SICK GM700-02, GM700-03, GM700-04, GM700, GM700-05 Operating Instructions Manual
...
GM700
In-Situ Gas Analyzer Probe Version
Installation, Operation, Maintenance
O P E R A T I N G I N S T R U C T I O N S
Described product
GM700
Measuring Probe Version
Version GM700-02, GM700-03, GM700-04, GM700-05, GM700-07, GM700-08,
GM700-09
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Production location
SICK AG
Nimburger Str. 11 · D-79276 Reute · Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
CONTENTS
1 About this document........................................................................ 7
1.1 Function of this document....................................................................... 7
1.2 Scope of application................................................................................. 7
1.3 Target groups (and document structure)................................................. 7
1.4 Further information................................................................................... 7
1.5 Data integrity............................................................................................. 7
1.6 Symbols and document conventions...................................................... 8
1.6.1 Warning symbols...................................................................... 8
1.6.2 Warning levels / Signal words................................................. 8
1.6.3 Information symbols................................................................ 8
2 Safety information............................................................................ 10
2.1 Main operating information..................................................................... 10
2.2 Warning information on the device.......................................................... 13
2.3 Intended use............................................................................................. 15
2.4 Responsibility of user............................................................................... 15
3 Product description........................................................................... 16
3.1 Product identification............................................................................... 16
3.2 Product characteristics............................................................................ 16
3.3 Device variants......................................................................................... 16
3.4 Options...................................................................................................... 16
3.5 Layout and function.................................................................................. 17
3.6 Purge air unit............................................................................................. 17
3.7 Check cycle............................................................................................... 18
3.8 GMP and GPP measuring probes ........................................................... 18
3.8.1 GMP measuring probe in detail.............................................. 19
3.8.1.1 Gas connection for sample gas sampling on
purge air fixture of GMP measuring probe............ 20
3.8.2 GPP gas diffusion probe in dry or wet version....................... 20
3.8.2.1 GPP measuring probe gas connections for zero
and span gas........................................................... 21
4 Transport and storage....................................................................... 22
4.1 Transport protection................................................................................. 22
4.2 Storage...................................................................................................... 22
5 Mounting............................................................................................. 24
5.1 Assembly information............................................................................... 24
5.2 Tools required............................................................................................ 24
5.3 Preparing the measuring point................................................................ 24
5.4 GM700 scope of delivery......................................................................... 25
5.5 Installation sequence............................................................................... 25
5.5.1 Installation example................................................................ 25
5.5.2 Overview of installation steps (duct-side preparation).......... 26
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5.5.3 Installation preparation for the purge air unit........................ 26
5.5.4 Installing the flange with tube................................................. 26
5.5.5 Installing the control units...................................................... 27
5.5.5.1 Install the control unit away from the SR-unit....... 29
5.5.6 Installing the terminal box (option)......................................... 30
5.5.7 Installing the purge air unit..................................................... 30
6 Electrical installation........................................................................ 31
6.1 Electrical installation safety information................................................. 31
6.2 Connection overview................................................................................ 32
6.2.1 Lines......................................................................................... 33
6.2.2 Information on laying lines...................................................... 33
6.3 Connecting I/O interfaces........................................................................ 34
6.3.1 Leading the CAN bus line correctly through the PG screw
fitting........................................................................................ 34
6.3.2 Wiring the evaluation unit....................................................... 35
6.3.3 Customer wiring of the terminal box (optional)...................... 37
6.4 Connecting the SR-unit............................................................................. 38
6.5 Grounding conductor, evaluation unit..................................................... 38
7 Commissioning.................................................................................. 40
7.1 Safety information on commissioning..................................................... 40
7.2 Prerequisites for successful commissioning.......................................... 40
7.3 Overview of commissioning steps........................................................... 41
7.4 Material required ..................................................................................... 42
7.4.1 Material required - included in scope of delivery................... 42
7.5 Fitting the SR-unit on the purge air fixture of the measuring probe...... 43
7.6 Optical fine alignment for device versions for NH3 and HF measure‐
ment.......................................................................................................... 43
7.7 Optical fine alignment on the version for HCI measurement................ 45
7.8 Two types of zero point checks................................................................ 46
7.8.1 Selecting the ambient temperature range............................. 46
7.8.2 Carrying out zero adjust (on the measuring path free from
sample gas).............................................................................. 47
7.8.3 Zero point check with GPP measuring probe......................... 47
7.9 Repositioning the probe reflector............................................................ 48
