SICK GM700-02, GM700-03, GM700-04, GM700, GM700-05 Operating Instructions Manual

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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.

Original document

This document is an original document of SICK AG.

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Subject to change without notice

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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CONTENTS

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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CONTENTS

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.

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.

Observe the regulations for protective clothing (e.g., safety shoes, non-slip gloves).

Grip underneath the equipment when possible to carry it safely.

Do not use projecting parts on the device to carry the device.

Call in further personnel for assistance as required.

Use a hoist or transport equipment as an option.

Pay attention to the transport safety device.

Clear obstacles that could cause falls and collisions out of the way.

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

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.

Laser protection class 1: Wear laser protection glasses despite low radiation.

Observe national valid limit values and standards that refer to these for industrial

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.

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

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

9105060_YEK0 or a newer software version. Never look directly into the laser aperture when opening the SR-unit.

Always wear laser goggles or switch the device off during maintenance work.

Observe valid national limit values and respective standards for work safety.

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!

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‐

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

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

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

breaker in accordance with DIN EN 61010-1:2010. 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.

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

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.

Ensure the potential equalization is connected during all work on the device

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

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

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).

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.

Observe all safety instructions.

If anything is not clear: Please contact SICK Customer Service.

Document retention

Must be kept for reference.

Must be passed on to new owners.

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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

•

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

2 3

PRODUCT DESCRIPTION 3

3.6 Purge air unit

Figure 5: GM700 layout (version representation)

Sender/receiver unit GM700 (SR-unit)

Purge air fixture

Flange with tube

Evaluation unit

Purge air unit

CAN lines

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

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.

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

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

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.

Figure 8: GPP measuring probe description

Reflector unit

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Subject to change without notice

Ceramic filter (gas permeable)

PT1000 temperature sensor

Light beam, sender-reflector

CAN connection

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

Test gas connection

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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

4.2 Storage

Figure 11: Transport safety device on the GMP measuring probe

2 plastic protective caps to cover the optics

Remove the protective stickers

Set the locking device to the “close” position

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.

Wear the specified protective clothing for all work with a contaminated measuring

probe.

Clean all components of the measuring system with slightly damp cleaning cloths.

Use a mild cleaning agent here.

Protect the openings of the SR-unit and measuring probe from atmospheric influ‐

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.

Store all components of the measuring system in a dry, clean room.

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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

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

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:

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)

Measuring probe (GMP version)

Evaluation unit (EvU) and optional terminal box

Purge air unit

Dimensions

Max. distance SR-unit - EvU: 4 m CAN line

When using a terminal box, extension up to 1000 m overall length

Duct wall - SR-unit: Depending on flange with tube length

a Consider space required for fitting and removing the measuring probe in the duct!

Minimum clearance (center) - working platform: 1300 - 1500 mm

Min. flange length in gas duct: 30 mm

L = flange with tube length: Standard 240 mm

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5 MOUNTING

Angle of flange inclination: Max. 1°

Minimum clearance flange (center) to purge air supply: >700 mm

Horizontal and vertical clearance of fastening drill holes - purge air supply assembly plate: 470 mm

Purge air unit fastening: 50 mm protrusion for circular duct cross-section

Miscellaneous

Working platform

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.

If you have questions concerning the purge air pressure, contact SICK Customer

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.

Work on the gas duct may only be performed by skilled persons who, based on

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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200

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‐

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

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.

160

322

MOUNTING

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

Mounting surface

Fastening brackets

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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Control unit version with cast metal enclosure

117.5

330

235

MOUNTING 5

Figure 15: Fitting the control unit (cast metal version)

1 Bore the mounting holes according to the drilling plan. 2 Fasten the control unit to the three mounting holes with M8 x 20 bolts.

NOTE

The mounting holes are accessible with the swivel door open.

5.5.5.1 Install the control unit away from the SR-unit

NOTE

The total length of the CAN bus connections may be up to 1000 m.

