clean the gas path with a suitable method. ▸ In case of doubt, take appropriate protective measures before working on the gas

path: Ensure adequate ventilation at the workplace or work under a vent. Wear protective goggles or a safety mask, protective gloves and acid-proof protective clothes.

SAFETY INFORMATION 1

WARNING: 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 plants with overpressure as well as gas temperatures over 200°C:

▸ Ensure reverse flow is prevented by fitting a (trip) flap or a valve. ▸ Regularly check the functionality of the reverse flow safeguard.

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1 SAFETY INFORMATION

Laser outlet

Laser warning sign

1.1.4 Protection against laser radiation

WARNING: Eye injuries possible due to laser radiation



Observe all relevant information in these Operating Instructions.

NOTE: Deviations of EN60825-1:2014-08 “Laser safety” from the Directive 2006/25/EC

Due to the Implemented health and safety regulation for artificial optical radiation concerning the Directive, deviations of EN60825-1:2014-08 “Laser safety” from Directive 2006/25/EC have occurred.

▸ Always observe the user information in the Annex of these Operating Instructions!

“User information “Laser safety””, page 97.

The GM700 laser warning sign is located on the sender/receiver unit.

Fig. 1: Laser warning sign on the GM700 sender/receiver unit

Fig. 2: Laser sign for NH

measurement

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SAFETY INFORMATION 1

Fig. 3: Laser sign for HCI measurement

The invisible laser beam within the SR-unit is not accessible when fitted. There is no risk for the human eye when looking into the optic visor on the right side of the SR-unit.

CAUTION: Observe the following for the GM700 HF version:

As the limit values of laser class 1 of the IEC 60825-1:2014-5 are neither exceeded in single case malfunctions nor normal operation under consideration of the service and measuring state, the device is classified as laser class 1. Requirement: Use of device software 9105060_YEK0 or a newer software version with equal functionality.

CAUTION: Important information for safe handling of the GM700 SR-unit HF version

For device software versions older than 9105060_YEK0, a higher laser radiation might occur.

▸ Laser class 1 of the IEC 60825-1:2014-5: Only use device software

9105060_YEK0 or a newer software version.

CAUTION: Important information for safe handling of the GM700 SR-unit (all versions)

▸ Never look directly into the output lens when opening the SR-unit or the reflector. ▸ Always wear laser goggles or switch the device off during maintenance work. ▸ Observe valid national limit values and respective standards for work safety.

Laser capacity

The wavelength of the laser varies for the respective measuring components (NH HCl).

The maximum laser output capacity on the optical interface (front window) depends on the respective measuring component and is shown on the laser warning sign.

–HF: “Laser warning sign on the GM700 sender/receiver unit”, page 12. –NH

: “Laser sign for NH3 measurement”, page 12.

– HCI: “Laser sign for HCI measurement”, page 13.

, HF,

The emitted radiation is harmless to human skin.

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1 SAFETY INFORMATION

1.1.5 Behavior during purge air failure

GM700 measuring system configurations demand immediate or short-term measures to protect the measuring system should the purge air supply fail.

Measures for purge air feed failure

▸ Refer to Purge Air Unit Operating Instructions.

1.2 Intended use

1.2.1 Purpose of the device

The gas analyzer GM700 measures the sample gas component concentration, e.g. HF, NH3 or HCl in a gas mixture (sample gas). For this purpose, the GM700 analyzer is assembled at the measuring location and measures directly onsite (in-situ measurement).

!▸

Do not use the device to expose persons to radiation.

1.3 Responsibility of user

Intended users

The GM700 may be operated by competent persons only who, based on their devicespecific training and knowledge of the device as well as knowledge of the relevant regulations, can assess the tasks given and recognize the dangers involved.

Correct use

▸ Use the device only as described in these Operating Instructions. The manufacturer

bears no responsibility for any other use.

▸ Carry out the specified maintenance work. ▸ Do not remove, add or change any components in or on the device unless such changes

are officially allowed and specified by the manufacturer. Otherwise – the device may become dangerous – the manufacturer’s warranty becomes void – the approval for usage in potentially explosive atmospheres becomes void.

Special local requirements

Follow local laws, regulations and company-internal operating directives applicable at the installation location.

Responsibility for dangerous substances

WARNING: Mortal/health danger as a result of a gas path leakage

When the device is used to measure toxic gases: A leak, for example in the purge air supply, can be an acute hazard for persons.

▸ Take sui tab l e sa fet y me asu res . ▸ Make sure these safety precautions are followed.

Safety precautions examples:

● Marking the device with warning signs

● Marking the operating area with warning signs

● Safety-related instruction of personnel who could be in the vicinity of the installation

site.

Retention of documents

▸ Keep these Operating Instructions available for reference. ▸ Pass on to a new owner/operator.

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1.3.1 Disposing of device parts harmful to the environment

DANGER: Possible materials harmful to the environment and health

GM700 components can have small shares of pollutants or hazardous substances such as low lead content in printed circuit boards. The optional permanent cuvette contains low concentrations of HF or HCl (according to device configuration, see scope of delivery).

▸ Dispose of all GM700 components according to local laws, regulations and

company-internal operating directives applicable at the installation location such as:

▸ Printed circuit boards and similar electronic components ▸ Dispose of the permanent cuvette, when fitted, safely because it contain low

concentrations of HCl or HF. Therefore, do not simply destroy the cuvette.

SAFETY INFORMATION 1

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2 PRODUCT OVERVIEW

2Product Overview

2.1 Product identification

Product name: GM700

Device versions GM700 version with probe

Manufacturer:

Type plates:

GM700 version: Measuring component:

GM700-2 HF

GM700-3 HCI

GM700-5 NH

GM700-8 HCI / H2O

GM700-9 NH

SICK AG Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

● SR-unit: On the right side

● On the purge air fixture

3/H2

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2.2 GM700 system, measuring probe version, layout

maintcalpardiag

Evaluation Unit

CO CO

H2O

mg/ m

236

Ref. conditions

Hum: wet

Measuring

Operation

Service

Warnin Malfunction

Sender/receiver unit with GMP measuring probe

Evaluation unit EvU

CAN bus

CAN

Inputs/outputs, analog, binary

Interfaces to plant peripherals:

● Measured data processing

● Status signals

Purge air unit SLV 4 (not fitted for GPP probes)

Fig. 4: GM700 system overview (measuring probe version)

PRODUCT OVERVIEW 2

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2 PRODUCT OVERVIEW

Sender/receiver unit (SR-unit)

The sender/receiver unit contains the optic and electronic subassemblies of the measuring system. The gas concentration is captured here and the measured value determined.

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 sinter filter not requiring purge air (GPP: G

detail”, page 19 onwards.

Purge air unit

To supply purge air to the SR-unit with open measuring probe (GMP) and thus to protect against contamination and high gas temperatures. Use a certain purge air unit each for the SR-unit depending on the application. The blower types for the SR-unit are designed differently depending on the application.

as Permeable Probe). Both versions are described from “Measuring probe in

Further information on the purge air unit

▸ Refer to Purge Air Unit Operating Instructions.

Evaluation unit

The evaluation unit in the GM700 measuring system serves as user interface and is responsible for measured value processing and output as well as control and monitoring functions. The EvU can be located in the vicinity of the SR-unit. It can also be located up to about 1000 meters from the sampling point, e.g. installed in the switch center or monitoring center, and performs functions such as:

● 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 – purge air fixture measuring probe, length 0.8 m 2 023 704

● Cable (CAN bus), SR-unit – evaluation unit, length 4 m

● Extension up to 1000 m, with terminal box ; with 24 V supply

[1]

Cable (only for version Cross-Duct and GMP probe)

2 cables extension (only for GMP probe)

Cable SR-unit purge air fixture – filter monitor of purge air unit, length 3 m extension (only for Cross-Duct and GMP probe version)

Tab le 1 : Connection cable Part Nos.

[1] One length included in scope of delivery [2] Included in scope of delivery

SR-unit purge air fixture – filter monitor of purge air unit, 5 m

[2]

SR-unit purge air fixture - filter monitor of purge air unit, length 2 m

● Scope of delivery

● Option: 2020440

2 032 143

6 025 923

6 028 663

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Flange with tube

2.2.1 Measuring probe in detail

Fig. 5: GPP measuring probe with ceramic filter

PRODUCT OVERVIEW 2

To install the purge air fixtures of the SR-unit and reflector on the gas duct. The purge air fixture is fitted on the flange and then the SR-unit is fitted on the purge air fixture. ANSI or DIN flanges provided by the customer can be used alternatively to the flanges supplied.

Integrated sensors

All probe versions have a built-in pressure sensor as well as an integrated temperature sensor PT 1000 that continually measures the medium temperature of the probe in the active measuring path. The measured data are transferred via the CAN bus interface of the measuring probe and can then be displayed on the evaluation unit.

EPA conformity

When using a GPP probe, an audit measurement conforming to EPA CFR 40 Part 60 and/ or Part 75 can be carried out with the device fitted as far as usable for the application.

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2 PRODUCT OVERVIEW

Temperature sensor

PT 1000

Purge air outlet

Open measuring path (measuring gap)

Lever position

Lever and locking device: Open

2.2.1.1 GMP probe with open measuring gap

Shortest reaction times and high temperature stability characterize the GMP series measuring probes. Continuous purge air feed 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 locking device on the opening for sample gas that is activated with a lever on the probe flange.

Fig. 6: GMP measuring probe (with open measuring gap)

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2.2.1.2 GPP gas diffusion probe in dry or wet version

Temperature sensor PT 1000

Gas permeable ceramic filter

This version is more suitable for higher dust contents because, on GPP probes, dust particles are separated on the filter element and therefore kept away from the measuring path. The GPP (G

as Permeable Probe) should also be chosen to allow an EPA-conform

audit measurement as well as for low flow speeds or irregular flow profiles.

Fig. 7: Measuring gap of the GPP measuring probe

PRODUCT OVERVIEW 2

Both variants of the GPP differ in the respective filter which provides suitability for different application areas in accordance with Table “GM700 measuring probes in comparison”,

page 22.

Advantages of GPP probes

GPP probes do not require a purge air supply and are easy to maintain. They are fitted with an automatically controlled heater to reliably prevent condensate on the optical interfaces. The electronics for heating control, temperature and pressure measurement are located reliably protected in a sturdy cast-metal enclosure acting as measuring probe section between duct flange and SR-unit. Both the electric connections for CAN bus and power supply as well as the test gas connection with which the audit measurement according to EPA Guideline CFR 40, Part 60 or Part 75 can be carried out are located on the enclosure as shown.

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2 PRODUCT OVERVIEW

2.2.1.3 GM700 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 before delivery.

Measuring probe GMP (open probe) GPP (dry)

Design

Max. gas temperature. 430°C

Gas check according to EPA specification possible

Purge air supply required Yes –

Heating on optical interfaces in the probe

Flow rate of sample gas 1...40 m/s < 40 m/s

Suitable for wet sample gas Yes –

Maximum duct pressure

Measurable components NH

System-response time (T90) ≥ 5s ≥ 120 s

Duct diameter

Dust concentration <2g/m

Probe lengths available [m] 1.0/1.5/ 2.0 1.0/1.5 / 2.0

Active measuring paths available [mm]

Tab le 2 : Measuring probes in comparison

[1] The maximum temperature used for the measurement depends on the application. [2] As from gas temperature 300 °C [3] As from a gas temperature of minimum 130 °C [4] Probes with shorter active measuring paths on request (possibly required for higher concentrations or

narrower duct diameters)

[4]

Measuring path open in flow direction; purge air guidance with outlet aligned 90° to gas flow

[1]

Gas diffusion probe with ceramic filter, for dry sample gas

–Yes

– Yes, with integrated control

±120 hPa, depending on purge air supply

, HF, HCl NH

±120 hPa

[2]

, HCl

[3]

> 360 mm > 300 mm

act. <30g/m3 act.

250/500/750/1000/1250 250/500/750/1000

2.2.1.4 Special versions

Apart from the standard probes shown, other versions made from stainless steel type

1.4539 especially resistant to acid are available. Special versions can be manufactured according to customer demands on request.

2.3 GM700 options and accessories

● Terminal b ox for CAN bus with 24 V power supply

The optional terminal box is available for distances between SR-unit and EvU larger than 4 meters via a CAN bus cable provided by the customer. The total length of all the CAN bus connections in the GM700 measuring system can be up to 1000 m in this case.

● Cover plate for purge air fixture of the sender/receiver unit

To maintain purge air supply in cases where this must remain in operation at the measuring location when the SR-unit is dismounted.

● Weatherproof cover for SR-unit and purge air unit

Required for outdoor installation - dimension drawings, see “Dimensions of weatherproof

cover for GM700 SR-unit”, page 89.

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● Chart recorder, single or multi-channel, 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 small. The following practical rule of thumb serves as guideline: An air heater is recommended when Gas temperature [°C] – dew point temperature [°C] < abs. humidity [%]. Values are compared without considering the units of measure.

2.4 Measuring principle

The light of the laser diode radiates through the sample gas and is then detected by a photo diode. The laser diode wavelength is set to a single absorption line of the sample gas component. This absorption line is scanned by modulating the wavelength and then the transmission signal (relation between signal sent and received) captured by a photo diode. An appropriate signal evaluation returns the magnitude of the absorption line from which the gas concentration is then calculated. This method is called Tunable Diode Laser Spectroscopy (TDLS) or Tunable Diode Laser Absorption Spectroscopy (TDLAS).

A laser specially developed for gas analysis is used as light source in the GM700. This laser diode radiates a wavelength with a narrow line width so that an absorption line can be reliably scanned. A Peltier element and a temperature sensor fitted in the laser diode enclosure ensure a precise temperature and therefore exact wavelength stabilization of the system.

PRODUCT OVERVIEW 2

The laser beam from the sender/receiver unit travels through the active measuring path and then impinges on the reflector on the other side of the gas duct. The beam is then reflected back to the sender/receiver unit. After the beam has passed through the measuring path twice, during which laser light absorption specific to the gas occurs, the light is focused on a receiver optics.

2.4.1 Reference cuvette for wavelength stabilization

The GM700 is equipped with:

● A permanently filled cuvette for the adjustment of the analyzer laser diode to the

reference position of the gas absorption line (Line-Locking).

2.4.2 Signal evaluation

The optimized algorithms of the GM700 evaluation electronics process the measurement signal of the receiver element together with the corresponding parameters based on the TDLS measuring method. This is based on the physical characteristics of the gas molecules that absorb light energy in certain wavelengths. These optimized algorithms ensure the concentrations of sample gas components are determined without crosssensitivities to other gases. The differential absorption measurement also eliminate dust influences.

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3 PROJECT PLANNING INFORMATION

3 Project Planning Information

3.1 Work steps from system selection to start-up

Application changes

If you make changes to the specifications ordered for your application or if a device is to be used for an application different to the one originally planned, please pass this information onto your local sales representative so that we can determine the application options under changed conditions and whether new adjustment/parameter settings are required.

The following steps are normally taken before starting-up the measuring system

● Project planning

“Project Planning Checklist”, page 24.

● Initial onsite installation

▸ The following preparatory work normally carried out by the customer is described in

“Initial onsite installation”, page 27:

▸ Flange installation, “Installing the flanges with tube”, page 28. ▸ Preparation for installing the purge air unit, “Installation preparation for the purge air unit

(for GMP probe)”, page 30.