7.10 Fitting the measuring probe on the flange with tube............................. 51
7.11 Putting the purge air unit into operation................................................. 52
7.12 Fitting the sender/receiver unit on the intermediate housing............... 52
7.13 Installing the weatherproof cover ........................................................... 53
7.14 Starting measuring operation.................................................................. 54
7.14.1 Operating states...................................................................... 55
7.14.2 Select the ambient temperature range.................................. 55
8 Operation............................................................................................ 56
8.1 Safety......................................................................................................... 56
8.1.1 Check before start-up.............................................................. 56
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8.2 Operating and display elements (evaluation unit).................................. 56
8.3 Menu tree of the evaluation unit............................................................. 58
8.3.1 Menu tree Measuring.............................................................. 58
8.3.2 Menu tree Diagnosis............................................................... 58
8.3.3 Menu tree Parameter.............................................................. 59
8.3.4 Menu tree Calibration.............................................................. 61
8.3.5 Menu tree Maintenance.......................................................... 61
8.4 Operating using the serial interface........................................................ 62
8.4.1 Significance of command line elements................................ 62
8.4.2 Setting for serial interfaces..................................................... 62
8.4.3 Serial interface commands - Meas........................................ 62
8.4.3.1 Serial interface command - MEAS ........................ 62
8.4.4 Serial interface commands - Diag.......................................... 62
8.4.4.1 Table with warning messages................................ 62
8.4.4.2 Error messages Table ............................................ 63
8.4.4.3 View the device configuration................................ 63
8.4.4.4 Check the system state and configuration........... 63
8.4.4.5 Call up diagnostic data........................................... 63
9 Maintenance...................................................................................... 64
9.1 Safety......................................................................................................... 64
9.2 Maintenance plan..................................................................................... 65
9.2.1 Maintenance protocol.............................................................. 65
9.2.2 Expendable, wearing and spare parts.................................... 65
9.3 Preparatory work....................................................................................... 66
9.4 Removing the SR-unit from the intermediate housing........................... 66
9.5 Visual check.............................................................................................. 67
9.6 Cleaning the optical interfaces................................................................ 67
9.7 Cleaning the purge air unit....................................................................... 69
10 Troubleshooting................................................................................. 70
10.1 Safety......................................................................................................... 70
10.2 Monitoring and diagnostic system........................................................... 70
10.3 Device not functioning.............................................................................. 71
10.4 Evaluation unit not functioning................................................................ 71
10.4.1 Communication fault between evaluation unit and receiver 72
10.5 Error messages......................................................................................... 72
10.5.1 Error messages........................................................................ 72
10.5.2 Warning messages.................................................................. 74
10.6 Repairing inadequate purge air supply................................................... 74
10.7 Corrosion on flange.................................................................................. 75
11 Decommissioning............................................................................. 76
11.1 Safety information for decommissioning................................................ 76
11.2 Removing the device................................................................................ 77
11.3 Preparing the device ready for shipping.................................................. 77
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11.4 Environmentally compatible disposal ..................................................... 78
12 Technical data.................................................................................... 79
12.1 System: GM700........................................................................................ 79
12.2 Sender/receiver unit................................................................................ 80
12.3 GMP measuring probe.............................................................................. 80
12.4 GPP measuring probe............................................................................... 80
12.5 Evaluation unit: Sheet steel enclosure.................................................... 81
12.6 Evaluation unit: Cast metal enclosure..................................................... 82
12.7 Terminal box.............................................................................................. 82
12.8 Dimension drawings, sender/receiver unit ............................................ 83
12.9 Dimension drawings, open measuring probe (GMP).............................. 84
12.10 Dimension drawings GPP measuring probe (Gas Permeable Probe).... 85
12.11 Dimension drawing evaluation unit......................................................... 86
12.12 Dimension drawings: Mounting flange DN125....................................... 87
12.13 Dimension drawing terminal box............................................................. 87
12.14 Dimension drawing, purge air unit........................................................... 88
12.15 Dimension drawing, weatherproof cover, sender/receiver unit............. 88
13 Annex.................................................................................................. 89
13.1 Possible ambient temperatures............................................................... 89
13.1.1 Ambient temperature ranges (closed cell)............................. 89
13.2 User information on laser safety GM700................................................ 89
14 Index.................................................................................................... 91
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1 About this document
1.1 Function of this document
These Operating Instructions describe:
Device components
•
Installation
•
Operation
•
Maintenance work required for reliable operation
•
1.2 Scope of application
These Operating Instructions are only applicable for the measuring device described in
the product identification.