A terminal box with 24 V power supply unit is used to install the control unit at a longer distance from the SR-unit. This is connected to the SR-unit using the delivered CAN bus line (4 m).

A suitable customer 6-pole line (twisted pair wires and shielded), suitable for CAN bus applications, leads to the control unit. The total length of the CAN bus lines, including the one to the reflector, may be up to 1000 m. When performing maintenance or ser‐ vice, it must be possible to deinstall the control unit temporarily and connect it directly to the SR-unit at the measuring point.

Further information on laying lines, see "Information on laying lines", page 33.

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5 MOUNTING

5.5.6 Installing the terminal box (option)

Install the terminal box with 24 V power supply unit in the vicinity of the measuring

•

point. Fasten the enclosure on both mounting holes.

•

The line length available from the terminal box to the SR-unit is 4 m.

•

NOTE

Take the empty conduits laid for the prefabricated lines during onsite preinstallation into account.

Figure 16: Mounting fixtures of the terminal box

Mounting holes Ø 5 mm

5.5.7 Installing the purge air unit

NOTE

Purge air hose to the device according to project planning.

NOTE

For information on installing the purge air unit, see the Operating Instructions of the purge air unit.

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6 Electrical installation

6.1 Electrical installation safety information

Electrical safety

WARNING Endangerment of electrical safety during installation and maintenance work when the power supply is not switched off

Before starting the work on the device, ensure the power supply can be switched

off using a power disconnector switch/circuit breaker in accordance with DIN EN 61010-1:2010. Make sure the power disconnector switch is easily accessible.

An additional disconnecting device is mandatory when the power disconnector

switch cannot be accessed or only with difficulty after installation of the device connection. 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

Electrical accidents can occur when the specifications for replacement of a power line have not been adequately observed.

ELECTRICAL INSTALLATION 6

Always observe the exact specifications in the Operating Instructions (Technical

Data Chapter) when replacing a power line.

DANGER Danger of electrical accidents

Incorrect performance of electrical work could result in serious electrical accidents.

Only let the work described in the following be carried out by electricians familiar

with potential hazards.

CAUTION Risk of device damage

Electronic components are accessible when the enclosure is open. The circuit board can be severely damaged when a contact is not grounded when the power supply is switched on.

First switch the power supply on when the sender/receiver unit and the control

unit are closed.

NOTICE Observe connection values for power supply

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

Plug the respective bridges for 115 V AC as shown on the connection plate of the

evaluation unit.

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5 m

6 7

max. 100 m

0,8 m

4 m

6 ELECTRICAL INSTALLATION

CAUTION Device damage through short circuit on the device

The internal electronics can be damaged when signal connections are established and the power supply is switched on. This is also valid for plug connections.

Disconnect the GM32 Ex and any connected devices from the voltage supply.

6.2 Connection overview

Figure 17: Overview of electrical connections, GM700

Power supply 230 /115 V AC; 50/ 60 Hz

•

EvU: 3 x 0.75 mm

•

SLV: 4 x 1.5 mm

•

Terminal box: 4 x 1.5 mm

CAN line standard, in scope of delivery

Optional: Can bus line extension:

•

EvU - terminal box, ready for connection, 15 m

•

Terminal box - SR-unit (from customer) up to 100 m

Optional: Terminal box:

To extend the CAN bus connection (1 x 2 x 0.5 mm2, twisted pair, shielded)

SLV4 filter monitoring (standard for GMP measuring probe):

•

2 x 0.6 mm2, on pressure controller with flat pin bushings

•

6.3 x 0.8 mm (DIN 46247) pressure connection

•

2 m and 3 m extensions possible

Inputs (6 x 0.5 mm2):

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6.2.1 Lines

ELECTRICAL INSTALLATION 6

•

3 x digital inputs

•

2 x analog inputs

Outputs (6 x 0.5 mm2):