▸ Laying the signal and power supply cables to the measuring point, “Signal and power

supply cables”, page 31.

● Installation preparation for the EvU, “Electrical connection in the evaluation unit EvU”, page 40

▸ Possibly preparation of signal cables for the interface to the peripheral equipment,

“Signal and power supply cables”, page 31.

● Device installation

To allow speedy start-up, the following components are normally installed ready for operation before the start-up date; see also “Installation”, page 34. – Purge air unit – Evaluation unit(s).

● Start-up

The actual start-up is carried out by trained personnel or Customer Service. This work is described in “Start-up”, page 46. The main activities are adjustment tasks on the GM700 system related to the application.

3.2 Project Planning Checklist

Project planning, step by step

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, see “Dimension drawing”, page 85 and following.

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PROJECT PLANNING INFORMATION 3

4F (Cross-sectional area)

U (Circumference)

-------------------------------------------------------------------------------------=

Top ic Tas k Measure/determination

Provide for unhindered inlet and outlet paths:

▸ For round duct cross-sections: 3 times the duct diameter ▸ For rectangular cross-sections: Hydraulic diameter ▸ If these specifications cannot be met: Inlet section > outlet section,

/3 : 1/3; uniform concentration spread whenever possible

e.g.

Determine sampling point Observe national regulations such as VDI 3950

Emission sampling point

Application conditions

Pressure conditions at the sampling point

▸ Obtain official approval for emission sampling point. ▸ Provide for calibration openings at an easily accessible place. ▸ Ensure the GM700 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, upstream

▸ Observe Technical Data for duct/ambient conditions! ▸ Gas temperature above/below dew point (dry/wet)

▸ A fitting location with partial vacuum in the duct is ideal. ▸ For duct pressures > 10 mbar, contact SICK on correct selection of

the purge air blower.

▸ Flange fitting is planned in steel ducts as standard; corresponding

flanges with tube are normally included in the GM700 scope of delivery.

▸ Stone stacks or ducts with thick walls demand an onsite retaining

plate and, possibly, a longer version of the flange with tube; “Install-

ing the flanges with tube”, page 28.

● “Dimension drawings of flange with tube”, page 89.

▸ Provide an opening of suitable size for the flange tube. ▸ Plan adequate clearance for installation and maintenance activities

for the duct insulation cutout.

▸ Plan clearances for handling the SR-unit ▸ Ensure the ambient temperature for the SR-unit is within the

specified range.

SR-unit

→

p. 25, §3.3.1

Select suitable flange with tube

Duct openings selection

▸ For installation outside, plan a weatherproof cover

Tools for start-up and maintenance

▸ When working on the zero path; prerequisites: Clean ambient

atmosphere free from sample gas; weatherproof: Plan the zero path or order from SICK.

▸ Plan installation location on the duct in immediate vicinity (5 m) of

the GM700 SR-unit.

▸ Keep purge air hoses to the purge air fixture (SR-unit) as short as

possible (pressure loss approx. 1.2 mbar per meter).

Purge air unit

→

p. 28, §3.3.4

Fitting location selection

▸ Ensure secure cable laying. ▸ Ensure dry and, whenever possible, dust-free intake air on the

purge air unit, use a preliminary filter as necessary.

▸ The intake air temperature should be between 0 and 55 °C. Heat

the purge air for T < 0 °C; see air heater option ( “GM700 options

and accessories”, page 22).

▸ For installation outside, plan a weatherproof cover

Evaluation unit

→

p. 28, §3.3.6

Determine the fitting location

Tab le 3 : Project Planning Checklist

▸ Plan assembling the unit at an easily accessible location ▸ Ambient temperature within the specifications, “Technical data

GM700 probe system”, page 80.

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3 PROJECT PLANNING INFORMATION

Topic Task Measure/determination

▸ Provide a suitable working platform for installation on the outside of

a duct/stack.

▸ The fitting location of the GM700 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

Installation platform

Accident prevention

Specify the installation platform

▸ Applicable (national) regulations on accident prevention must be observed.

Tab le 3 : Project Planning Checklist

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3.3 Initial onsite installation

470

M10

Ø13

1

FL. 60x8x60 D I N 174

min. 700

1,3 – 1,5 m

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

The work described in the following can be carried out by the customer's installers. Prerequisite is that all the required specifications have been made based on the Project Planning Checklist.

3.3.1 Installation preparation at the sampling point

This Section describes the welding work on the duct including making fixing elements onsite.

Fig. 8: Installation recommendation: Mounting flange and purge air unit (duct diameter not representative)

PROJECT PLANNING INFORMATION 3

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3 PROJECT PLANNING INFORMATION

















CAUTION: Protective measures at the sampling point

▸ Always shut down the installation before any work on the duct! ▸ Secure parts to be separated, e.g. with wire binding, to prevent damage caused

by falling par ts.

▸ Take appropriate protective measures against hot, explosive gases or toxic gases

that could possibly escape from the duct.

▸ Take all the necessary safety measures during welding work, among others

against the risk of explosion or fire in the duct atmosphere and on the duct insulation.

▸ If necessary, seal off the mounting flange with a cover securely until device

installation (e,g, for overpressure in duct).

3.3.2 Uncovering the duct

▸ Remove any duct insulation to uncover an area of approx. 800 x 1500 mm (W x H) to

prepare the duct for the following work.

▸ Keep the insulation material removed for later refitting and/or provide new suitable

insulation material.

3.3.3 Installing the flanges with tube

SICK delivers two flanges 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.

Fig. 9: Standard flange with tube

Reinforcement with junction plates recommended

Due to the weight of the sender/receiver unit, we recommend reinforcing the flange tube fixture onsite with junction plates.

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Fig. 10: Reinforcing with junction plates

Duct wall (steel)

Flange with tube

Reinforcing sheets (onsite)

Gas carrying duct made of stone/concrete

An additional retaining plate with suitable opening can be manufactured for ducts not made of steel and in which the flange with tube can be welded.

3.3.3.1 Installing the flange with tube

PROJECT PLANNING INFORMATION 3

CAUTION: Always observe safety information on “Main hazards”, page 10!

1 Mark the flange center point exactly on the duct wall.

– On ducts made of stone/concrete: Cut the duct opening out approx. 2 cm larger than

the outer flange tube diameter; at the same time, plan a light downward incline of the flange tube by approx. 1°. Provide a suitable retainer plate.

2 Cut an opening matching the outer flange tube diameter (standard Ø

= 133 mm) out of

the duct wall and/or retainer plate.

3 Position the flange tube so that marking points exactly in gas flow direction. Incline

the tube slightly downwards in the duct resp. on the retainer plate (approx. 1°, “Stan-

dard flange with tube”, page 28) to prevent condensate deposits later between tube and

probe.

4 Affix in the fitting position.

– Whenever possible, weld on junction plates as reinforcement; cf. “Reinforcing with

junction plates”, page 29. For ducts made of stone/concrete: Anchor the retainer

plate with flange with tube welded on securely to the duct.

5 Weld the flange tube on.

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3 PROJECT PLANNING INFORMATION

3.3.4 Installation preparation for the purge air unit (for GMP probe)

● Maximum length of cable to measuring device complies with project planning.

Installation of purge air unit , see Operating Instructions of purge air unit.

NOTE: Adequate purge air pressure

▸ During project planning, make sure the purge air pressure is sufficient to force the

purge air into the gas duct. Please contact SICK Customer Service or your local representative when necessary.

3.3.5 Duct insulation

▸ Refit the thermal duct insulation; reinforce the insulation when necessary.

WARNING: Observe the ambient temperature!

The SR-unit of the GM700 is designed for an ambient temperature of max. +50 °C. Radiant heat on the enclosure surface can, among others, create temperatures higher than the measured air temperature. Therefore, design insulation and radiation shielding so that temperature limits are reliably maintained.

3.3.6 Installation preparation for the evaluation unit

The installation location for the evaluation unit was defined within the project planning framework ( “Project Planning Checklist”, page 24). The maximum total cable length of all CAN bus connections in the GM700 measuring system of 1 000 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 has fastening openings in the enclosure for easy fixing.

▸ Based on the EvU dimensional drawing according to “Dimension drawing evaluation

unit GM700: Sheet steel enclosure (dimensions in mm)”, page 88 and/or “Dimension drawing evaluation unit GM700: Cast metal enclosure (dimensions in mm)”, page 88

ensure enough space is available at the planned installation location to attach these, for wiring as well as opening the enclosure door.

▸ Drill suitable openings as installation points as required.

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3.4 Preparations for electrical installation

The onsite supply and signal cables are laid beforehand to facilitate subsequent installation and start-up of the GM700 system components. Suitable cable ducts and/or empty conduits are installed for cables already prefabricated and delivered with the GM700 system. Suitably qualified personnel or Customer Service connect the prepared cables to the device during installation and/or start-up.

3.4.1 Signal and power supply cables

WARNING: Observe safety information!

● Always observe safety information and relevant safety regulations.

● During all work on electrical equipment, disconnect such equipment from the mains,

check that the equipment is potential free and make sure that no third person can switch the equipment back on again without authorization. Leave the power supply switched off during the following device installation.

● The power connection must be made via a circuit-breaker switch.

● The grounding cable must be connected.

PROJECT PLANNING INFORMATION 3

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3 PROJECT PLANNING INFORMATION

maintcalpardiag

GM 35

Evaluation Unit

CO CO

H2O

mg/ m

236

Ref. conditions

Hum: wet

Measuring

Operation

Service

Warnin Malfunction

SR-unit

Measuring probe (example: GMP)

CAN *

0.8 m

Evaluation unit

CAN bus extension, ready for connection, 15 m (option)

CAN bus cable (standard), 4 m *

Terminal box (option)

Standard cable connection

Cable connection, option

Cable in scope of delivery

Prefabricated with plug-in connector(s)

Purge air unit SLV 4 (Standard for GMP measuring probe)

Power supply (230/115 V AC) 3 x 0.75 mm

3 binary inputs 6 x 0.5 mm

3 analog inputs 6 x 0.5 mm

3 binary outputs 6 x 0.5 mm

3 analog outputs 6 x 0.5 mm

to extend the CAN bus

connection with a cable

(1 x 2 x 0.5 mm2, twisted pair,

shielded) provided by the

customer

Cable connection for optional terminal box

Power supply 115/230 V AC;

50/60 Hz 4 x 1.5 mm

(see safety information)

Signal cable for: Filter monitoring of the SLV 4 – 2 x 0.6 mm

, on pressure controller with flat pin bushings 6.3 x 0.8 mm (DIN 46247) Pressure connection

Power supply 4 x 1.5 mm

(see safety information)

Fig. 11: Circuit diagram (probe version)

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3.4.2 CAN bus wiring

PROJECT PLANNING INFORMATION 3

Standard cables

An installation location in the vicinity of the sampling point is generally selected for the EvU so that the 4 m CAN bus cable in the scope of delivery is sufficient for cabling without additional installation effort.

Installation away from the evaluation unit

A terminal box with a 24 V power supply unit can be delivered when the EvU is to be located at a greater distance from the SR-unit. This is then connected to the SR-unit using the 4 m CAN bus cable delivered with the measuring system. A customer cable suitable for CAN bus applications, 6-pole cable (twisted pair wires and shielded), then leads to the EvU. The total length of the CAN bus connections, including the one to the reflector, may be up to 1000 meters. When performing maintenance or service, it must be possible to deinstall the EvU temporarily and connect it directly to the SR-unit at the sampling point.

Laying the cables

▸ Provide adequate cable lengths at the connection points. ▸ Whenever possible, do not lay power supply cables immediately next to signal cables. ▸ Protect open ends of preinstalled cables against weather effects until device

installation.

▸ Install separate power supply cables and circuit breakers for:

– Purge air units; additional motor circuit breakers and optional protective phase failure

switches.

– Evaluation unit

WARNING: Take precautions to prevent accidental switching off of the purge air supply.

▸ Attach a clearly visible warning against accidental switching off the separation

equipment for the purge air unit.

▸ Install easily accessible cable ducts or empty conduits for the prefabricated cables to

those delivered with the system ( “Circuit diagram (probe version)”, page 32) marked with one or two plug-in connectors . Approx. 2 m cable lengths each should be available at the sampling point for later maintenance work on the measuring system when dismounted from the duct.

▸ Lay onsite cables (shown without plugs) according to “Circuit diagram (probe version)”,

page 32.

– Wire cross-section specifications are recommendations from which cables for analog

and binary signals can slightly deviate (not however for the CAN bus connections

and/or power supply cables). – Start with the system internal connections of the GM700. Status and signal cables from the EvU to the connection terminals of the customer's status/message devices can be added later as required.

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4 INSTALLATION

4 Installation

4.1 Preparations

This Section describes the installation and installation work for the GM700 measuring system before the actual start-up. Completion of the onsite preinstallation in accordance with “Preparations”, page 34 is assumed.

4.1.1 Checking the scope of delivery

▸ Check the delivery against the belonging delivery note and make sure the complete

measuring system has been delivered as ordered.

▸ Check the specifications on mains voltage and frequency on the type plates of the

GM700 components match the installation conditions, delivery note and the order.

4.1.2 Installation prerequisites

The following prerequisites are applicable for the work described in the following:

▸ Plan safe usage/application within the limits defined in “Technical data GM700 probe

system”, page 80.

▸ Compliance with the specifications made during project planning (according to “Project

Planning Checklist”, page 24) and correct performance of onsite preinstallation

according to “Mechanical preparation”, page 47.

WARNING: Power supply OFF!

During the following work, it must be ensured that the power supply to the devices and cables involved is switched off and can only be activated by the personnel carrying out the work when the work is completed and/or for test purposes and then under consideration of valid safety regulations.

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4.2 Fitting system components

163

4.5

Mounting holes

4.2.1 Information on the SR-unit and measuring probe

The GM700 SR-unit and measuring probe are first fitted on the duct during start-up ( “Fit-

ting the SR-unit on the measuring probe”, page 48) because these components first

require an adjustment away from the gas-carrying duct. To avoid problems during start-up, the SR-unit and measuring probe must be stored in a dry place free from dust, preferably at room temperature, until start-up.

CAUTION: Do not fit the SR-unit and measuring probe before start-up

Unfavorable ambient conditions or atmosphere in the measuring channel can damage the measuring system which prevents start-up.

Apart from that, there is a health risk when opening the duct depending on the pressure, gas temperature and composition in the sample gas duct.

4.3 Installing the purge air units (for GMP probe)

Installation of purge air unit → Operating Instructions of purge air unit.

INSTALLATION 4

4.3.1 Terminal box with 24 V power supply unit (option)

▸ Install the terminal box with 24 V power supply unit in the vicinity of the sampling point. ▸ Secure the enclosure using both mounting holes (∅ 5 mm) ▸ The cable length available from the terminal box to the SR-unit is 4 m.Take the empty

conduits laid for the prefabricated cables during onsite preinstallation into account.

Fig. 12: Fitting the terminal box with power supply unit

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4 INSTALLATION









4 mounting holes ∅ 8mm

Mounting surface

Fastening brackets

4.4 Installing the evaluation unit

The fitting location for the evaluation unit was defined during project planning ( “Project

Planning Checklist”, page 24) and prepared during onsite preinstallation as required.