They are not applicable for other SICK measuring devices.
The standards referred to in these Operating Instructions are to be observed in the
respective valid version.
1.3 Target groups (and document structure)
ABOUT THIS DOCUMENT 1
This Manual is intended for persons installing, operating and maintaining the device.
Operation
The device may only be operated by qualified persons who, based on their device-spe‐
cific training and knowledge as well as knowledge of the relevant regulations, can
assess the tasks given and recognize the hazards involved.
Installation and maintenance
Skilled persons are required for installation and maintenance.
Please observe the information at the beginning of the respective Sections.
1.4 Further information
Operating Instructions of the purge air supply
•
Final inspection record
•
NOTE
Observe all supplied documents.
b
1.5 Data integrity
SICK AG uses standardized data interfaces such as, for example, standard IP technol‐
ogy, in its products. The focus here is on product availability and features.
SICK AG always assumes that the customer is responsible for the integrity and confi‐
dentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures
suitable for the respective situation, e.g., network separation, firewalls, virus protection
and patch management.
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1 ABOUT THIS DOCUMENT
1.6 Symbols and document conventions
1.6.1 Warning symbols
Table 1: Warning symbols
Symbol Significance
Hazard (general)
Hazard by voltage
Hazard by oxidizing substances
Hazard by laser radiation
Hazard by toxic substances
1.6.2 Warning levels / Signal words
DANGER
Risk or hazardous situation which will result in severe personal injury or death.
WARNING
Risk or hazardous situation which could result in severe personal injury or death.
CAUTION
Hazard or unsafe practice which could result in less severe or minor injuries.
Notice
Hazard which could result in property damage.
Note
Hazard by noxious substances
Hazard by high temperature
Hazard for the environment/nature/organic life
Hints
1.6.3 Information symbols
Table 2: Information symbols
Symbol Significance
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Important technical information for this product
Subject to change without notice
Symbol Significance
Important information on electric or electronic functions
ABOUT THIS DOCUMENT 1
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2 SAFETY INFORMATION
2 Safety information
2.1 Main operating information
Lifting and carrying
WARNING
Injury risk through incorrect lifting and carrying of the device
Injuries can occur due to the weight and projecting enclosure parts when the equip‐
ment tips over or drops.
Consider the device weight before lifting.
b
Observe the regulations for protective clothing (e.g., safety shoes, non-slip gloves).
b
Grip underneath the equipment when possible to carry it safely.
b
Do not use projecting parts on the device to carry the device.
b
Call in further personnel for assistance as required.
b
Use a hoist or transport equipment as an option.
b
Pay attention to the transport safety device.
b
Clear obstacles that could cause falls and collisions out of the way.
b
DANGER
Risk for system safety through work on the device not described in these Operating
Instructions
Carrying out work on the device not described in these Operating Instructions or associ‐
ated documents can lead to unsafe operation of the measuring system and therefore
endanger plant safety.
Only carry out the work on the device described in these Operating Instructions
b
and associated documents.
Laser radiation
WARNING
Eye injuries through laser radiation
The invisible laser beam within the SR-unit is not accessible when fitted. Observe the
following when the SR-unit of the device is swiveled open during installation work for
test purposes and the laser beam is activated:
Never look directly into the laser aperture when opening the SR-unit.
b
Laser protection class 1: Wear laser protection glasses despite low radiation.
b
Observe national valid limit values and standards that refer to these for industrial
b
safety.