•

3 x digital outputs

•

3 x analog outputs

Table 5: PG screw fittings

Line opening size Line diameter (clamp‐

ing range)

PG9 4-8 mm 4 Nm SW17(GG9) 1

PG11 5-10 mm 8 Nm SW20(PG11) 1

PG13.5 6-12 mm 10 Nm SW22(PG13.5) 3

Table 6: Technical data, lines

Lines Remark

Power supply From customer: 3 x 1.5 mm

Power supply of control unit From customer: 3 x 1.5 mm

Control unit - sender/receiver unit with connecting hose

Pressure/temperature input From customer

Service interface From customer, RS232

Inputs/outputs From customer: Terminal connections: 6 x 0.75

Control unit - temperature sensor From customer

Control unit - pressure sensor From customer

Tightening torque Key width Qty.

In accordance with project planning

5 m

•

10 m

•

6.2.2 Information on laying lines

CAN bus

Installation location of the control unit close to the measuring point :

Control unit - SR-unit connection: 4 m CAN bus line (in scope of delivery).

•

No extra installation effort.

•

Fitting the control unit at a distance

Terminal box with a 24 V power supply unit (available from SICK).

•

Terminal box - SR-unit: 4 m CAN bus line (in scope of delivery).

•

Terminal box - control unit: Suitable 6-pole cable for CAN bus applications (pro‐

•

vided by customer). The total length of the CAN bus connections may be up to 1000 m.

•

When performing maintenance or service, it must be possible to deinstall the con‐

•

trol unit temporarily and connect it directly to the SR-unit at the measuring point.

Laying the cables

Provide adequate cable lengths at the connection points.

•

Do not lay power supply and signal lines immediately next to each other.

•

Protect open ends of preinstalled cables against weather effects until device

•

installation.

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6 ELECTRICAL INSTALLATION

Install separate power supply cables and circuit breakers for:

•

– Purge air units. Additionally install motor circuit breakers and protective

phase failure switches.

– Control unit.

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

•

or those delivered with the system, marked with one or two plug-in connectors. Approx. 2 m cable lengths each should be available at the measuring point for later maintenance work on the measuring system when dismounted from the duct.

Wire cross-section specifications are recommendations from which cables for ana‐

•

log and digital signals can slightly deviate (not however for the CAN bus connec‐ tions and/or power supply cables).

Start with the system internal connections of the device.

•

Status and signal cables from the control unit to the connection terminals of the

•

customer's status/message devices can be added later as required.

6.3 Connecting I/O interfaces

1 Route the data lines through the M screw fittings. 2 Connect the data line.

NOTE

The analog input assignment shown in the following Chapter is the factory setting and may not be modified.

6.3.1 Leading the CAN bus line correctly through the PG screw fitting

CAUTION

Risk of injury when touching the cable gland

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

Let the device cool down before performing work on the CAN screw fitting.

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







ELECTRICAL INSTALLATION 6

Figure 18: CAN bus line fitted correctly (shown on the EvU)

PG screw fitting on the evaluation unit

CAN bus line

Shielding of CAN cable

PG screw fitting fitted in the control unit

6.3.2 Wiring the evaluation unit

1. Check that the power supply is switched off.

2. Open enclosure door of evaluation unit.

3. Check that the power supply has been installed in accordance with the project planning (under consideration of national requirements).

4. Connect protective conductor (PE) to the terminal on the enclosure base.

5. Lead signal lines for inputs and outputs through the PG screw fitting on the housing base of the EvU.

6. Wire the evaluation unit,

7. When using a CAN line provided by the customer, connect the wires to the “Sensor” terminal strip. Do not connect +24 V and GND (ground).