▸ Make sure the CAN bus connection to the SR-unit selected during project planning is

usable at the planned installation location. The CAN bus connection cable delivered as standard is 4 m long and serves to connect the evaluation unit directly at the sampling point.

▸ Ensure easy access without problems. In particular, make sure the swivel door of the

evaluation unit can be opened without hindrance after fitting.

4.4.1 Installing the evaluation unit – sheet metal enclosure version

▸ Drill mounting holes ∅7.2 mm (for M8) at the fitting location according to the Drilling

plan.

▸ Attach the evaluation unit at the installation location using the 4 planned fastening

brackets with suitable screws.

Fig. 13: Installing the evaluation unit (sheet metal enclosure version)

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4.4.2 Installing the evaluation unit – cast-metal enclosure version

117.5

330

235

Swivel door

Mounting holes ∅ 7.2 mm

Mounting surface

The mounting holes are

accessible when the swivel

door is open.

Mounting holes

∅ 7.2 mm

▸ Drill mounting holes ∅7.2 mm (for M8) at the fitting location according to the Drilling plan.

Fig. 14: Mounting holes layout (Drilling plan) to fit the EvU (cast-metal enclosure)

INSTALLATION 4

▸ Open the enclosure cover with a control cabinet key and swivel open. ▸ Attach the evaluation unit at the installation location using the 3 planned mounting

holes with suitable screws (M8 x 20).

Fig. 15: Fitting the evaluation unit (cast enclosure)

▸ Close and lock the cover again.

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4 INSTALLATION

4.5 Electrical connection of system components

Onsite preparation for electrical installation has been described in “Preparations for elec-

trical installation”, page 31. The cables laid as described there are now connected to the

system components.

CAUTION: Observe safety information as well as relevant safety regulations!

During all work on electrical equipment, disconnect such equipment from the mains, check that the equipment is potential free and make sure that no third person can switch the equipment back on again without authorization.

Electrical connections for purge air unit → Purge air unit Operating Instructions.

4.5.1 CAN bus wiring options

As already described in the project planning on “Preparations for electrical installation”,

page 31, the following options are available for wiring the CAN bus connection between SR-

unit and evaluation unit:

● Standard cable, 4 m, prefabricated

● Terminal box with prefabricated 4 m long cable to SR-unit; a cable provided by the

customer is used to connect to the evaluation unit.

Information on selecting a suitable type of wiring can be found under “Circuit diagram

(probe version)”, page 32.

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INSTALLATION 4

Fuse 2.5 AT

230 /115 V AC 40…60 Hz

ST 1

250 V

ST 2

PENL1

ST 5ST 6 ST 7

ST 4

PG 13.5

CAN-L

+24

GND

CAN-H

CAN GND

CAN-L

CAN-H

CAN GND

CAN-L

+24

GND

CAN-H

CAN GND

CAN Terminator

Power supply 115 V/230 V AC

Sensor

Evaluation unit

Sensor

Prefabricated cable with plug, 4 m long, to SR-unit

Cable to evaluation unit (provided by customer)

Cable to power supply (provided by customer) (see safety information)

CAN cable signals

Color Signal

Pink +24 V

Grey GND

Yel low C AN- H

Green CAN-L

Brown CAN-GND

White n.c.

WARNING: Endangerment of electrical safety

● The power cables must be adequately dimensioned.

● The power connection must be made via a circuit-breaker switch.

● The grounding cable must be connected.

Wiring in terminal box

Connections in the terminal box are wired as follows:

Fig. 16: Terminal box for CAN bus connection between SR-unit and evaluation unit

▸ Connect bridge (jumper) according to suitable voltage supply (ST2). ▸ Lead CAN cable (provided by customer) through the right PG screw fitting to terminal

strip.

▸ Connect shielding on the PG screw fittings on the enclosure. ▸ Connect wires to terminal strip ST5 as shown in “Evaluation unit connections”, page 40;

check that a twisted pair cable is used for CAN-H and CAN-L. Connect the respective signals in the EvU and terminal box.

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4 INSTALLATION

+ – + – + –

+ –

+ – + –

PE N L1

V 42+



H NAC

L NAC



V 42+



+– +– +–

115/230 V AC;

50/60 Hz

(3 x 1.5

)

+– +– +–

12 3

Power +5V +24V

Power CAN +24V + – H L GND

Digital in

Analog i n

0.. 20mA 100 100 100

40..60Hz

230V

115V

AO1 AO2 AO3DI1 DI2 AI1 AI2 AI3

Sensor

DO1 DO2 DO3

Digital out

AC/DC 48V 30VA 1A

Analog out

0.. 20mA

Sensor

Fuse 2.5 AT 250V

PE N L1

contrast

Enter meas

diag par cal maint

Operation

Service

Warning Malfunction

GM 35

Evaluation Unit

Plug this bridge for 115 V and/or 120 V voltage supply.

48 V AC/DC; 60 VA, 1 A (6 x 0.75

)

relay outputs

0...20 mA (6 x 0.75

)

Analog outputs

0...20 mA (6 x 0.5

)

Analog inputs

Pot.-free contact (6 x 0.75

)

Digital inputs

Failure

Maintenance request

Function contr.

(CAN H, L twisted pair, shielded) GM700 SR-unit and/or terminal box

Operating elements board

Connections board

Cast-metal enclosure shown

N/C contact

N/O contact

WARNING: Endangerment of electrical safety

● The power cables must be adequately dimensioned.

● The power connection must be made via a circuit-breaker switch.

● The grounding cable must be connected.

(see safety information)

4.5.2 Electrical connection in the evaluation unit EvU

Cable laying to the evaluation unit and relevant specifications have already been shown in

“Circuit diagram (probe version)”, page 32.

Fig. 17: Evaluation unit connections

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INSTALLATION 4

CAN cable shielding

PG screw fitting on the evaluation unit

CAN bus cable

PG screw fitting on the EvU

▸

Open enclosure door of evaluation unit.

WARNING: Observe connection values for power supply!

The evaluation unit is configured to 230 V AC on delivery.

▸ Plug the respective bridges for 115 and/or 120 V AC as shown on the connection

plate of the evaluation unit.

▸ Ensure the power supply has been installed (see evaluation unit connections) according

to the specifications (observe national requirements), but with the power switched off.

▸ Connect protective conductor (PE) to the terminal on the enclosure floor ▸ Lead the signal cable for inputs and outputs through the PG screw fittings on the EvU

enclosure floor and wire according to “Evaluation unit connections”, page 40.

▸ When using the CAN cable provided by the customer, connect the wires to the “Sensor”

terminal strip. Do not connect +24 V and GND (ground).

Fig. 18: See steps 1 to 4 below Connecting the CAN bus cable to the evaluation unit

WARNING: Burns by touching the cable glands

The temperature on the cable glands can be >60 °C.

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5 HANDLING THE EVALUATION UNIT

GM700

Evaluation Unit

NH3

mg/ m

236

Operation

Service

Warning Malfunction

Evaluation Unit

NH3

mg/ m

236

Ref. conditions

Hum: wet

Enter meas

diag par cal maint

Measuring

Operation

Service

Warning Malfunction

GM 35

Evaluation Unit

CO CO

H2O

mg/ m

236

Ref. conditions

Hum: wet

Enter meas

diag par cal maint

Measuring

Enter meas

maintcalpardiag

Operation

Service

Warning Malfunction

Ref. conditions Hum: wet

Graphic display for measured value display and navigation

Status LEDs to indicate operating and malfunction states

Key pad for navigation and

entering data

Key pad for menu selection

5 Handling the Evaluation Unit

5.1 User qualifications

This Section describes how to operate the GM700 measuring system with the evaluation unit (EvU). The evaluation unit is available with either a sheet metal enclosure (protection class IP 65) or a cast-metal enclosure (protection class IP 67). The work described in this Section can be carried out by qualified customer operating personnel. Setting parameters does however demand comprehensive knowledge of the measuring system, measuring technology and specific measuring task.

5.2 Operating elements

The evaluation unit of the analysis system serves to display, enter and set parameters and control functions on the system. The operator panel with the display, status indicators and key pad is accessible when the enclosure door is opened.

Fig. 19: Evaluation unit display and operating elements (shown with sheet metal enclosure)

Arrow keys

Enter

Display in measuring mode

Navigate, select, scroll or edit menu items, variables, units or digits.

Execute the selected menu contents or commands.

Displays all current measured values (temperature values resp, gas concentration); Displays computed values

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LEDs

Measuring

T=150 °C

←

● Operation

● Service

● Warning

● Malfunction

Display contents

HANDLING THE EVALUATION UNIT 5

Measuring operation Service mode Warning messages, see Diagnostic mode (diag) Device malfunction, error message, see Diagnostic mode (diag)

● The header line shows the selected operating mode (e,g,

parameter settings) or the menu items just selected during navigation.

● 4 lines to show submenus, plain-text messages or settings

(values)

● Function line:

←

back Use button Arrow ← to return to next higher level

edit Enter Use button Enter to activate menu item or confirm

input

select Use button Enter to select a variable

↑ (↓) When selecting a variable requiring numeric input,

use buttons per digit

Password When a password is prompted, enter the code

1 2 3 4 using↑ (↓).

Arrow ↑ (↓) to set the numeric value

5.2.1 Menu overview

Mode Menu

Measuring Measuring

operation

Diagnosis Malfunction

Warning

Sensor values

GM700 Sens. values

Sample Cross-Duct: OH

Parameters Setting

Physical Unit

GM700

Cross-Duct Refl.

Component Unit:

Ref. condition:

Average Avg. Time:

Meas. Distance Active:

Gas Temperature Source:

Subst.

Pressure Source:

Subst.

Tab le 4 : GM700 menu overview

● Current measured values depending on device

version

● Reference variables (wet, dry)

● Current error messages (plain-text)

● Current warning messages (plain-text)

● Displays diagnostic values and control values

● Current monitored sensor values (amplification

setting, internal temperature control, control values, etc.)

● Parameter settings/display of system

components

● mg/m

● t: actual, 25 °C, 20 °C, 0 °C

● p: actual, 1013 mbar

● Hum.: wet, dry

● 0 ... 300 s

● 200 ... 8000 mm

● Probe, Subst. Analog In

● –100 ... 2000 °C

● Probe, Subst. Analog In

● 600 ... 15000 hPa

, ppm

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5 HANDLING THE EVALUATION UNIT

Humidity Subst.

Analog Out Live Zero

Output 1

Output 2

Output 3

Analog In Input 1 T

Input 2 p

Coefficients Funct.

Span (HF)

Zero (HF)

Ambient Temp. Range

t (Feed Test Gas) Period

Check cycle Period

Zero Adjust Enable

Repet.

t (purge)

t (delay)

Delta T

Device Serial Number Head.

Laser

EvU

Software Revision

Tab le 4 : GM700 menu overview

● 0 ... 93.0 percent by volume

● 0, 4 mA

● Component: e.g. HF, - -, p, T

● Range low: 0 ... 999999

● Range high: 0 ... 999999

● Cycle Out: No, Yes

● Component: e.g. HF, - -, p, T

● Range low: 0 ... 999999

● Range high: 0 ... 999999

● Cycle Out: No, Yes

● Component: e.g. HF, - -, p, T

● Range low: 0 ... 999999

● Range high: 0 ... 999999

● Cycle Out: No, Yes

● Unit: °C, K, °F

● Live Zero: 0, 2, 4 mA

● Range low: 0 ... 15000

● Range high: 0 ... 15000

● Unit: hPa

● Live Zero: 0, 2, 4 mA

● Range low: 0 ... 15000

● Range high: 0 ... 15000

● 0.50 ... 1.99

● ±999

● 0 ... 50 °C, –10 ... 40 °C, –20 ... 30 °C, –30 ...

20 °C, –40 ... 10 °C

● 0 ... 3666 d (day)

Only when permanent cuvette fitted.

● 0 ... 24 h

● Yes, No

● 0 ... 24 h (only GPP)

● 0 ... 900 s; purge time until zero is executed

● 0 ... 1800 s; delay until gas enters again

● 0 ... 999 °C; temperature difference at which a

zero adjust is carried out

● _ _ _ _ _ _ _ _

● GMM700-X

● XXXXXXX XXXX

● GMM700/DSP

● XXXXXXX XXXX

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HANDLING THE EVALUATION UNIT 5

cal

Service

Calibration Check cycle Start CCY (Check Cycle)

Zero Adjust Start ZeroAdjust Password

(1 2 3 4)

Zero Adj. Stack Start ZeroAdjust Password

(1 2 3 4)

Box measuring Start Meas. Password

(1 2 3 4)

Check cycle Start CCY (Check Cycle)

Mainte-

Maint. Mode Mode: Off, On

Adj. Opt. Align. Opt. Alignment

nance

Tes t Analog Out AO 1 : 4 m A

AO 2: 4 mA

AO 3: 12.5 mA

Test Analog In AO 1: 0 mA

AO 2: 0 mA

AO 3: 0mA

Test Relay Relay 1: On (Off)

Relay 2: On (Off)

Relay 3: Off (On)

Test Digital In DI 1: Open

DI: 2: Open

DI: 3: Open

Push Diag RS232

Reset System

Reset Parameter

Tab le 4 : GM700 menu overview

● Not defined

● Check cycle for test purposes, e.g. after

maintenance (preliminary)

● Zero point determination, e.g. during start-up

or af ter maintenance task based on the zero path

● Only GPP probe:

Zero point determination with measuring device on gas duct

● Check of measuring components with test gas

via a filter box

● Check cycle for test purposes, e.g. after

maintenance

● Maintenance operation: On, Off

● Displays optical alignment of SR-unit

● Tests the analog outputs

● Tests the analog inputs

● Tests the re lay ou tpu ts

● Tests the di git al i npu ts

● Outputs the complete parameter set via the

RS232 Service interface

● Restarts the measuring system

● Resets parameters to factory settings

Attention: All settings are overwritten!

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6 START-UP

6 Start-up

6.1 Preparations

This Section describes the standard start-up at the end of which GM700 starts measuring operation.

6.1.1 Required qualifications and further prerequisites

Previous training by SICK or a qualified sales partner is recommended for technicians or engineers planning on performing a start-up. This training provides knowledge so that participants can recognize and handle situations that demand measures going beyond the standard procedures described here. Apart from the start-up itself, employees of SICK or trained sales partners are also able to make recommendations for the actual measuring operation as well as to define the maintenance interval based on the specific plant conditions.

Standard start-up

Each individual measuring system is already configured to the individual usage conditions at the factory and therefore the standard start-up procedure described in this Section can normally be carried by qualified engineers or measurement technicians without the special training. Prerequisites are:

● Exact adherence to the application requirements specified in the order

● The possibility, during start-up, to ask the advice of a trained specialist from SICK or the

respective sales partner should special questions arise that go beyond the normal scope of the standard procedures described

Start-up procedure overview

After the general preparation which mainly deals with checking the work already carried out, it is then necessary to carry out a zero adjust with the measuring system on a measuring path free from sample gas, the zero path. This can be done either at the sampling point or another location, e.g. in a closed room. At the sampling point itself, the purge air unit and the SR-unit are then put into operation in succession. Finally, the evaluation unit is switched on and checked; the parameters can then be set for the individual demands.

6.2 Start-up steps overview

Prerequisites for successful start-up:

● Installation conditions match the requirements for the measuring system (temperature,

pressure).