Laser radiation, HF version
CAUTION
Pay attention to device software 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. Prerequisite is using device
software 9105060_YEK0 or newer.
10
Laser class 1 of the IEC 60825-1:2014-5: Only use device software
b
9105060_YEK0 or a newer software version.
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SAFETY INFORMATION 2
DANGER
Important information for safe handling of the GM700 SR-unit on the device version
with HF measurement
For device software versions before 9105060_YEK0, a higher laser radiation might
occur.
Laser class 1 of the IEC 60825-1:2014-5: Only use device software
b
9105060_YEK0 or a newer software version.
Never look directly into the laser aperture when opening the SR-unit.
b
Always wear laser goggles or switch the device off during maintenance work.
b
Observe valid national limit values and respective standards for work safety.
b
NOTICE
Deviations of EN60825-1:2014-08 “Laser safety” from the Directive 2006/25/EC
The Directive has been adapted to cover changes in the health and safety regulation for
artificial optical radiation. Deviations occurred through changes in EN60825-1:2014-08
“Laser safety” from Directive 2006/25/EC.
Always observe the user information in the Annex of these Operating Instructions!
b
Escaping hot gas
DANGER
Risk of fire through hot gas escaping in installations with overpressure conditions
On installations with overpressure, the purge air hose can be severely damaged by
escaping hot gas and can catch fire depending on the temperature. On installations
with overpressure and gas temperatures over 200°C at the same time:
Regularly check the functionality of the reverse flow safeguard in the purge air fix‐
b
tures.
DANGER
Danger to life by leaking hot/toxic gases
Hot and/or noxious gases can escape during work on the gas duct, depending on the
plant conditions.
Work on the gas duct may only be performed by skilled technicians who, based on
b
their technical training and knowledge as well as knowledge of the relevant regula‐
tions, can assess the tasks given and recognize the hazards involved.
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2 SAFETY INFORMATION
Electrical safety
WARNING
Endangerment of electrical safety during installation and maintenance work when the
power supply is not switched off
An electrical accident can occur during installation and maintenance work when the
power supply to the device and/or lines is not switched off using a power isolating
switch/circuit breaker.
b
b
b
b
DANGER
Endangerment of electrical safety through missing power isolating switch
An electrical accident can occur during installation and maintenance work when the
power supply to the device and/or lines cannot be switched off using a power isolating
switch/circuit breaker.
Before starting the work, 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 separation device is mandatory when the power isolating switch can‐
not be accessed or only with difficulty after installation of the device connection.
The power supply may only be switched on again after work completion or for test
purposes by the persons carrying out the work under consideration of the valid
safety regulations.
Ensure the power supply can be switched off using a power isolating switch/circuit
b
breaker in accordance with DIN EN 61010-1:2010.
An additional separation device is mandatory when the power isolating switch can‐
b
not be accessed or only with difficulty after installation of the device connection.
WARNING
Endangerment of electrical safety through power cables with incorrect rating
Electrical accidents can occur when the specifications for replacement of a removable
power cable have not been adequately observed.
Always observe the exact specifications in the Operating Instructions (Technical
b
Data Chapter) when replacing a removable power line.
Potential equalization
CAUTION
Device damage through incorrect or non-existing grounding
To avoid device damage, a correctly connected potential equalization is mandatory on
all system components with external ground connections in all operating conditions.
Connect a potential equalization on all planned points on the device components.
b
Ensure the potential equalization is connected during all work on the device
b
described in these Operating Instructions.
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Contamination caused by purge air failure
112 2
CAUTION
A faulty purge air supply can damage the measuring system
The measuring system can no longer be protected from contaminated sample gas and
is damaged.
When the purge air supply appears faulty, immediately perform all actions
b
described in these Operating Instructions.
Responsibility for system safety
NOTICE
Responsibility for system safety
The person setting the system up is responsible for the safety of the system in which
the device is integrated.