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+ – + – + –

PE N L1

4 2+

H NA

L N

A C

4 2+

+ – + – + –

115/230 V AC;

50/60 Hz

(3 x 1.52)

+ – + – + –

1 2

1 2 3

Power +5V +24V

Power CAN +24V + – H L GND

Digital inAnalog in

0... 20mA 100 100 100

40...60Hz

230V

115V

AO1 AO2 AO3DI1 DI2 DI3

AI1 AI2 AI3

Sensor

DO1 DO2 DO3

Digital out

AC/DC 48V 30VA 1A

Analog out

0.. 20mA

Sensor

Fuse 2.5 AT 250V

PE N L1

contrast

T p

Enter meas

diag par cal maint

Operation

Service

Warning Malfunction

GMA700

Evaluation Unit

PROFIBUS

! " §

6 ELECTRICAL INSTALLATION

Figure 19: Electrical wiring of evaluation unit GMA700

1 2 3 4 5 6 7 8

Operating elements board

Connections board

Plug this bridge for 115 V or 120 V pow supply

CAN H + L, twisted pair, shielded. Connection for GM700 SR-unit or terminal box

Analog inputs: 0 ... 20 mA (6 x 0.52)

Digital inputs: Potential-free contacts (6 x 0.752)

Analog outputs: 0 ... 20 mA (6 x 0.752)

Digital outputs: 48 V AC/DC; 60 VA, 1 A (6 x 0.752)

! Failure (NC contact)

" Maintenance request (NO contact)

§ Function check (NO contact)

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6.3.3 Customer wiring of the terminal box (optional)

Fuse 2.5 AT

230/115 V AC 40 … 60 Hz

250 V

PENL1

5 4

PG 13.5

CAN- L

+24

GND

CAN- H

CAN GN D

CAN- L

CAN- H

CAN GN D

CAN- L

+24

GND

CAN- H

CAN GN D

CAN Terminator

NOTE CAN BUS WIRING PROJECT PLANNING

The following options are available for wiring the CAN bus connection between SR-unit and control unit:

Standard cable, 4 m, prefabricated.

•

Terminal box with prefabricated 4 m long cable to SR-unit; a customer line is used

•

to connect to the control unit.

ELECTRICAL INSTALLATION 6

Figure 20: Customer wiring for terminal box

Power supply 115 V / 230 V

Operating voltage selection: 115 V / 230 V

CAN terminator

Sensor CAN connection 1*: Prefabricated line to SR-unit with plug, 4 m long

Sensor CAN connection 2

Evaluation unit CAN connection

Only one of the two CAN connection terminal strips available is required for the device

Connecting the CAN line to the terminal box

1. Check that the power supply is switched off.

2. Connect bridge (jumper) according to suitable voltage supply (ST2).

3. Lead CAN line for the evaluation unit through the right PG screw fitting to terminal strip.

4. Connect shielding on the PG screw fitting on the housing.

5. Connect leads, see Figure.

6. Connect the respective signals in the control unit and terminal box.

NOTICE

The CAN-H and CAN-L lines must be twisted pairs.

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6 ELECTRICAL INSTALLATION

Color marking of wiring in the control unit

Wiring Color code

CAN-H Yellow

CAN-L Green

CAN GND Brown

0 ... 20 mA White

GND Black

NOTE

Line length between terminal box and evaluation unit is maximum 1000 m.

Color marking of wiring in the SR-unit

Wiring Color code

+24 V Pink

GND Grey

CAN-H Yellow

CAN-L Green

CAN-GND Brown

6.4 Connecting the SR-unit

Figure 21: Connections on SR-unit

Temperature sensor PT1000

Low-pressure monitor SLV (SR side)

CAN line connection, control unit to SR-unit (via terminal box when necessary)

CAN line connection to control unit (via terminal box when necessary)

6.5 Grounding conductor, evaluation unit

Connect the grounding conductor on the EvU

1 Lead the potential equalization (4 mm2) of the plant ground with one eyelet over

the bolt.

2 Position and tighten the M6 nut.

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1 2

ELECTRICAL INSTALLATION 6

Figure 22: Connections for grounding conductors on the two EvU versions

EvU, cast metal version

EvU, sheet metal version

Connection for grounding conductor

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7 COMMISSIONING

7 Commissioning

7.1 Safety information on commissioning

NOTICE

Observe information in Chapter “Main operating information”.