● Sampling point must be accessible without danger or problems.

● All power supply and signal cables installed and connected.

● The system, apart from the SR-unit and purge air fixtures which are attached to the duct

flange later, must be fully installed and wired.

● Purge air supply, when fitted, must be ready for use.

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START-UP 6

● Sampling point technical data must be known:

– Measuring range – Limit values – Inputs and outputs to be used

Start-up runs in two main steps:

● 1

main step: Zero adjust on the measuring path free from sample gas ( “Zero adjust”,

page 52)

● 2

main step: Installation and start-up at the sampling point

( “Evaluation unit start-up”, page 56)

Tools and equipment

▸ Provide the following tools and equipment:

– Personal protective equipment as required, e.g. for hot and/or aggressive sample

gases – 1 19 mm open-end wrench – Allen key set – Insulated screwdriver set for electrical connection work etc.

● Fastening parts included in the GM700 measuring system scope of delivery:

– 4 each M 16 x 60 screws with washers and self-locking nuts to fasten the purge air

fixtures on the duct-side flange with tube – For each purge air fixture:

3 nuts with washers and each with 10 cup springs to fasten the purge air fixtures on

the SR-unit and/or reflector – Sealing ring to seal the SR-unit, reflector and purge air fixture connection

● Optical cleaning cloth without detergents, e.g. SICK Part No. 4003353

6.3 Mechanical preparation

WARNING: Avoid hazards through sample gases!

To avoid health hazards, the following work step may not be carried out during the preparation described in this Section but first within the scope of the respective descriptions in the following Sections:

▸ Connect the power supply to the SR-unit

6.3.1 Checking the scope of delivery

▸ Check the exterior of the SR-unit and measuring probe to ensure they are not damaged. ▸ Make sure the supply voltages on the type plates of the GM700 device components

comply with the installation conditions.

The supply voltage of the GM700 components can be changed between 115 V and 230 V on site by the SICK service personnel when necessary.

6.3.1.1 Transport safety devices

▸ Remove the transport safety devices shown below as well as any protective stickers,

marked as such, depending on the device version. The front cover of the SR-unit is clamped between the flange fixture and enclosure. To remove it, open the lock and swivel the flange fixture up (see Fig.). Keep the transport safety devices as required.

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6 START-UP

Plastic protective caps on the openings in the measuring gap on GMP measuring probes

Front cover of the SR-unit (shape can differ from that shown)

Cup springs: 10 per attachment

Sealing ring

Device flange

Centering disc and nut

Threaded pin of flange fixture

Flange fixture of the SR-unit (removable)

Fig. 20: Transport safety devices to be removed from the SR-unit and measuring probe

6.3.2 Fitting the SR-unit on the measuring probe

The installation procedure is identical for all measuring probe versions. The fixing parts are supplied with the GM700 measuring system.

Fig. 21: Fixing the measuring probe on the SR-unit (Fig.: GMP measuring probe)

▸ Place 10 cup springs in each case, with the front ends facing each other, that is, 5 pairs,

on the three threaded pins on the flange fixture of the SR-unit. The sectional view (see

“Fixing the measuring probe on the SR-unit (Fig.: GMP measuring probe)”, page 48)

shows the exact arrangement.

▸ Pull the sealing ring over the device flange and hang it loosely over the measuring probe

where it is then ready for use.

▸ Carefully position the measuring probe with the device flange on the three threaded pins

fitted with cup springs on the flange fixture without damaging the threads.

▸ Fit the centering discs and tighten the nuts using a 19 mm wrench so that the cup

springs are pressed together slightly.

▸ Leave a gap between the flange fixture of the SR-unit and the device flange of the

measuring probe to allow adjustment of the optical alignment (as shown in the Figure above).

▸ Close the gap with the sealing ring so that the ring rests on the smooth surfaces of the

flange fixture and device flange as shown on Page 48.

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START-UP 6

Flange fixture of the SR-unit

Cup springs: 10 per attachment, facing each other (= 5 pairs)

Centering disc

Sealing ring

Device flange of the

measuring probe

Lock nut

Threaded pin of the flange

fixture (fixed)

Measuring probeSR-unit/ flange fixture

For GMP probe: 3±0.5 For GPP probe: 2±0.5

Connection CAN cable

(SR-unit and probe)

SR-unit

Low-pressure monitor SLV

Temperature sensor

PT 1000

Connection CAN cable to evaluation unit (via terminal box when necessary)

Fig. 22: Cross-section of the connection fitted between the SR-unit and measuring probe

6.3.3 Electrical connections on the sender/receiver unit

▸ If the flange fixture was removed from the SR-unit, attach it again. Insert the hinge

bolt again and close the quick-release fasteners.

Set the lever at the probe flange to “open” to open the closing device of the probe in sample gas direction. See GMP measuring probe (with open measuring gap)

▸ Connect cables accordingly:

– Connect and secure CAN bus cable between SR-unit and probe. – Connect and secure CAN bus cable to EvU. – When necessary, connect the temperature sensor and the low-pressure monitor (to

SLV, when fitted).

▸ Switch the power supply on.

Fig. 23: Connections on the SR-unit with GMP measuring probe

→

p. 17, Figure 4

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6 START-UP

Maintenance Mode Test Analog Out Test Analog In Test Relay

Maintenance

ß back

Mode: On

Maintenance Mode

ß back

Alignment tool lever

6.3.4 Optical alignment

6.3.4.1 Optical alignment for device version for NH

Alignment of the optical axis is checked using the visor on the right hand side of the SR-unit enclosure and adjusted using the screws on the mounting flange according to the Ladjustment. “Using the alignment tool”, page 51. The power supply for the evaluation unit must be switched on.

1 Switch to Maintenance mode

On the evaluation unit:

▸ Press button “maint” ▸ Select “Maintenance Mode” and activate with ▸ Activate Maintenance mode

Mode: On (maintenance mode active)

2 Align the sender/receiver unit

▸ First turn (1.) and then pull down (2.) the lever of the built-

in alignment tool to bring the alignment tool into adjustment position “Using the alignment tool”, page 50.

▸ Look through the visor on the right enclosure side diago-

nally from above at the mirror with the target.

▸ As shown in “Using the alignment tool”, page 51, align

the position of the light spot (red on the HF device version, green on the NH the screws of the purge air fixture on the flange so that the light spot appears on the target in position “Circle”.

device version) of the laser beam from the reflector. To do this, adjust

and HF measurement

Enter

Fig. 24: Using the alignment tool

▸ Only adjust the screws as shown in “Using the alignment tool”, page 51.

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Fig. 25: Using the alignment tool

X-alignment; horizontal

Visor of the optical alignment

Y-alignment; vertical

Alignment on probe version

Target of the alignment tool

(Alignment on Cross-Duct version)

LED display for rough view of optical alignment

Maintenace Mode

P, m xxx.x

k back

START-UP 6

6.3.4.2 Optical alignment of device version for HCl measurement

▸ After successful alignment, push the lever of the alignment tool back to its original

position and secure it with a quarter turn.

The wavelength used for HCI measurement is not visible on the target. The power supply for the evaluation unit must be switched on.

1 Switch to Maintenance mode

On the evaluation unit:

▸ Press button “maint” ▸ Select Maintenance Mode and activate with Enter ▸ Select Adjust Optical Alignment

Maintenance mode/Optical Alignment is active. The EvU display switches to display the measuring channel brightness.

2 Align the sender/receiver unit

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6 START-UP

6.3.5 Zero adjust

▸ First turn (1.) and then pull down (2.) the lever of the built-in alignment tool to bring

the alignment tool into adjustment position “Using the alignment tool”, page 51.

Adjust the screws of the purge air fixture on the flange so that the measuring channel brightness reaches the maximum value.The adjustment, including the warming up time, takes about 2.5 to 5 hours whereby the actual work is completed in less than 30 minutes. Devices with automatic check cycle perform the first check cycle after the warming up phase.

The LED display of the device side serves as additional aid for rough setting.

After the evaluation unit has been connected to the power supply, a warm-up time of approx. 2.5 - 5hours (depending on ambient conditions) is required before zero adjust can be carried out.

▸ After the warm-up phase, align the optical axis as described in “Optical alignment”,

page 50.

Select menu cal:

● Zero Adjust – manual zero adjust (measuring path free from sample gas)

▸ Activate Calibration mode (button “cal”), execute menu item Zero Adjust.

Confirm the prompt. Zero point adjustment runs and

6.3.5.1 Types of zero point checks

also see “Gas connections on the GPP measuring probe for zero gas and/or test gas”,

page 57.

● When removed:

SR-unit installed and aligned on probe in ambient air suitable for zero conditions.

● Devices with GPP type probes can be checked when fitted by feeding suitable zero gas

(nitrogen, clean compressed air in instrument air quality) the check with test gas. This function can also be executed in intervals, controlled by the device. During this procedure, the probe can cool down and swivel, resulting in a zero point error. This effect can be minimized by setting the gas flow to the required amount and limiting the duration needed for the check. Especially for higher gas temperatures (from 200°C), the zero gas has to be pre-heated to minimize swiveling. This can be achieved by feeding the zero gas via a heated sample gas line or passively with a ¼“ metal tube, which is pushed beneath the channel insulation for contact with the hot duct wall. Here, the pre-heating spiral 2065326 can be used or an installation fitted to the construction.

Zero Measuring is displayed.

[1]

. The sequence is equal to

[1] ISO8573 Class 2 for particle size, amount of contaminator and oil, H2O dew point

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START-UP 6

Fig. 26: Pre-heating spiral

The transition from the outlet of the channel insulation to the connection at the zero gas inlet or the probe has to be insulated, has to reach at least 100°C, but may not exceed 120 °C on the probe connection.

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6 START-UP

Lock

Mounting ring

Installation plate

6.3.6 Fitting the weatherproof cover for the SR-unit

The weatherproof cover is used when the measuring system is operated outdoors. It is available as an accessory.

Fig. 27: Weatherproof cover for the GM700 SR-unit

The weatherproof cover is installed in two steps:

Fig. 28: Weatherproof cover for GM700 SR-unit and reflector unit

1 Installing the installation plate on the flange of the purge air fixture.

▸ Lay the weatherproof cover upside down on the floor. ▸ Open and unhinge the locks on both sides. ▸ Pull the installation plate upwards and remove it from the cover.

2 Installing the cover

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Fig. 29: Installing the cover on the purge air fixture

Upper mounting ring

Installation plate

Lower mounting ring

Detailed view

Position the top mounting ring on the side of the purge air fixture.

(1)

(2)

(3)

START-UP 6

▸ Remove the bottom mounting ring. ▸ Place installation plate (1) from the top on the rubber band of the purge air fixture.

Position the mounting ring on the side of purge air fixture (2); see detailed view in

“Weatherproof cover for the GM700 SR-unit”, page 54.

▸ Fasten bottom mounting ring (3) again.

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6 START-UP

Installation plate

Weatherproof cover

Fig. 30: Fitted weatherproof cover

▸ Place the cover from above on the installation plate. ▸ Click the locks in and close.

6.3.7 Evaluation unit start-up

The evaluation unit is configured with a standard parameter set at the factory and, therefore, is ready to start measuring operation immediately. With the exception of the following steps, therefore, no additional measures are required for start-up for standard applications:

▸ Based on the operator information in “Handling the Evaluation Unit”, page 42, check

whether the measured values are output correctly on the LCD.

If error or warning messages are displayed:

▸ Use the operator information in “Handling the Evaluation Unit”, page 42 as well as the

display of error and warning messages in “Error messages”, page 76 to locate and rectify the error cause.

If the error cause cannot be rectified with this information, contact the Service department at SICK or your local sales partner for further advice.

▸ If necessary, parameterize the evaluation unit in accordance with the requirements of

the measuring task and the installation environment “Handling the Evaluation Unit”,

page 42.

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6.3.8 Operating states

1st gas inlet: Zero gas

2nd gas inlet: Test gas

During actual operation, the following operating states can be shown on the evaluation unit display:

Message in 1st text line Significance

INIT

INITIALISATION

SIGNAL_ADJUST

MEASURING

MEASURING LL

MEASURING LD

MAINTENANCE

DOWNLOAD

Tab le 5 : Operating states

EvU initialization

Initializing the SR-unit

Adjusting amplification to changed transmission

Measuring operation

Measuring mode with active tracking of laser wavelength (line-locking)

Measuring mode; wavelength tracked (line-locking done)

Maintenance mode (no measurement)

Download new software (for Service purposes only)

6.3.8.1 Gas connections on the GPP measuring probe for zero gas and/or test gas

Depending on the variant, the GM700 analyzer performs independent zero point measurements in certain intervals to ensure high precision with very small measuring ranges. A zero gas/test gas connection and a second gas connection for nitrogen purging or dynamic zeroing directly on the measuring probe are available.

An overpressure is created in the measuring path of the probe during zero or test gas feed. If this pressure is high enough, the complete sample gas is drained out of the measuring path because a gas flow runs in the reverse direction through the probe filter. The gas flow in the filter must be larger than the diffusion velocity of the gases in order to drain out the sample gas from the measuring path. The analyzer performs the zero point measurements automatically during measuring operation. They can also be triggered manually with the cal button on the evaluation unit. “Menu overview”, page 43 and following.

START-UP 6

Fig. 31: Gas inlets on the measuring probe

Equipment

● Gas hoses:

– Teflon hose (PTFE), type 650 P 0707, – Steel pipe 1.4571,

● Zero gas: Instrument air, class 2

● Pressure reducer

● Supply line

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/4" with cutting-clamping ring connection (Swagelok)

/4"

6 START-UP

Clamping rings

Gas pipe

(open end)

Cap nut

Inner

bushings

1 Connecting the measuring probe

▸ Connect zero gas (instrument air) to 1st gas inlet “Zero

gas”.

▸ Take off the cap nut from the gas inlet. ▸ Place the cap nut and clamping rings on the open end

of the gas pipe.

▸ Insert the pipe in the open screw fitting. ▸ Tighten the nut with an open end wrench.

▸ Connect zero gas (instrument air) “N

zeroing to 3rd gas inlet as described above.

2 Connecting the instrument air

▸ Connect the pressure reducer to the instrument air supply. ▸ Connect the gas hose from the probe to the pressure regulator outlet. ▸ Set pressure reducer to 250 kPa.

6.3.9 Starting operating mode

On the evaluation unit:

▸ Switch Maintenance mode off:

Mode: Off

Start Measuring mode by pressing the meas button.

The analyzer now starts in Measuring mode.

purging or dyn.

When using a gas hose, an inner bushing (Part No. 5309138) must be used to support the hose and clamping ring.

▸ Check for error or warning messages, especially on the

status LEDs.

▸ If error messages are displayed, clear according to “Error

messages”, page 76.

▸ Set parameters, special times and measuring range, “Handling the Evaluation Unit”, page 42.

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START-UP 6

Selecting the ambient temperature

NOTE: Change of temperature range

The device performs temperature stabilization after a change of the temperature range. This can take approx. half an hour depending on the environment.

● Warning message “DEV TEMP” is output

▸ Wait for half an hour before performing a zero adjust.

On the evaluation unit:

▸ Select a suitable ambient temperature so that the heater of the SR-unit can stabilize the

optics temperatures.

▸ Activate Parameter mode. ▸ Select menu Settings, then Ambient Temp. ▸ Select the temperature range according the Table below that matches the ambient

conditions at the measuring location.