2.2 Warning information on the device
GM700 SR-unit
SAFETY INFORMATION 2
Figure 1: Warning information on the sender/receiver unit
SR-unit, front side
1 Danger sign: Laser radiation
2 Type plate GM700
SR-unit, right side
1 Danger sign: Laser radiation
2 Type plate GM700
Laser sign
The wavelength of the laser varies for the respective measuring components (NH3, HF,
HCl). The maximum laser output at the optical interface depends on the respective
measuring component and is shown on the laser warning sign.
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2 SAFETY INFORMATION
Figure 2: Laser sign for HF measurement
14
Figure 3: Laser sign for NH3 measurement
Figure 4: Laser sign for HCI measurement
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2.3 Intended use
The device serves exclusively for emission and process monitoring of gases in industrial
plants.
The device measures continuously directly in the gas duct (in-situ).
2.4 Responsibility of user
Designated users
see "Target groups (and document structure)", page 7.
Correct project planning
Basis of this Manual is the delivery of the device according to the preceding
•
project planning (e.g., based on the SICK application questionnaire) and the rele‐
vant delivery state of the device (see delivered System Documentation).
w
Contact SICK Customer Service if you are not sure whether the device corre‐
sponds to the state defined during project planning or to the delivered system
documentation.
Special local conditions
SAFETY INFORMATION 2
In addition to the information in these Operating Instructions, follow all local laws, tech‐
nical rules and company-internal operating directives applicable wherever the device is
installed.
Read the Operating Instructions
Read and observe these Operating Instructions.
b
Observe all safety instructions.
b
If anything is not clear: Please contact SICK Customer Service.
b
Document retention
Must be kept for reference.
b
Must be passed on to new owners.
b
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3 PRODUCT DESCRIPTION
3 Product description
3.1 Product identification
Product name GM700
Device version Measuring Probe Version
Manufacturer SICK AG
Type plates Measuring Probe Version
3.2 Product characteristics
■
The device serves for continuous measurement of gas concentrations in industrial
plants
■
For application with high water ratios, i.e. waste incineration, we offer a specific
version, the GM700-04 or GM700-07.
■
The device is an in-situ measuring system which means measuring is done directly
in the gas carrying duct
■
Measuring components: HF, HCI, NH3, NH3 + H2O, HCI + H2O
■
Measuring principle: Diode laser spectroscopy (TDLS)
Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
Sender/receiver unit: On right side
•
On purge air fixture: On tube
•
3.3 Device variants
Variants Measured components
GM700-02 HF
GM700-03 HCI
GM700-04 NH3, high humidity
GM700-05 NH
GM700-07 NH3 / H2O, high humidity
GM700-08 HCI / H2O
GM700-09 NH3 / H2O
3.4 Options
•
•
•
•
3
Terminal box: For CAN bus with 24 V power supply.
The optional terminal box is available for distances between SR-unit and EvU >4
meters via a CAN bus cable provided by the customer.
Cover plate: For the purge air fixture of the SR-unit.
To maintain purge air supply in cases where this must remain in operation at the
measuring point when the SR-unit is dismounted.
Weatherproof cover: Required for installation outdoors
Air heater for purge air supply: For special application conditions to prevent con‐
densate. 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:
Gas temperature [°C] – dew point temperature [°C] < abs. humidity [Vol.-%].
Values are compared without considering the units of measure.
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3.5 Layout and function
1
2 3
1
4
5
6
6
PRODUCT DESCRIPTION 3
3.6 Purge air unit
Figure 5: GM700 layout (version representation)
Sender/receiver unit GM700 (SR-unit)
1
Purge air fixture
2
Flange with tube
3
Evaluation unit
4
Purge air unit
5
CAN lines
6
Function
The device serves for continuous measurement of gas concentrations in industrial
•
plants.
The device is an in-situ measuring system which means measuring is done directly
•
in the gas carrying duct.
Measuring components: see "Device variants", page 16.
•
Measuring principle: Diode laser spectroscopy (TDLS) (laser protection class 1).
•
To safeguard measuring reliability, a permanent air flow (optics purge air) keeps
•
the optics free from soot and dust particles.
This protects the front window of the SR-unit and the reflector in the measuring
•
probe against contamination and high gas temperatures
The purge air is blown into the gas duct through the “flange with tube”.