Technical knowledge needed / requirements for commissioning

NOTICE

You have fundamental knowledge of the GM700

•

You are familiar with conditions at the installation location, especially possible haz‐

•

ards through the gases in the gas duct (hot/dangerous to health). You are capable of recognizing and preventing danger by possibly escaping gases.

If one of these requirements is not met:

Contact SICK Customer Service or your local SICK representative.

Laser radiation

WARNING Eye injuries through laser radiation

Never look directly into the laser aperture when opening the SR-unit.

Laser protection class 1: Wear laser protection glasses despite low radiation.

Observe national valid limit values and standards that refer to these for industrial

safety.

Grounding

CAUTION Device damage through incorrect or missing grounding

It must be ensured during installation and maintenance work that the protective grounding of the device or lines involved is established in accordance with EN 61010-1:2010.

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.

7.2 Prerequisites for successful commissioning

Required Operating Instructions:

Operating Instructions, measuring system GM700

•

Operating Instructions, purge air supply

•

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COMMISSIONING 7

Final inspection protocol

•

Table 7: Prerequisites for successful commissioning

All specifications are met in accordance with the project planning. Inspection based on the Final inspection protocol carried out.

Electrical installation - completed and checked.

The measuring system is installed and electrically connected. SR-unit, measuring probe and purge air fixture are first fitted and connected electrically during commissioning.

Function test (blower rotation direction) of the purge air unit has been carried out.

Sampling point has been checked for free access without hazards.

The optical interfaces of the device have been cleaned.

Technical data of the measuring point (customer's notes)

Table 8: Technical data of the measuring point

Measuring range

Limit values

Inputs and outputs to be used



7.3 Overview of commissioning steps

Commissioning comprises two main steps:

1 Zero adjust on the measuring path free from sample gas. 2 Fitting and zero adjust in measuring duct.

The purge air unit and the SR-unit are put into operation with the measuring probe. The control unit is then switched on and checked. This can then be configured for the plantspecific requirements.

Table 9: Commissioning steps, Part 1: Before installation in gas duct

Step Procedure Reference

1 Remove the transport safety devices. "Transport protection", page 22.

2 Fit the SR-unit on the measuring probe. "Fitting the SR-unit on the purge air fixture

3 Electrical connection of sender/receiver

unit.

4 Preheat the measuring probe. Approx. 30 minutes.

5 Carry out fine optical adjustment.

6 Carry out zero adjust on the measuring

path free from sample gas.

7 Remove the SR-unit from the measuring

probe ÉFor this step, disconnect the SR-unit

from the power supply

of the measuring probe", page 43.

"Connecting the SR-unit", page 38.

"Optical fine alignment for device versions for NH3 and HF measurement", page 43.

"Optical fine alignment on the version for HCI measurement", page 45.

"Carrying out zero adjust (on the measuring path free from sample gas)", page 47.

"Removing the SR-unit from the intermedi‐ ate housing", page 66.

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7 COMMISSIONING

Table 10: Commissioning steps, Part 2: On gas duct

Step Procedure Reference

8 When necessary, reposition reflector on

GMP measuring probe

9 Fit the measuring probe on the gas duct. "Fitting the measuring probe on the flange

10 Put the purge air supply into operation. "Putting the purge air unit into operation",

11 Configure I/O connections. "Connecting I/O interfaces", page 34.

12 Connect CAN bus lines on all compo‐

nents.

13 Preheat the measuring probe. Approx. 30 minutes.

14 Carry out fine optical adjustment. "Optical fine alignment for device versions

15 Carry out zero adjust. "Carrying out zero adjust (on the measuring

16 Optional: Fit the weatherproof cover. "Installing the weatherproof cover ",

17 When necessary: Make specific parame‐

ter settings on the control unit for the measuring point.