Possible ambient temperature ranges (test cuvette)

Degrees Celsius [°C] Kelvin [K] Degrees Fahrenheit [°F]

–40 … 10 233 … 283 –40 …50

–30 … 20 243 … 293 –22 … 68

–20 … 30 253 … 303 –4 … 86

–10 … 40 263 … 313 14 … 104

0 … 50 273 … 323 32 … 122

Tab le 6 : Ambient temperature ranges with test cuvette

Possible ambient temperature ranges (closed cuvette)

Degrees Celsius [°C] Kelvin [K] Degrees Fahrenheit [°F]

–40 … 15 233 … 288 –40 … 59

–30 … 25 243 … 298 –22 … 77

–20 … 35 253 … 308 –4 … 95

–10 … 45 263 … 318 14 … 104

0 … 52 273 … 325 32 … 122

Tab le 7 : Ambient temperature ranges with closed test cuvette

The GM700 determines the appropriate temperature for the optics heater automatically.

▸ Zero point adjustment:

NOTE: After changing the temperature range

● Warning message “DEV TEMP” may no longer be shown.

● The temperature change should have been made approx. half an hour ago.

▸ Activate Calibration mode (button “cal”), select menu item Zero Adjust and trigger

with Enter.

▸ Confirm the prompt. Zero point adjustment runs and Zero Measuring is displayed.

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7 MAINTENANCE

7 Maintenance

7.1 Maintenance intervals

The GM700Version with Measuring Probe requires very little maintenance. This Section describes regular maintenance work to be carried out on the GM700 measuring system.

Qualifications

Inspection and maintenance tasks described in this Section can be carried out by Service technicians familiar with the device based on the information in these Operating Instructions and having an in-depth knowledge of the relevant safety regulations.

Maintenance intervals depend on individual application conditions and should be clarified with SICK Service and/or with a trained engineer or technician at the local sales partner.

If no other specifications have been made, the following recommendation is applicable:

● Maintenance interval – 4 weeks

7.1.1 Maintenance protocol

Keep a log of maintenance work done. A simple notebook recording the maintenance dates, work done, special observations, and required consumables and spare parts is adequate.

DANGER: Important safety information for all service work

Always observe the following information when carrying out service work to avoid injury or damage to the measuring system:

▸ Wear suitable protective clothing and a protective mask when the sample gas is hot

and/or aggressive or has a high dust load, or when the sample gas duct is pressurized. Never open the enclosure or disengage the quick-release locks without taking suitable protective measures.

▸ If the conditions in the sample gas duct are particularly problematic and hinder or

prevent work on the open duct, despite the use of protective equipment, the maintenance work must be carried out when the sample gas duct is out of service or after it has been flooded with ambient air.

▸ The purge air supply must run continuously. ▸ If visual inspection of the power supply cable reveals damage to the insulation or

strain-relief clamp, switch off the power supply to the cable in question immediately.

7.2 Preparation and general preparatory work

▸ Have the following equipment available for service work:

– At least the following tools: 2 x 24 mm open-end or box wrenches, 1 x 19 mm open-

end or box wrench, Allen key set, insulated screwdriver set for electrical connection

work – Optical cleaning cloth without detergents, e.g. Part No. 4 003 353 – Distilled water, clean cloths and, if necessary, a dusting brush – If the duct is pressurized, a suitable protective cover is required for the duct-side

flange with tube.

Maintenance tasks for purge air unit→ Purge air unit Operating Instructions.

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7.3 Maintenance work on SR-unit

7.3.1 Visual inspection and enclosure cleaning

▸ Check the enclosure of the SR-unit for damage such as cracks. ▸ If a weatherproof cover is used, check its condition. ▸ Clean contaminated GM700 system components. ▸ Inspect cables thoroughly for damage and pay particular attention to any signs of

abrasion or bending at cable ducts. Prefabricated cables are available as spare parts.

7.3.2 Cleaning the front window on the SR-unit

WARNING: Take care when the duct is pressurized!

▸ If the duct is pressurized, you must take the appropriate protective measures, in

particular wear a protective mask.

▸ Prepare a suitable cover for the opening on the device flange of the SR-unit and keep

it available.

▸ Fit the cover immediately on the device flange opening after swiveling the SR-unit

open.

CAUTION: Important information for safe handling of the GM700 SR-unit HF version

For device software versions older than 9105060_YEK0, a higher laser radiation might occur.

▸ Laser class 1 of the IEC 60825-1:2014-5: Only use device software

9105060_YEK0 or a newer software version.

▸ Never look directly into the exit lens when opening the SR-unit or the reflector. ▸ Always wear laser goggles or switch the device off during maintenance work. ▸ Observe valid national limit values and respective standards for work safety.

MAINTENANCE 7

NOTE: Deviations of EN60825-1:2014-08 “Laser safety” from the Directive 2006/25/EC

▸ Always observe the user information in the Annex of these Operating Instructions!

“User information “Laser safety””, page 97.

▸ Switch the GM700 off. ▸ Open the SR-unit enclosure with a control cabinet key and swivel open. ▸ Check the optical interface (front window) on the SR-unit for contamination and, if

necessary, clean using an optical cleaning cloth. Do not use any detergents because these leave invisible residues that could falsify the measuring result. The cleaning cloths can be moistened with distilled water if necessary.

▸ Close and lock the enclosure again to protect the cleaned optical interface against

humidity or dust.

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7 MAINTENANCE

Optical interfaces (Front window)

Fig. 32:

7.4 Evaluation unit (EvU)

The evaluation unit is designed for maintenance-free operation over the entire service life of the measuring system. If the evaluation unit is mounted outdoors, the following simple checks should be carried out regularly due to the load resulting from changing weather conditions:

▸ Visual inspection

– Is the enclosure undamaged and the fitting intact? – Does the enclosure front door open and close easily? – Is the enclosure window free from moisture?

▸ Does the illuminated LC-Display on the evaluation unit function correctly?

▸ Open the evaluation unit door and check the following:

– Are the cable connections OK? – Is the enclosure dry inside?

▸ If any one of these points is negative, clarify the cause when possible. ▸ Carry out the necessary repairs.

If the evaluation unit is damaged (e.g. LC-Display failure):

▸ Contact SICK Service or the local sales representative.

Exposed electrical connections

The electrical connections are exposed when the evaluation unit door is open. Follow the relevant safety regulations

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MAINTENANCE 7

7.5 Controlling and tracking the laser working point during measurement

The working point of the laser needs to be tracked when the concentration in the sample gas is not sufficient. This is done automatically with the help of the fitted reference cell.

7.5.0.1 Selecting the ambient temperature range

NOTE: Change of temperature range

The device performs temperature stabilization after a change of the temperature range. This can take approx. half an hour depending on the environment.

● Warning message “DEV TEMP“ is output

▸ Wait 30 min. before performing filter box measurement.

On the evaluation unit:

▸ Select the appropriate ambient temperature to allow the heater of the SR-unit to

stabilize the optics temperature. –Activate Parameter mode – Select Settings and then the Ambient Temp. menu. – Select the temperature range according the Table below that matches the ambient

conditions at the measuring location.

Possible ambient temperature ranges (test cuvette)

Degrees Celsius [°C] Kelvin [K] Degrees Fahrenheit [°F]

–40 … 15 233 … 288 –40 … 59

–30 … 25 243 … 298 –22 … 77

–20 … 35 253 … 308 –4 … 95

–10 … 45 263 … 318 14 … 113

0 … 50 273 … 325 32 … 125

Tab le 8 : Possible ambient temperature ranges (test cuvette)

Possible ambient temperature ranges (cuvette filled with gas)

Degrees Celsius [°C] Kelvin [K] Degrees Fahrenheit [°F]

–40 … 15 233 … 288 –40 … 59

–30 … 25 243 … 298 –22 … 77

–20 … 35 253 … 308 –4 … 95

–10 … 45 263 … 318 14 … 113

0 … 52 273 … 325 32 … 125

Tab le 9 : Possible ambient temperature ranges (cuvette filled with gas)

The GM700 analyzer automatically determines the appropriate temperature for the optics heater.

7.5.1 Filter box measurement to check the measuring channels for NH

The gas filter box serves to check the GM700 with test gases.

Requirements

Components required:

● Reflector enclosure with gold-plated hollow triple reflector;

Part No. 2030206

● Filter box with adapter plate for the GM700

, HF or HCl

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7 MAINTENANCE

Adapter plate for GM700

Reflector enclosure

Fig. 33: Components required: Filter box for GM700

Measured values are displayed on the EvU in mg/m3 • m (operation).

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7.5.2 Determining the necessary test gas concentration

Test gas conc. [ppm or % by vol.]

Meas. range [ppm or % by vol.] act. meas. path [m]

•

0.15 m max. filter chamber length

-----------------------------------------------------------------------------------------------------------------

Tetarg

Test gas conc. [ppm] 0.758

273

353

----------

••

act. air pressure [hPa]

1013

--------------------------------------------------------

• L [mm]

Chamber

• 0.001•=

Conversion factor depends on the component

NH3: 0.758, HF: 0.892, HCl: 1.628

Intermediate housing

Bolt

1 General calculation:

2 Calculating setpoint values for all 6 chamber lengths:

Comp. Required test gas concentration

Filter chamber lengths

25 mm 50 mm 75 mm 100 mm 125 mm 150 mm

HCl

Table 10: Test gas concentrations for the respective filter chamber lengths

MAINTENANCE 7

7.5.3 Installing the filter box

Fig. 34: Filter box

▸ Swivel the intermediate GM700 enclosure open, remove the bolts and take off the

intermediate enclosure. Store safely until filter box measurement is completed.

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7 MAINTENANCE

Bolt

SR-unit

Filter box

Reflector

Fig. 35: Installing the filter box on the GM700

▸ Position the filter box with adapter plate on the SR-unit:

▸ Insert the filter box in the SR-unit hinge ▸ Insert and fasten the bolt ▸ Swivel the filter box on the SR-unit in and lock with the locking device

▸ Fit the reflector for GM700 on the filter box.

Fig. 36: Installing the filter box on the measuring device

7.5.4 Carry out filter box measurement

▸ Switch the filter box on; the warm-up phase takes about 2.5 hours. ▸ Switch on the zero gas pump or connect a different zero gas. ▸ Switch all chamber valves to “Zero gas” and the Measure/Purge valve to “Purge”.

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MAINTENANCE 7

ON/OFF switch

Power supply connection

Test ga s val ve to s witc h individual measuring chambers

Purge valve

Zero gas valve

Zero gas connection

Gas connection, measuring chamber 75 mm

Gas connection, measuring chamber 50 mm

Gas connection, measuring chamber 25 mm

Pump ON/OFF switch

Temperature displays, preheater and measuring chamber

On the EvU:

▸ After about 3 minutes, call Box measuring in menu cal (button cal) and select the option

“gas”.

▸ Enter password “1 2 3 4”. ▸ The measuring device now starts a zero adjust and then switches to operating mode

“Box measuring”.

Fig. 37: Control elements on the filter box

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▸ Connect test gas; set the primary pressure to approx. 1000 hPa (1 bar). ▸ Note the diameters of individual chambers and/or chamber combinations of the filter

box and the concentration values; see Section 9.6.1, page 96.

▸ At the same time, set the respective filter chambers to “Test gas”. ▸ Switch the Measuring/Purging valve to “Purging” for 2 to 3 minutes (until the

measured value has stabilized) and then to “Measuring”.

▸ The overpressure from the purge phase now dissipates. ▸ When the measured value has stabilized again, read off and note the value.

Restart measuring mode

▸ Purge the filter box with zero gas.

On the EvU:

▸ Exit operating mode “Box measuring” by pressing back. ▸ Disassemble the filter box with plate and reflector from the SR-unit and store safely. ▸ Refit the SR-unit back onto the sampling point in the correct position.

7 MAINTENANCE

Nominal value

Test cell

Test value

1000 mm

150 mm

---------------------------------

• 5 mg/m

3 1000 mm

150 mm

---------------------------------

• 33.3 mg/m

===

Output

Device

Test value

273°C

273°C Temp

Cell

---------------------------------------------------------------

• 5 mg/m

3 273°C

393°C

-----------------------

• 3.47 mg/m

===

Test value Output

Device

273°C Temp

Cell

273°C

---------------------------------------------------------------

• 3.47 mg/m

3 393°C

273°C

-----------------------

• 5 mg/m

===

7.6 Checking the gas analyzer with test cell GMK10

Special characteristics of a measuring component or also the availability of test gases with the precision required for reference materials require the generation of the span gas from aqueous solutions with known content. This is the standard case for GM700-2 (HF).

A test gas system with hose pump, scales and evaporator is required in addition to the heated test cell GMK10 (example: Hovacal).

Requirements

WARNING: Aggressive and corrosive gases

All materials used must be suitable for the measuring components, e.g. HCl, HF.



The manufacturer recommends to exclusively use the evaporator of the test gas system for this check.

Components required:

● Zero path; Part No. 46483

● Test cell GMK10 with heated sample gas line

● Settings of the test gas system (Hovacal)

Consider the following when entering the nominal value of the concentration (mg/m

− Test cell length of 150 mm

− Test gas temperature depending on setting (120 ...

140 °C)

− Measured value output in mg/m state relative to an active measuring path length of 1 m (1000 mm)



Input nominal value (in standard state; 0 °C, 1013 hPa) in test gas system (Hovacal):

Example: Test value = 5 mg/m

in the operating

The values are displayed in mg/m3 (operation):

Comparison of actual display with entered nominal value:

● Aqueous solution of test component (e.g. 0.01 M for HF)

● Distilled water

● Nitrogen 4.6 or better (compressed gas cylinder)

● Length of hose for safe discharge of the test gas

● Measurement of ambient air pressure

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On the evaluation unit:

GM700 SR-unit

GMK10 test cell

Zero path

Power supply

Gas outlet

Sample gas connection

Set the measuring system to maintenance mode before removing the device from the sampling point. On the evaluation unit:



Press button “maint”



Select “Maintenance Mode” and activate maintenance operation

7.6.1 Installation of the GM700 components with the test cell GMK10

Fig. 38: Assembly of the GM700 components and the test cell

MAINTENANCE 7



Remove the SR-unit and the measuring probe from the sampling point.



Use the 4 M16 screws to fit the GMK10 with device flange to the measuring probe.

Installation of GM700 components “Fitting system components”, page 35.



Perform connections on the GMK10:



Connect the cables for energy supply.



Connect the sample gas line



Connect the hose for gas discharge from the test gas system to the gas outlet



Prepare the test gas system and put it into operation. Refer to separate Operating Instructions etc. of the test gas system.

Fig. 39: Connections of the GMK10 test cell

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7 MAINTENANCE

7.6.2 Carrying out measurement

Step 1: Checking optical alignment

– The CAN line from the SR-unit to the purge air fixture may not be connected, the

system switches to using the default values for pressure and temperature.



If necessary, disconnect this CAN line. Connect the remaining connections of the measuring system, “Electrical connections on the sender/receiver unit”, page 49.



Connect the cable for power supply to the GMK10.



Connect the sample gas line from the test gas system.



If necessary, connect the power supply for all GM700 components

Step 2: Settings:



As standard, the temperature of the test cell and the heated sample gas line is 120 °C. Temperatures up to 140°C are possible depending on the application.