•
Further information on the purge air unit, see Operating Instructions of the purge air
unit.
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NOTE
17
3 PRODUCT DESCRIPTION
3.7 Check cycle
Cyclic check cycle for zero and sensitivity checks
Start a check cycle via
•
•
Purpose of check cycle
■
Check cycle procedure
The measuring sequence to determine the zero and check point is performed. The digi‐
tal input uses a falling edge for triggering, i.e. performance of a check cycle is sup‐
pressed as long as the signal is high (e.g., for control purposes).
Signaling
“Function control” (relay 3) is signaled per digital output during output of the zero and
check point.
Timer trigger: Configurable 0 ... 1440 minutes (= 1 day), see menu “Settings /
Check Cycle”
External digital input signal (Di 1)
Checking the zero point and span point without feeding span gases.
Output
The output runs for 90 seconds each for the zero point followed by the check point.
Unit and scaling for the current zero point according to the settings.
•
Check or span point is displayed as percentage scaled to 70% of the measuring
•
range.
The same calculation method is used for the deviation as for the gas concentration with
the exception of correction factors which result from a gas adjustment as well as cus‐
tomer correction factors from menu PAR/SETTINGS / REGRESS. FUNCT. During the
check cycle output, the zero and span point are displayed in the lower display line paral‐
lel to the analog output. These can be viewed in menu DIAG/CHECK VALUES/<GAS> for
subsequent checks. Prerequisite is that the output has already been made via an ana‐
log output.
Deviations
A warning message is output, e.g., “AO1 NH3 ZEROPoint” when the zero or check point
deviation is above 2% of the upper display limit of an analog output.
The warning message remains until the next check cycle output is within the tolerance.
3.8 GMP and GPP measuring probes
The measuring probe included in the scope of delivery was defined during project plan‐
ning in accordance with the application requirements.
18
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.
Table 3: Measuring probes
Measuring probe GMP (open measuring probe) GPP (for dry gases)
Version Measuring path open in flow
direction; purge air guidance
with outlet aligned 90° to gas
flow
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Gas diffusion probe with
ceramic filter, for dry sample
gas
Subject to change without notice
pen Close
2
5
7
6
4
3
1
4
PRODUCT DESCRIPTION 3
Measuring probe GMP (open measuring probe) GPP (for dry gases)
Max. gas temperature 250°C 430°C
Gas test according to EPA reg‐
ulation
Purge air supply required Yes No
Optical interface heating in
measuring probe
Sample gas flow velocity 1 ... 40 m/s < 40 m/s
Suitable for wet sample gas Yes No
Maximum duct pressure ±120 hPa, depending on
Measurable components NH3, HF, HCl NH3, HCl
System response time (T90) > 5 s > 120 s
Duct diameter > 360 mm > 300 mm
Dust concentration < 2 g/m3 in operating state < 30 g/m3 in operating state
Probe lengths available "Dimension drawings, open measuring probe (GMP)",
Active measuring paths avail‐
able [mm]
No Yes
No Yes, with integrated control
±120 hPa
purge air supply
page 84 and "Dimension drawings GPP measuring probe
(Gas Permeable Probe)", page 85.
250/500/750/1000/1250 250/500/750/1000
3.8.1 GMP measuring probe in detail
Figure 6: GMP measuring probe description
1
2
3
4
5
6
7
Reflector unit
PT1000 temperature sensor
Purge air outlet: Air outlet in the duct 90° to gas flow direction (directed purge air)
Locking device for opening between measuring probe and SR-unit
Light beam, sender-reflector
Purge air connection
CAN connection
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3 PRODUCT DESCRIPTION
3.8.1.1 Gas connection for sample gas sampling on purge air fixture of GMP measuring probe
For the reference measurement, sample gas can be extracted from the gas duct via a
gas sampling valve on the purge air fixture of the GMP measuring probe.
Figure 7: Gas sampling valve on the GMP measuring probe
Gas sampling screw fitting
1
NOTE
The reference measurement is not part of maintenance tasks carried out by the cus‐
tomer.
