SICK GM700 Operating Instructions Manual
I
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.
© SICK AG. All rights reserved.
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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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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
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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
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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
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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.
3
– HCI: “Laser sign for HCI measurement”, page 13.
, HF,
3
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.
14
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
O
3/H2
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2.2 GM700 system, measuring probe version, layout
maintcalpardiag
GM
Evaluation Unit
CO
CO
2
H2O
mg/
m
3
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
3
±120 hPa
[2]
, HCl
3
[3]
> 360 mm > 300 mm
3
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
D
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,
2
/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
30
L
50
470
M10
Ø13
3
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
o
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
a
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
2
H2O
mg/
m
3
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
2
3 binary inputs 6 x 0.5 mm
2
3 analog inputs 6 x 0.5 mm
2
3 binary outputs 6 x 0.5 mm
2
3 analog outputs 6 x 0.5 mm
2
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
2
(see safety information)
Signal cable for:
Filter monitoring of the SLV 4 – 2 x 0.6 mm
2
, on pressure
controller with flat pin bushings 6.3 x 0.8 mm (DIN 46247)
Pressure connection
Power supply 4 x 1.5 mm
2
(see safety information)
Fig. 11: Circuit diagram (probe version)
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