Check the temperature on the GMK10. – Check the temperature indicator on the GMK10 cover. – Set the desired temperature accordingly when the indicator does not show 120 °C: – Remove the cover of the GMK10 and set the temperature on the temperature

controller. If required, see separate Operating Instructions of the temperature

controller.

Checking optical alignment → “Zero adjust”, page 52.

CAUTION:

It is possible to perform the check of the GM700 with a separate reflector on a zero tube or a similar construction. Independent therefrom, the optical alignment is always performed to the probe position (marking "O, circle" on the target).

WARNING: Hazard by dangerous laser radiation

When the device is operated without probe, dangerous exposure to radiation may occur.

▸ Always close the reflector when the device is operated without measuring probe.

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Fig. 40: Temperature indicator on GMK10

Temperature indicator

Temperature controller

MAINTENANCE 7



On the EvU: Enter the temperature chosen for the test cell, e.g. 120 °C, as default value and enter 1013 hPa as default value for pressure.

Step 3: Set the evaporator temperature on the test gas generator to 180 °C. The test cell is

purged with nitrogen during the warming up phase.

Warming up time: Approx. one hour

Measurement can begin after a warming up time of at least one hour. However, we recommend to first purge the system by evaporating pure water.

NOTE: Software version UD81 or higher

Software version UD81 or higher must be installed in the GM700 measuring system for this procedure!



See Section “Menu overview”, page 43 →p. 45, 5.2.1

Step 4: Perform measurement:



When stable conditions exist − to be seen by the trend of the measured values − activate boxmeasuring mode on the GM700 EvU

– On the EvU: Call up menu cal with the cal button, activate

with

Enter.

– Enter password

“1 2 3 4”.

“Boxmeasuring” and start

The measuring device now starts a zero adjust and then switches to operating mode “Box measuring”. As for each filter box measurement, the system first performs a temporary zero adjust and then changes to boxmeasuring mode. The output of the measured values is performed analog to standard filter box measurement in mg/m

(during operation, relative to 1 m active measuring path).

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7 MAINTENANCE



Since the setpoint setting at the test gas system (Hovacal) is "standard", correct the value comparison (ambient) pressure and (test cell) temperature.

Recommendation

● To prevent pressure build-up in the measuring cell, do not use higher flow

rates than

● Pay attention to the unhindered discharge of the sample gas at the gas

4 l/min. for the measurements.

outlet.

● The standard solution used for the test must be chosen so that the H

concentration of the generated test gas does not exceed 30% by volume at any test point. Typical value for HF: 0.01M.

Step 5: Terminate the measurement

After termination of boxmeasuring mode (“

back“ button), the conditions for normal

measuring mode are reestablished, e.g. indication of measured value as parameterized.



Terminate the measurement with the “back” button.



Reinstall the GM700 SR and reflector unit to the purge air fixtures at the sampling

point and continue Measuring mode.

NOTE: Purge the measuring system with evaporated distilled water



After the end of the measurements, the system must be purged with vaporized distilled water until the zero point is reached again!



Before switching off the heaters, the system must be purged with dry nitrogen for a minimum of 5 minutes.



Make gas connections.

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TROUBLESHOOTING AND CLEARING MALFUNCTIONS 8

maintcalpardiag

GM 35

Evaluation Unit

CO CO

H2O

mg/ m

236

Ref. conditions

Hum: wet

Measuring

Operation

Service

Warnin

Malfunction

8 Troubleshooting and Clearing Malfunctions

8.1 Malfunction categories/possible effects

This Section shows how malfunctions of the GM700 can be recognized, diagnosed and cleared. It is primarily aimed at the operating personnel responsible for the current operation of the measuring system as well as maintenance technicians responsible for clearing malfunctions.

GM700 malfunctions are categorized according to the anticipated effects.

Damage to the measuring system itself

Depending on the installation conditions and measuring system version, a purge air failure could cause damage to the GM700 .

8.2 Purge air failure

Failure of the purge air supply demands measures to be taken immediately or within a short time, depending on the installation conditions, to protect the measuring system. A purge air failure, however, rarely occurs in practice. It is still however wise to be prepared for such an occurrence to prevent damage to the measuring system.

Indications of a potential purge air failure

● Error message on systems that are equipped with a pressure difference sensor

● Purge air unit power supply failure

● Increase in enclosure temperature of the GM700 SR-unit

● Rapid increase in contamination on optical interfaces of the SR-unit

● Hose for the purge air supply to the purge air fixture is loose or visibly damaged

Tools for troubleshooting

● Suitable protective equipment (protective clothing, gloves, etc.) that enable the gas duct

to be opened safely and the SR-unit as well as the reflector removed under the given installation conditions (hot/aggressive/noxious/dust-laden sample gases, overpressure in the duct).

● 2 wrenches to remove the SR-unit and reflector and, possibly, other tools required to

restore the power supply.

● Flange cover to seal off the flange opening when the measuring system is removed.

8.3 Integrated monitoring and diagnosis system

The GM700 is equipped with an integrated system that constantly monitors the operating state of the SR-unit and evaluation unit. Appropriate messages are generated and logged in the devices for subsequent evaluation should any deviations from normal operating conditions occur. Depending on the anticipated effects, the messages of the system components are categorized into error messages and warning messages: Warning messages are generated if the measurement results are not (yet) directly affected by the change in the system state. Nevertheless, it is important that the cause(s) be investigated and corrected, e.g. by means of maintenance measures, to avoid further malfunctions and damage to the device in particular.

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8 TROUBLESHOOTING AND CLEARING MALFUNCTIONS

Error messages are generated when measuring operation is no longer possible or no longer reliable. These warning and error messages are stored in the integrated message memory of the evaluation unit.

8.3.1 Display and retrieval of messages on the evaluation unit

Component/Tool Signals Note

Operation

Service

Warning Malfunction

Diagnosis mode

Functional impairment on system

Warning LED goes on

Front panel

Evaluation unit

Malfunction LED blinks

Error Storage Table Call menu Malfunction

Warning Storage Table Call menu Warning

Output

for serious problems

(malfunction, error

message)

[1]The relay is active during normal operation (no malfunctions), i.e. the contact is closed.

Relay 1 inactive

[1]

that will not directly lead to corrupt measured values.

Functional impairment on system that can lead to system failure or restricted function.

Plain-text message(s) for errors that have occurred to localize and clear the problem. See “Troubleshooting Table”.

Plain-text message(s) for pending warnings

Group malfunction

Troubleshooting Table

If a warning or malfunction is signaled, first call up pending error messages in the Error menu. Then localize the possible cause and clear the malfunction; see Troubleshooting Tab le.

Error indication Possible causes Clearance

● LED Malfunction blinks;

(

LED Warning could go on)

● Relay 1:

Group malfunction

Plain-text error messages indicate possible causes

Tab le 1 1: Troubleshooting Table

▸ Start Diagnosis mode (diag):

–Call menu – Check and clear the specified malfunction.

Malfunction (and/or Warning)

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TROUBLESHOOTING AND CLEARING MALFUNCTIONS 8

Jumpers: Open: 230 V AC Plugged: 115 V

Fuses:

2.5 AT, 250 V

Screw terminals (CAN) for SR-unit

Display for 24/5 V

8.3.2 Troubleshooting and clearing malfunctions, evaluation unit

Evaluation unit not responding

Evaluation unit:

● Evaluation unit power supply

defective

Evaluation unit:

● Incorrect operating voltage

Evaluation unit:

● Defective fuse

Evaluation unit:

● No defect localized yet

Evaluation unit:

● Error occurs again

Evaluation unit:

● 24V/5V supply defective

Evaluation unit:

● Inconsistent data detected in

parameter memory

▸ Check power supply on all system components:

– If necessary, provide power supply on site – If necessary, check/reconnect connections on the

system components

▸ Check operating voltage set on the evaluation unit:

– If necessary, change setting

▸ Check fuse in the evaluation unit:

– If necessary, replace fuse

▸ Disconnect all system components from the power supply

and reconnect one at a time – Check the CAN bus cable from the evaluation unit to

the SR-unit and/or terminal box

▸ Replace the last component connected, contact Service

▸ Check 24V/5V supply, replace

evaluation unit and/or electronic board module; contact Service

▸ Press Enter to restart the system; the factory parameter

settings are then active;

▸ If necessary, reconfigure the parameters ▸ If the same error message occurs again, replace the EvU

and contact Service.

Fuses

▸ Open the EvU enclosure ▸ Check fuses and replace when necessary

Power supply

▸ Check the indicator for the 24 V/5V supply and, if

necessary, remove the screw terminal (CAN) of the signal cable to the SR-unit.

▸ If these indicators only light up when the connector has

been removed, check the cabling first.

▸ If no error is found, connect the system components one

by one – Only connect the cable between the EvU and SR-unit – Connect the cable to the reflector

Table 12: Troubleshooting and clearing malfunctions, evaluation unit

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8 TROUBLESHOOTING AND CLEARING MALFUNCTIONS

8.3.3 Error messages

Error message Component/possible causes Clearance

Air purge low SLV

CD: Filter watch SLV

CD: P No Signal SLV

CD: P out of range SLV

CD: T Air Sign. SLV

CD: [t] No Signal SLV

CDOH: No communication SLV

CDR: No communication SLV

DSP: BOOT ERROR

DSP…Digital Signal Processor

DSP: INV PARA

DSP: NO RESP

EEPROM: CONTROL

EEPROM: LASER

FIT: DIV BY 0

FIT: NO CONV

FIT: S MATRIX

Tab le 1 3: Error messages

The volume flow is below the set limit.

Low-pressure monitor of purge air unit switches on binary input

No signal from pressure sensor

Sample gas pressure < 500 or >1200hPa/mbar

Broken sensor and/or no temperature sensor (purge air temperature) connected

Broken sensor and/or no temperature sensor (exhaust gas temperature) connected

CAN connection EvU – purge air fixture SR interrupted

CAN connection EvU – purge air fixture reflector interrupted

Error during start process

Incompatible software (SR-unit) Invalid values entered

Electronics communication problem (SR-unit)

Invalid microcontroller parameters (SRunit)

Invalid laser parameters

Error during signal evaluation:

● Incorrect parameter values

● Hardware defective

Error during signal evaluation:

● Incorrect parameter values

● Hardware defective

Error during signal evaluation:

● Incorrect parameter values

● Hardware defective

▸ Check the purge air supply (blower, hoses), if

necessary, exchange filter on purge air blower,

→ Purge air unit Operating Instructions.

▸ Check the purge air supply (blower, hoses), if

necessary, exchange filter on purge air blower,

→ Purge air unit Operating Instructions.

▸ Check connection and cable connection of pressure

sensor on purge air fixture and repair if necessary

▸ Check and/or replace pressure sensor

▸ Check connection and cable connection of

temperature sensor (purge air temperature) on purge air fixture and repair if necessary

▸ Check connection and cable connection of

temperature sensor (exhaust gas temperature) on purge air fixture and repair if necessary

▸ Check CAN connection; disconnect and reconnect

plug, repair if necessary

▸ Check CAN connection; disconnect and reconnect

plug, repair if necessary

▸ Restart device

–Press maint button to activate maintenance –Trigger menu – switch device off and on again

▸ If not successful, contact Service ▸ Check software version, contact Service if

necessary

▸ Correct erroneous values ▸ Restart device, see above

▸ If not successful, contact Service ▸ Restart device, see above

▸ If not successful, contact Service ▸ Check parameters measuring distance,

substitute for temperature and pressure and

correct if necessary

▸ Restart device, see above ▸ If not successful, contact Service

▸ Check parameters measuring distance,

substitute for temperature and pressure

▸ Increase parameter Average

Attention: Only by trained personnel!

▸ Restart device, see above ▸ If not successful, contact Service

▸ Check parameters measuring distance,

substitute for temperature and pressure and

correct if necessary

▸ Restart device, see above ▸ If not successful, contact Service

Reset System or

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TROUBLESHOOTING AND CLEARING MALFUNCTIONS 8

Error message Component/possible causes Clearance

Incompatible device

INIT: NO LINE

LD: PELT ERROR

LD…laser diode

LD: TEMP ERROR

MEAS: M PLAUS

MEAS: R PLAUS

MEAS: REF CONC (only for devices with closed cuvette)

Sensor communication

SIG: DARK VALUE

SIG: K HIGH

SIG: K LOW

SIG: M HIGH

SIG: M LOW

SIG: R HIGH

SIG: R LOW

Z MEAS: RANGE (only for devices with NH3 measurement)

Table 13: Error messages

Incompatible software (SR-unit)

No absorption line found

Temperature measurement on Peltier element defective:

● Possible hardware defect

Laser wavelength adjustment outside allowed range

● Absorption line “lost”

● Laser diode defective

Measuring results from measuring channel not plausible:

● Incorrect parameter values

● Strong signal interference

● Hardware defect

Measuring results from measuring channel not plausible:

● Incorrect parameter values

● Strong signal interference

● Hardware defect

Gas concentration in reference cuvette too low

SR-unit not connected correctly ▸ Check CAN connection and repair if necessary

Dark values of receiver element too high:

● Possible hardware defect

Monitoring channel signal too high ▸ Contact Service Monitoring channel signal too low ▸ Contact Service Measuring channel signal too high ▸ Contact Service

Measuring channel signal too low:

● Optical interfaces (front window) of

SR-unit or reflector contaminated

● Optical axes alignment too

inaccurate

● Hardware defect

Reference channel signal too high ▸ Contact Service Reference channel signal too low ▸ Contact Service

Unallowed results during zero gas measurement:

● Zero gas missing

● Optical interfaces (front window) of

SR-unit or reflector contaminated

● Optical axes alignment too

inaccurate

▸ Check software version ▸ Contact Service

▸ Restart device, see above ▸ If not successful, contact Service

▸ Check parameters measuring path, substitute

for

temperature and pressure

▸ Increase parameter Average

Attention: Only by trained personnel!

▸ Restart device, see above ▸ If not successful, contact Service

▸ Restart device, see above

▸ If not successful, contact Service

▸ Exchange reference cuvette ▸ Contact Service

▸ Contact Service

▸ Clean front window, “Cleaning the front window on the

SR-unit”, page 61.

▸ Check optical alignment and correct if necessary,

→

“Optical alignment”, page 50.

▸ If not successful, contact Service

▸ Check zero gas supply and repair if necessary ▸ Clean front window, “Cleaning the front window on the

SR-unit”, page 61

▸ Check optical alignment and correct if necessary,

“Optical alignment”, page 50.

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8 TROUBLESHOOTING AND CLEARING MALFUNCTIONS

8.3.4 Warning messages

Warning message Component/possible causes Clearance

Feed Test Gas

FIT: LINEPOS

H2O Undef. (only for GM700-8)

MEAS: REF CONC

(only for devices with closed cuvette)

DEV: TEMP

No detectable sample gas concentration (see Interval)

Deviation of absorption line position:

● Line not adjusted perfectly dur-

ing start process

Monitoring measurability of H2O:

● This warning appears when the

gas temperature drops below the switch threshold set

Gas concentration in reference cuvette too low; measurement still possible

Optic of SR-unit out of allowed temperature range:

● Warm-up phase after switching

● Ambient temperature too high

Tab le 1 4: Warning messages

▸ Feed test gas

▸ Wait until the warning message disappears after a few

minutes

▸ Restart device

– Activate Maintenance mode with maint button – Trigger menu item Reset System or – switch device off and on again – If not successful, contact Service

“---” appears on the EvU display. This signals that no value is available. The warning message disappears again as soon as the temperature exceeds the switch threshold

▸ Plan and prepare reference cuvette replacement

▸ Wait until the temperature has stabilized ▸ Select different ambient temperature range, “Selecting

the ambient temperature range”, page 63.