3.8.2 GPP gas diffusion probe in dry or wet version
Project planning information: There are two versions of the GMP measuring probe that
differ in the filter used. This supports differing application areas regarding the moisture
content of the sample gas.
Characteristics
Suitable for higher dust contents than the GMP probes.
•
For EPA-conform audit measurement.
•
For applications with low flow velocities or varying flow profiles.
•
Integrated sensors
Temperature sensor PT 1000: Continuously measures the media temperature on
•
the active measuring path of the probe
Pressure sensor
•
The measured data are transferred via the CAN bus interface of the measuring
•
probe and can then be displayed on the evaluation unit.
20
Figure 8: GPP measuring probe description
Reflector unit
1
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Ceramic filter (gas permeable)
2
PT1000 temperature sensor
3
Light beam, sender-reflector
4
CAN connection
5
3.8.2.1 GPP measuring probe gas connections for zero and span gas
Two gas inlets are located on the purge air fixture of the GPP measuring probe for the
zero point test.
PRODUCT DESCRIPTION 3
Figure 9: Gas inlets on the measuring probe
Zero gas connection
1
Test gas connection
2
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4 TRANSPORT AND STORAGE
4 Transport and storage
4.1 Transport protection
Removing the transport safety device on the SR-unit
1 Open the lock and swivel the flange fixture open.
2 Check the transport safety device for damage.
3 Remove the transport safety devices (see Figure).
4 Store the transport safety device.
Figure 10: Transport safety device on the SR-unit
Remove the front cover of the sender/receiver unit
1
4.2 Storage
Figure 11: Transport safety device on the GMP measuring probe
2 plastic protective caps to cover the optics
1
Remove the protective stickers
2
Set the locking device to the “close” position
3
DANGER
Risk to health through contaminated measuring probe
Depending on the composition of the gas in the measuring channel, the measuring
probe could be contaminated with substances which could result in serious health
damage.
Decontaminate the measuring probe before storage.
b
Wear the specified protective clothing for all work with a contaminated measuring
b
probe.
Clean all components of the measuring system with slightly damp cleaning cloths.
b
Use a mild cleaning agent here.
Protect the openings of the SR-unit and measuring probe from atmospheric influ‐
b
ences, preferably with the original transport safety devices.
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TRANSPORT AND STORAGE 4
Pack all components for storage or transport. Preferably use the original packing.
b
Store all components of the measuring system in a dry, clean room.
b
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5 MOUNTING
5 Mounting
5.1 Assembly information
Project planning for measuring channel
NOTICE
Observe information in Chapter “Main operating information”.
Correct installation
DANGER
Risk for system safety through work on the device not described in these Operating
Instructions
Carrying out work on the device not described in these Operating Instructions or associ‐
ated documents can lead to unsafe operation of the measuring system and therefore
endanger plant safety.
Only carry out the work on the device described in these Operating Instructions
b
and associated documents.
WARNING
Risk of injury when the device drops down
The weight of the device can cause it to drop down and cause injuries during the work
described in this Chapter.
Carry out assembly work on parts of the device together with another person when
b
necessary.
5.2 Tools required
Tools Part No. Required for
Adjustment device 2034121 Alignment of "flanges with tube"
19 mm jaw wrench Flange screw fitting
Screwdriver Connections
Allen key Connections
5.3 Preparing the measuring point
The operator is responsible for preparing the measuring point
NOTICE
Basis for determining the measuring point:
24
Preceding project planning (e.g., based on the SICK application questionnaire)
•
Final inspection specifications for device
•
Regulations of local authorities
•
Responsibility of the operator:
The operator is responsible for preparing the measuring point
Determination of measuring point (e.g. determining a representative sampling
•
point)
Preparing the measuring point (e.g. load capacity of welded on flange)
•
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MOUNTING 5
5.4 GM700 scope of delivery
Check the scope of delivery according to the order confirmation/delivery note.
Ensure the specified supply voltages correspond with the plant conditions.
5.5 Installation sequence
5.5.1 Installation example
Carry out assembly according to the project planning and the Inspection protocol. The dimensions specified in the
drawings are guidelines and can deviate strongly from the project planning.