▸ Cool device

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8.3.5 Further tips on troubleshooting

Fuses

2.5 AT, 250 V

Operating voltage: 230 V AC – no jumper 115 V AC – jumper

5 V DC

LEDs light up: Internal voltage supply

present

24 V DC

LEDs light up when inputs are connected, i.e. a signal is pending

Digital inputs, 2 and 3

Analog output

Relay outputs

1...4

Fig. 41: Troubleshooting on the evaluation unit: LED displays, signals and fuses

TROUBLESHOOTING AND CLEARING MALFUNCTIONS 8

Evaluation unit not responding

▸ Check the power supply on the GM700, check the operating voltage set ▸ Check the fuse in the evaluation unit; check the 24 V/5 V supply indicator in the

evaluation unit, when doing so, remove the plug-in terminal on the cable to the receiver.

▸ If these indicators only light up when the plug-in connector has been removed, check the

cabling first.

Communication fault between evaluation unit and GM700 SR-unit

Error message:

Check following connections:

Sensor Communication???

▸ Connection between evaluation unit and SR-unit. ▸ Cable connection on the plug-in terminal in the evaluation unit. ▸ Cable to SR-unit. ▸ Outer plug-in connectors on SR-unit. ▸ Inner plug-in connectors in SR-unit.

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9 TECHNICAL DATA, EXPENDABLE AND SPARE PARTS

9 Technical Data, Expendable and Spare Parts

9.1 Technical data GM700 probe system

Combination of measuring components

Minimum and maximum measuring range end values are only applicable for single components. Extremely small or large end values for different components cannot be combined in all cases.

Measured data GM700 system

Measured variables NH

Performance-tested measured variables

Measuring principle Diode laser spectroscopy (TDLS)

Measuring path length

Measuring ranges

HF 0 ... 5 ppm / 0 ... 2,000 ppm

HCl 0 ... 10 ppm / 0 ... 3,000 ppm

Dual measuring ranges

HCI / H

O 0 ... 10 ppm / 0 ... 3,000 ppm (HCI)

/ H2O 0 ... 25 ppm / 0 ... 4,000 ppm (NH3)

Response time 1 s ... 360 s

Accuracy

Zero point

Sensitivity

Process temperature

Ambient temperature

Storage temperature –40 °C … +55 °C

Ambient humidity ≤ 85% relative humidity; non-condensing

Tab le 1 5: Technical data GM700 system

HF, HCl, H2O

● Open measuring probe (GMP): 0.25 mm ... 1.5 m,

depending on application

● Gas-testable measuring probe (GPP): 0.227 m ... 0.977 m,

depending on application

0 ... 25 ppm / 0 ... 4,000 ppm

Measuring ranges refer to 1 m measuring path Measuring ranges depend on the application and device version

0 ... 50 vol-% / 0 ... 100 vol-% (H

0 ... 5 vol-% / 0 ... 40 vol-% (H

Measuring ranges refer to 1 m measuring path Measuring ranges depend on the application and device version

≤± 2 %, relative to full scale value

≤± 2 %, in maintenance interval (6 months), relative to full

scale value

● GMP: –40 °C ... +250 °C

● GMP: –40 °C ... +430 °C

Depending on device version

–40 °C … +50 °C; depending on parameter settings; temperature change max. ± 10 °C/h

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TECHNICAL DATA, EXPENDABLE AND SPARE PARTS 9

EN 61010-1 EN 15267 EN 14181

Compliances

Electrical safety CE

Control functions Automatic check cycle for zero and reference point

Table 15: Technical data GM700 system

Sender/receiver unit

Description Analyzer unit of the measuring system

Degree of protection IP 65

Dimensions (W x H x D) 239 mm x 272 mm x 330 mm

Weight 13 kg

Power supply

Voltage Supply via the evaluation unit: 24 V DC

Auxiliary gas connections

Table 16: Technical data sender/receiver unit

EN 60825-1:2014-8 EN 61326-1 2000/76/EC (17. BlmSchV)

27. BlmSchV

(only for

and

HCl)

Test gas: Swagelok 1/4″ Purge gas: Swagelok 1/4″

Open measuring probe (GMP)

Description

Process temperature –40 °C ... +250 °C

Process pressure Depending on purge air supply

Process gas humidity Non-condensing

Degree of protection IP 65

Dimensions (W x H x D) See dimension drawings

Weight 25 kg

Power supply

Voltage Supply via the evaluation unit: 24 V DC

Built-in components

Table 17: Technical data GMP measuring probe

Measuring probe in open design version with integrated purge air guidance system

● Flow monitor (to monitor the purge air supply)

● Temperature sensor PT1000 (to measure the gas

temperature)

● Pressure sensor

Gas-testable measuring probe (GPP)

Description

Process temperature

Process pressure 120 hPa

Degree of protection IP 65

Dimensions (W x H x D) See dimension drawings

Weight 45 kg

Table 18: Technical data GPP measuring probe

Measuring probe with gas permeable filter element for adjustment with test gas

● HCl: +130 °C ... +430 °C

● NH3: +300 °C ... +430 °C

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9 TECHNICAL DATA, EXPENDABLE AND SPARE PARTS

Power supply

Voltage 150 V / 230 V

Frequency 50 Hz / 60 Hz

Power input

Built-in components

Tab le 1 8: Technical data GPP measuring probe

GM700 evaluation unit: Sheet steel enclosure

Description

Degree of protection IP 65 / NEMA 4x

Analog outputs 3 outputs:

Analog inputs 2 inputs:

Digital outputs

Digital inputs 3 inputs: 24 V

Interfaces and bus protocols

RS-232 Proprietary (service interface)

Display

Input

Design Sheet steel enclosure

Dimensions (W x H x D) 200 mm x 346 mm x 97.5 mm)

Weight ≤ 4.7 kg kg

Power supply

Voltage 115 V / 230 V

Frequency 50 Hz / 60 Hz

Power input ≤ 50 W

Tab le 1 9: Technical data GM700 evaluation unit: Sheet steel enclosure

≤ 150 W

● Temperature sensor PT1000 (to measure the gas

temperature)

● Pressure sensor

● Heating the optical interfaces

The evaluation unit serves as user interface, for data processing and output as well as control and monitoring functions

0/4 ... 20 mA, 500 Ω, Electrically isolated

0 ... 20 mA, 100 Ω, For gas temperature and gas pressure

3 relay contacts:

● 48 V AC

● 1 A, 60 W / 48 V DC

● 1 A, 30 W

● LC-Display

● Status LEDs: “Operation”, “Warning” and “Malfunction”

● Arrow keys

● Function buttons

GM700 evaluation unit: Cast metal enclosure

Description

Degree of protection IP 67 /NEMA 6

Analog outputs 3 outputs:

Tab le 2 0: Technical data GM700 evaluation unit: Cast metal enclosure

The evaluation unit serves as user interface, for data processing and output as well as control and monitoring function

0/4 ... 20 mA, 500 Ω, Electrically isolated

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TECHNICAL DATA, EXPENDABLE AND SPARE PARTS 9

Analog inputs 2 inputs:

0 ... 20 mA, 100 Ω, For gas temperature and gas pressure

3 relay contacts:

Digital outputs

Digital inputs

Interfaces and bus protocols

RS-232 Proprietary (service interface)

Display

Input

Design Cast metal enclosure

Dimensions (W x H x D) 289 mm x 370 mm x 138 mm

Weight ≤ 8.6 kg

Power supply

Voltage 115 V / 230 V

Frequency 50 Hz / 60 Hz

Power input < 50 W

Table 20: Technical data GM700 evaluation unit: Cast metal enclosure

● 48 V AC

● 1 A, 60 W / 48 V DC

● 1 A, 30 W

3 inputs: 24 V

● LC-Display

● Status LEDs: “Operation”, “Warning” and “Malfunction”

● Arrow keys

● Function buttons

Connection unit

Description

Dimensions (W x H x D) 175 mm x 110. 5 mm x 175 mm

Weight 3 kg

Power supply

Voltage 115 V / 230 V

Frequency 50 Hz / 60 Hz

Built-in components

Table 21: Technical data connection unit

To extend the CAN bus connection with a cable provided by the customer

Integrated 24 V power supply unit for supply of the sender/receiver unit

Purge air fixture

Description

Bus protocol CAN (internal system bus)

Dimensions (W x H x D) 420 mm x 429 mm x 220 mm

Weight 7 kg

Connections for auxiliary substances

Electrical connections Flow monitor

Table 22: Tech ni cal da ta pur ge air fixtu re

Flange attachment with connections for purge air hose and temperature sensor

Purge air: Hose connection 40 mm

Temperature sensor PT1000

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9 TECHNICAL DATA, EXPENDABLE AND SPARE PARTS

Connections SCU I/O

Relay contact <-> PE 860 V AC

Relay contact <-> relay contact 860 V AC

Relay contact <-> actuation 1376 V AC

Tab le 2 3: Characteristic data for electric isolation

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TECHNICAL DATA, EXPENDABLE AND SPARE PARTS 9

206

335

257

239

90°

45°

272

9.2 Dimension drawing

9.2.1 Dimension drawing sender/receiver unit GM700 (dimensions in mm)

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9 TECHNICAL DATA, EXPENDABLE AND SPARE PARTS

9.2.2 Dimensions of open measuring probe - GMP

227

L2 L3

76,4

Ø 254

45°

Ø 215,8

Ø 200

45°

Ø 18

Ø 40

Ø 14

45°

144

Ø 200

45°

176,9

360

233,2

Ø 114,3

GMP measuring probes Measuring gap L3 (active measuring path) [mm]

250 500 750 1000 1250 1750

Nominal probe length

0.9 m 935 296 46 – – – –

1.5 m 1644 1004.5 754.5 504.5 254.5 – –

2 m 2128 1489 1239 989 739 489 –

2.5 m 2628 1988 1738 1488 1238 988 488

Application-specific lengths on request

L1 [mm] L2 [mm] L2 [mm] L2 [mm] L2 [mm] L2 [mm] L2 [mm]

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9.2.3 Dimensions of GPP measuring probes

Ø 254

Ø 215,8

Ø 22,4

45°

Ø 18

45°

Ø 200

238

360

233

Ø 254

Ø 114,3

227

GPP measuring probes Length L3 [mm]

227 477 727 977

Nominal probe length L1 [mm] L2 [mm] L2 [mm] L2 [mm] L2 [mm]

0.9 m 904 353 103 – –

1.5 m 1614 1063 813 563 313

2.0 m 2098 1547 1297 1047 797

2.5 m 2598 2047 1797 1547 1297

Application-specific lengths on request

TECHNICAL DATA, EXPENDABLE AND SPARE PARTS 9

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9 TECHNICAL DATA, EXPENDABLE AND SPARE PARTS

97,5

90 82

322

300

160

200

Ø 8

260

289

R = 273

370

138

330

235

Ø 7

9.2.4 Dimension drawing evaluation unit GM700: Sheet steel enclosure (dimensions in mm)

9.2.5 Dimension drawing evaluation unit GM700: Cast metal enclosure (dimensions in mm)

9.2.6 Connection unit GM700 (Can bus option) (dimensions in mm)

163

4,5

175

30,5

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TECHNICAL DATA, EXPENDABLE AND SPARE PARTS 9

Versions deliverable from stock

Alternatively, an ANSI flange provided by the customer can be used.

Part No. Material Length [mm] 2016807 ST 37 240 2016808 1.4571 240 2017785 ST 37 500 2017786 1.4571 500

9.2.7 Dimensions of weatherproof cover for GM700 SR-unit

9.2.8 Dimension drawings of flange with tube

Ø 240

Ø 178

Ø 100,8

240 / 500 / 1.000

Ø 108

3,6 – 4,0

45°

Ø 18

Ø 200

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9 TECHNICAL DATA, EXPENDABLE AND SPARE PARTS

9.3 Accessories, expendable and spare parts

Please contact your local sales partner for order data for further spare parts as well as prices and packing units.

9.3.1 Consumable parts for 2-years operation

Part No. Description

4 003 353 Optical cleaning cloth

6 010 378 Lithium battery 3.00 V CR2032

5 312 881 Pressure compensation element

Tab le 2 4: Consumable parts for 2-years operation

9.3.2 Spare parts for the sender/receiver unit

Description Part No, for measuring components

Spare parts set, laser diode, sender unit 2055984 2034777 2043533

Spare parts set, receiver module, measuring channel

Spare parts set, receiver module

● Monitor channel

● Reference channel

Spare parts set, PCB heater 2055983 2030735 2043541

Spare parts set, PCB processor 2030737 2034778 2042707

Spare parts set, optics body module 2030720 2034774 2043540

Spare parts set, reference cuvette:

● Permanent cuvette 2030717 2043571 2042905

Spare parts set, alignment tool 2034780 2043538

Spare parts set, fiber optics with threaded sleeve

Spare parts set, insulation (optic body) 2030738 – –

Spare parts set, PCB CAN cable connector (socket)

Spare parts set, PCB CAN cable connector (plug)

Spare parts set, flange mounting kit 2039628

Spare parts set, lever (for alignment tool) 2030742

Spare parts set, clamping ring bolt 2030741

Bulkhead fitting 1/8" 5306073

Tab le 2 5: Spare parts for the sender/receiver unit

2055986 2034775 2043537

2055985 2055985

HF HCl

2034776 2034776

2030791 –

2030740

2030739

2043535 2043535

9.3.3 Spare parts for the measuring probe

Part No. Description

2 023 596 PCB IO GPP

2 032 767 PCB IO GMP

4 038 337 Heating triple, 48 V with terminal

2 030 190 Spare parts set, heating, front window, GPP

Tab le 2 6: Spare parts for the measuring probe

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TECHNICAL DATA, EXPENDABLE AND SPARE PARTS 9

Part No. Description

2 030 191 Spare parts set, heating, reflector, GPP

4 049 466 Wedge for GMP reflector and GPP window

4 034 658 Triple, gold-coated

2 026 457 Spare parts set, filter cartridge, L=250, ceramic

2 026 459 Spare parts set, filter cartridge, L=500, ceramic

2 026 460 Spare parts set, filter cartridge, L=750, ceramic

2 026 461 Spare parts set, filter cartridge, L=1000, ceramic

2 030 236 Spare parts set, filter cartridge, L=750, Teflon/ceramic

2 030 237 Spare parts set, filter cartridge, L=1000, Teflon/ceramic

2 017 832 Temperature sensor, PT 1000, length 610 mm

2 017 831 Temperature sensor, PT 1000, length 910 mm, probe 1.5 m, 500 measuring gap

2 017 830 Temperature sensor, PT 1000, length 1100 mm

2 018 181 Temperature sensor, PT 1000, length 1410 mm, probe 2 m, 500 measuring gap