Figure 12: Assembly example, all dimensions in mm
Sender/receiver unit (SR-unit)
1
Measuring probe (GMP version)
2
Evaluation unit (EvU) and optional terminal box
3
Purge air unit
4
Dimensions
Max. distance SR-unit - EvU: 4 m CAN line
5
When using a terminal box, extension up to 1000 m overall length
Duct wall - SR-unit: Depending on flange with tube length
6
a Consider space required for fitting and removing the measuring probe in the duct!
Minimum clearance (center) - working platform: 1300 - 1500 mm
7
Min. flange length in gas duct: 30 mm
8
L = flange with tube length: Standard 240 mm
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5 MOUNTING
Angle of flange inclination: Max. 1°
ß
Minimum clearance flange (center) to purge air supply: >700 mm
à
Horizontal and vertical clearance of fastening drill holes - purge air supply assembly plate: 470 mm
á
Purge air unit fastening: 50 mm protrusion for circular duct cross-section
â
Miscellaneous
Working platform
ã
5.5.2 Overview of installation steps (duct-side preparation)
Table 4: Installation steps overview
Step Procedure Reference
1 Fit flange with tube. "Installing the flange with tube",
page 26.
2 Fit control unit. "Installing the control units", page 27.
3 Optional: Fit terminal box. "Installing the terminal box (option)",
page 30.
4 Fit purge air unit or units. "Installing the purge air unit",
page 30.
5.5.3 Installation preparation for the purge air unit
NOTE
Observe the maximum line length between purge air unit and measuring device accord‐
ing to project planning.
NOTE
For information on installing the purge air unit, see the Operating Instructions of the
purge air unit.
CAUTION
Risk of purge air failure when purge air pressure too low
The purge air cannot enter the gas duct when the purge air pressure is too low. This can
lead to a purge air deficit which will cause the device to fail.
Pay attention to the correct purge air pressure during project planning.
b
If you have questions concerning the purge air pressure, contact SICK Customer
b
Service or your local SICK representative.
5.5.4 Installing the flange with tube
DANGER
Hazard through hot, explosive or toxic flue gases
Hot and/or noxious gases can escape during installation work on the gas duct, depend‐
ing on the plant condition.
26
Work on the gas duct may only be performed by skilled persons who, based on
b
their technical training and knowledge as well as knowledge of the relevant regula‐
tions, can assess the tasks given and recognize the hazards involved.
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1
200
18
4
5
°
MOUNTING 5
CAUTION
Device damage through incorrect/missing insulation of the duct when the measuring
channel is hot
When the gas duct is hot, insulate the duct and flanges so that the device is pro‐
b
tected from high temperatures.
Installing the flange with tube on the gas duct
1 Cut openings on the gas duct for the flange with tube.
2 Insert the flange with tube. Pay attention to the following:
The "Top" marking must point upwards vertically, irrespective of the gas duct
°
angle.
The tube must project at least 30 mm into the gas duct
°
Figure 13: "Top" marking on flange with tube
1
3 Attach the flange with tube.
NOTE
The measuring probe must not collide with other devices or fittings.
4 Tilt the tube slightly downwards (max. 1°) to allow any condensate to drain off.
5 Now fix the flange with tube properly to the gas duct. Make sure that the alignment
of the flange does not change.
6 If necessary, attach duct insulation to protect the device from heat.
5.5.5 Installing the control units
NOTE
The following criteria must be observed when selecting the installation location of the
control unit:
Good access
•
Sufficient space to open the swivel door of the evaluation unit
•
Protected from weather
•
Even, vertical installation surface
•
Marking “Top”
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Dimension drawings, see "Dimension drawing evaluation unit", page 86.
27
160
322
90
82
1
2
3
MOUNTING
5
Control unit version with sheet metal enclosure
Figure 14: Fitting the control unit (sheet metal housing version)
4 x mounting holes: ø 7.2 mm
1
Mounting surface
2
Fastening brackets
3
1 Bore the mounting holes according to the drilling plan.
2 Fasten the control unit to the four fastening brackets with M8 screws.
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