2 018 203 Temperature sensor, PT 1000, length 1610 mm

2 032 919 Spare parts set, GPP seal, 420 °C

4 041 347 Sealing tape for flange, 235 x 35 x 2, Neoprene for GMP

2 025 615 Sealing tape for flange, 235 x 35 x 2, Neoprene/Teflon for GPP

4 039 022 Seal, G x P 35 126/116 x x7, graphite

5 312 881 Pressure compensation element

Table 26: Spare parts for the measuring probe

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9 TECHNICAL DATA, EXPENDABLE AND SPARE PARTS

9.3.4 Spare parts for the evaluation unit

Part No. Description

2 021 795 PCB system control

6 021 782 Fuse 250 V, D8.5 x 8

6 020 125 Locking cap, fuse D5 x 20

6 007 328 Jumper, pluggable

6 020 400 Membrane keyboard

2 017 329 Hinge pin

6 010 378 Lithium battery 3.00 V CR2032

Tab le 2 7: Spare parts for the evaluation unit

9.3.5 Fixing accessories

Fixing accessories for the measuring probe - flange

Part No. Description

5 700 457 Screw, 6 Kt M16x 60-A2

5 700 482 Washer, A17-A2

5 700 471 Nut, 6 Kt M16 A2

5 700 480 Spring washer, A16

Tab le 2 8: Fixing accessories for the measuring probe - flange

Fixing accessories for the SR unit - measuring probe

Part No. Description

5 700 484 Cup springs A25

5 700 472 Nut SSI M12

5 700 494 Spherical washer

2 017 329 Hinge pin for GM700 flange fixture

4 023 743 Sealing tape

Tab le 2 9: Fixing accessories for the SR unit - measuring probe

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TECHNICAL DATA, EXPENDABLE AND SPARE PARTS 9

Optical Fiber

Hinge pin, set

Connector female

Connector male

Slide rod

Alignment assembly

Heater

Detector module Characteristics channel

Module laser diode

Reference cell

Detector module reference channel

Processor PCB

Heater

* Identical

Detector module laser diode

Detector module

mea-

surement

Heater

Optics body

9.3.6 Spare parts assignment for sender/receiver unit

Fig. 42: Spare parts assignment for GM700 SR-unit

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9 TECHNICAL DATA, EXPENDABLE AND SPARE PARTS

CAN cable connector

Fixing set, flange

SR-unit – intermediate enclosure

Bulkhead fitting

Clamping ring bolt

Lever for alignment tool

SR-unit: Flange fixture

Socket Plug CAN cable connector

Fig. 43: Spare parts assignment for GM700 SR-unit - intermediate enclosure and flange fixture

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TECHNICAL DATA, EXPENDABLE AND SPARE PARTS 9

Fig. 44: Spare parts assignment for reflector GMP probe

Fig. 45: Spare parts assignment GPP probe: Flange part

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9 TECHNICAL DATA, EXPENDABLE AND SPARE PARTS

Wedged window

4 049 466

Fig. 46: Spare parts assignment GPP probe: Reflector side

Fig. 47: Spare parts assignment GPP probe: Window

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10 Annex

10.1 User information “Laser safety”

Concerns the deviation of EN 60825-1:2014-08 “Laser safety” from Directive 2006/25/ EC and/or the health and safety regulation, issued based on the Directive, regarding artificial optical radiation (“OstrV”)

This product has been classified and manufactured according to the harmonized standard EN 60825-1:2014-08.

However, this manufacturer classification does not in every case result in the compliance/ non-compliance of the exposure limit values with the European Directive 2006/25/EC.

The limit values for the exposure of workers to artificial optical radiation are determined in “Directive 2006/25/EC of the European Parliament and of the Council of 5 April 2006 on the minimum health and safety requirements regarding the exposure of workers to risks arising from physical agents (artificial optical radiation)” of the European Union. This Directive has been implemented by the health and safety regulations concerning artificial optical radiation (OStrV) into national legislation.

The values for maximum permissible exposure (MPE) stated in EN 60825-1:2014-08, which are used as basis for the risk assessment, are based on the exposure limit values of an internationally accepted scientific board (ICNIRP), which represents international stateof-the-art technology with its guidelines. These MPE values of the EN 60825-1:2014-08, however, do not comply with the exposure limit values of the European Directive 2006/25/ EC, as they are higher or lower in certain areas. Both MPE observations are based on the ICNIRP, the EN 60825-1:2014-08, however, takes the more recent guidelines of the ICNIRP into account.

ANNEX 10

SICK assumes that the limit value concept of Directive 2006/25/EC will be adapted according to EN 60825-1:2014-08, however, SICK is not aware of the time horizon.

Our product has been manufactured and classified according to EN 60825-1:2014-08; it is therefore possible that it deviates from the European minimum requirements for protection against risks due to laser radiation at the workplace.

The following overview shows applications of the product where the exposure limit values of the European Directive 2006/25/EC can be exceeded under the predictable conditions.

The GM700-02 emits maximum 15 mW in correct operation, when a current software version is used (version 9105060_YEK0 or a newer version with same functionality), parameters are set correctly and measured values are valid. This is below the limit values of laser class 1, according to IEC 60825-1:2014-5 (or EN 60825-1:2014-8) and below the limit values of EN 60825-1:2007, as well as Directive 2006/25/EC and the limit values of the health and safety regulations concerning artificial optical radiation (“OstrV”).

When the enclosures of the sender unit and the reflector unit are closed (normal operation), no optical radiation emerges.

The GM700-02 can emit maximum 25 mW, provided software version 9105060_YEK0 (or a newer version with same functionality) is used, even in case of an unfavorable parameter choice or a reasonably predictable error case.

This is below the accessible emission limit (AEL = accessible emission limit) of laser class 1, according to IEC 60825-1:2014-5 (30.3 mW for GM700-02 laser radiation), but factor 1.6 above the limit value of the European health and safety regulations for artificial optical radiation or EN 60825-1:2007.

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10 ANNEX

As general precautionary measure for all GM700, the user is requested to avoid looking into the beam and to switch off the device and thus the laser for all maintenance and

service work.

The following overview shows applications of product GM700-02 where the exposure limit values of the European Directive 2006/25/EC can be exceeded under the predictable conditions

Limit values for accessible radiation for the radiation of the GM700-02

EN 60825-1:2007, Directive 2006/25/EC,

IEC 60825-1:2014-5

Limit value laser class 1

worst case

typical

=1272 nm

= 1278 nm

30.3 mW

41.3 mW

Limit value laser class 3R

worst case

typical

=1272 nm

= 1278 nm

155 mW

211.8 mW

Tab le 3 0: Limit values for accessible radiation for the radiation of the GM700-02

Power output of the GM700 in planned operating state (normal operation/maintenance)

Power output GM700 Normal operation, with correct parameter choice and valid measurement

15 mW

Correct operation with SW as from version 9105060_YEK0

Power output GM700 in reasonably predictable single error case or with incorrect

25 mW parameter settings with SW as from version 9105060_YEK0

Remark 1: 10% safety value additionally considered for the measurement uncertainties and rounded up to 1 mW. Remark 2: When old software versions are used (prior to 9105060_YEK0), dangerous laser radiation can be emitted especially during start-up with low ambient temperatures (<0°C).

Tab le 3 1: Power output of the GM700 in planned operating state

Health and safety regulations concerning artificial optical radiation (“OstrV”)

15.6 mW

80 mW 80 mW

< AEL of laser class 1 (IEC 60825-1:2014-05) < AEL of laser class 1 (IEC 60825-1:2007-03)

< AEL laser class 1 (IEC 60825-1:2014-05) < AEL laser class 3R (IEC 60825-1:2007-03) (factor approx. 1.6 above LK1 )

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10.2 Positioning the probe reflector when the probe must be realigned

Fitting the probe: Vertical measuring gap

Fitting the probe: Horizontal measuring gap

Only necessary when the measuring probe must be realigned in flow direction (e.g. from vertical to horizontal direction) but the SR-unit must sit vertically.

Fig. 48: Aligning the measuring probe

ANNEX 10

The reflector in the probe end must, in accordance with the probe rotation (e.g. at 90°), be turned in the opposite direction to this rotation (e.g. –90°) so that the alignment of the optical beam path to SR-unit is maintained.

▸ Loosen the 3 screws on the probe end (screws with nuts remain on the reflector

enclosure); turn the cover 30° to the right and pull the reflector unit out.

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10 ANNEX

Socket screw (hidden)

Socket screw to mark the reflector alignment

Socket and slotted screw position (view rotated 180°)

Slotted screw

Screw connection for reflector holder

Screws

Fig. 49: Reflector position and reflector position marking (socket screw)

100

▸ Loosen the screw connections in the reflector holder and remove it. ▸ Take both holders and the wedge with the graphite seals out. ▸ Take the hollow triple with the triple holder out, position it in the new probe alignment in

the appropriate position (e.g. –90°).

Swap the socket and slotted screws: The socket screw must be rotated in the triple holder groove.

The socket screw shows the position of the hollow triple. It must always point towards the connector on the SR-unit so that the alignment is correct.

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Fig. 50: Probe reflector assembly

Spring

Triple holder

Triple

Slotted screw

Socket screw

Hollow triple repositioned (e.g. –90°)

Wedge window with graphite seals

Socket and slotted screw positions on reflector enclosure swapped

Holder (triple-side)

Holder (flange-side)

Socket screw hidden

ANNEX 10

▸ Reassemble the reflector components in the reverse sequence (insert the reflector and

turn approx. 30° to the left to stop) and secure the reflector unit on the probe end.

Fig. 51: Positioning of probe reflector with probe aligned

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101

INDEX

Absorption line ................................................................................... 78

Aqueous solution

............................................................................... 68

CAN bus

............................................................................................... 41

-Cable

Clearing

- Evaluation unit

- Evaluation unit not responding

-Troubleshooting Table

Conduit thread connection

............................................................................... 79

..................................................... 79

................................................................... 74

............................................................... 41

Designated user ................................................................................ 14

Diagnosis

- Current warning messages

........................................................... 43

GM700 HF version ............................................................................ 13

Important information

-Intended use

-Main hazards

- Main operating information

Intended use

- User (target group)

-Users, intended

.................................................................................. 14

................................................................................. 10

.......................................................... 10

...................................................................................... 14

......................................................................... 14

.............................................................................. 14

Laser class 1 ...................................................................................... 13

Laser safety

....................................................................................... 97

Manufacturer ..................................................................................... 16

Measured value

- Measuring function (general) Measuring function (general) Measuring Mode Measuring operation

- Current dust concentration measured value

- Device malfunction, error message

- Maintenance or Service mode

-Malfunction

- Measuring operation

- Menu overview

-Operation

-Service

- Warning

- Warning message

................................................................................ 43

.................................................................................... 43

............................................................................... 43

........................................................................................ 43

............................................................................................ 43

.......................................................................................... 43

.......................................................................... 43

........................................................ 14

........................................................... 14

............................... 43

.............................................. 43

...................................................... 43

..................................................................... 43

Operating elements

-Graphic display

-Key panel

- Messages on operating and malfunction states

- Navigation and input

-System control Operation

-Display contents

- Displaying, entering and setting parameters

-Function line

- Measuring operation

-Operating mode

- Password

.............................................................................. 42

........................................................................................ 42

......................... 42

..................................................................... 42

............................................................................... 42

............................................................................ 43

............................... 42

................................................................................... 43

..................................................................... 42

............................................................................. 43

........................................................................................ 43

Product identification ........................................................................ 16

Product name

..................................................................................... 16

Responsibility of user ........................................................................ 14

Serial No. ............................................................................................ 16

Signal words

......................................................................................... 3

Target groups (users) .........................................................................14

Troubleshooting Table Type plate

........................................................................................... 16

....................................................................... 74

User

-Designated user

- Responsibility of user

User information “Laser safety”, page 102.

............................................................................. 14

..................................................................... 14

.................................... 12

Warming up time ................................................................................ 71

Zero gas pump ................................................................................... 66

Zero path

............................................................................................ 68

102

8010100/YK22/V4-0/2015-12 | SICKOPERATING INSTRUCTIONS | GM700

Subject to change without notice

SICK GM700 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 SAFETY INFORMATION

1.1 Main hazards

1.1.1 Electrical safety

1.1.2 Grounding the device

1.1.3 Protection against hazards through gases

1.1.4 Protection against laser radiation

Fig. 1: Laser warning sign on the GM700 sender/receiver unit

Fig. 3: Laser sign for HCI measurement

1.1.5 Behavior during purge air failure

1.2 Intended use

1.2.1 Purpose of the device

1.3 Responsibility of user

1.3.1 Disposing of device parts harmful to the environment

2 PRODUCT OVERVIEW

2.1 Product identification

2.2 GM700 system, measuring probe version, layout

Fig. 4: GM700 system overview (measuring probe version)

2.2.1 Measuring probe in detail

Fig. 5: GPP measuring probe with ceramic filter

Fig. 6: GMP measuring probe (with open measuring gap)

Fig. 7: Measuring gap of the GPP measuring probe

2.2.1.4 Special versions

2.3 GM700 options and accessories

2.4 Measuring principle

2.4.1 Reference cuvette for wavelength stabilization

2.4.2 Signal evaluation

3 PROJECT PLANNING INFORMATION

3.1 Work steps from system selection to start-up

3.2 Project Planning Checklist

3.3 Initial onsite installation

3.3.1 Installation preparation at the sampling point

Fig. 8: Installation recommendation: Mounting flange and purge air unit (duct diameter not representative)

3.3.2 Uncovering the duct

3.3.3 Installing the flanges with tube

Fig. 9: Standard flange with tube

Fig. 10: Reinforcing with junction plates

3.3.3.1 Installing the flange with tube

3.3.4 Installation preparation for the purge air unit (for GMP probe)

3.3.5 Duct insulation

3.3.6 Installation preparation for the evaluation unit

3.4 Preparations for electrical installation

3.4.1 Signal and power supply cables

Fig. 11: Circuit diagram (probe version)

3.4.2 CAN bus wiring

4 INSTALLATION

4.1 Preparations

4.1.1 Checking the scope of delivery

4.1.2 Installation prerequisites

4.2 Fitting system components

4.2.1 Information on the SR-unit and measuring probe

4.3 Installing the purge air units (for GMP probe)

4.3.1 Terminal box with 24 V power supply unit (option)

Fig. 12: Fitting the terminal box with power supply unit

4.4 Installing the evaluation unit

4.4.1 Installing the evaluation unit – sheet metal enclosure version

Fig. 13: Installing the evaluation unit (sheet metal enclosure version)

4.4.2 Installing the evaluation unit – cast-metal enclosure version

Fig. 14: Mounting holes layout (Drilling plan) to fit the EvU (cast-metal enclosure)

Fig. 15: Fitting the evaluation unit (cast enclosure)

4.5 Electrical connection of system components

4.5.1 CAN bus wiring options

Fig. 16: Terminal box for CAN bus connection between SR-unit and evaluation unit

4.5.2 Electrical connection in the evaluation unit EvU

Fig. 17: Evaluation unit connections

Fig. 18: See steps 1 to 4 below Connecting the CAN bus cable to the evaluation unit

5 HANDLING THE EVALUATION UNIT

5.1 User qualifications

5.2 Operating elements

Fig. 19: Evaluation unit display and operating elements (shown with sheet metal enclosure)

5.2.1 Menu overview

6 START-UP

6.1 Preparations

6.1.1 Required qualifications and further prerequisites

6.2 Start-up steps overview

6.3 Mechanical preparation

6.3.1 Checking the scope of delivery