18 Starting measuring operation. "Starting measuring operation", page 54.

"Repositioning the probe reflector", page 48.

with tube", page 51.

page 52 and purge air unit Operating

Instructions.

"Leading the CAN bus line correctly through the PG screw fitting", page 34.

for NH3 and HF measurement", page 43

and

"Optical fine alignment on the version for HCI measurement", page 45.

path free from sample gas)", page 47.

page 53.

"Menu tree Parameter", page 59.

7.4 Material required

Not contained in the scope of delivery

Optical adjusting device

•

19 mm open-end wrench

•

Insulated screwdriver set

•

Allen key set

•

Optical cleaning cloth without cleaner

•

Personal protective equipment

•

– Hot surfaces on device – In accordance with local regulations

7.4.1 Material required - included in scope of delivery

Per purge air fixture: Installation on duct-side flanges with tube:

•

4 screws M16 x 60 with washers

4 nuts M16-Cu

Per purge air fixture: Installation on SR-unit and reflector:

•

3 self-locking nuts M12

3 spherical washers

3 x 10 cup springs

To seal the connection between SR-unit, reflector and purge air fixture:

•

Rubber sealing ring

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COMMISSIONING 7

7.5 Fitting the SR-unit on the purge air fixture of the measuring probe

NOTE

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

Figure 23: Fitting the purge air fixture on the device flange

Intermediate flange of SR-unit (removable)

Cup springs, 10 per fastening

Rubber sealing ring

Threaded pin of flange fixture

Device flange

Centering disc and nut

Fitting the device flange

1. Put 10 cup springs each, back-to-back, onto the three threaded bolts on the inter‐ mediate housing.

2. Pull the sealing ring over the flange of the measuring probe and hang it loosely over the purge air unit.

3. Push the device flange onto the measuring probe.

4. Position the centering discs.

NOTICE

Observe the direction of the centering disc: The convex side must fit into the groove on the purge air fixture.

5. Tighten the self-locking nuts with a wrench (19 mm) so that the cup springs are slightly compressed and an even gap of approx. 4 mm remains.

Fitting the SR-unit on the intermediate housing

see "Fitting the sender/receiver unit on the intermediate housing", page 52.

7.6 Optical fine alignment for device versions for NH3 and HF measurement

CAUTION

Hazard by laser radiation

Device with a laser with protection class 1.

Do not hold any reflecting objects or objects that bundle the laser beam in the

laser beam. During installation or maintenance: Switch the power supply off before opening

the device.

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7 COMMISSIONING

WARNING Eye injuries through laser radiation

Never look directly into the laser aperture when opening the SR-unit or the reflec‐

tor. Laser protection class 1: Wear laser protection glasses despite low radiation.

Observe national valid limit values and standards that refer to these for industrial

safety.

Description of the alignment tool on the SR-unit

Figure 24: Alignment tool on the SR-unit

Visor of the optical alignment

LED display for rough view of optical alignment

Target of the alignment tool

(Alignment on probe version)

Alignment on Cross-Duct version

Adjusting screw for X alignment; horizontal

Adjusting screw for Y alignment; vertical

Alignment tool lever

Bring the alignment tool into the adjustment position:

1. Turn lever

2. Pull lever down

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COMMISSIONING 7

On the control unit:

1. Switch to Maintenance mode a) Press button “maint”. b) Select “Maintenance mode” and select “On” in selection menu “Mode”.

✓

This activates Maintenance mode

On the sender/receiver unit (XY adjustment with internal alignment tool)

2. First turn and then pull down the lever of the built-in alignment tool to bring the alignment tool into adjustment position, see Figure above.

3. Look through the visor on the right enclosure side diagonally from above at the mirror with the target.

NOTE

Light spot color:

HF device version: Red

•

NH3 device version: Green

•

4. Align the position of the light spot. To do this, adjust the nuts for the X and Y align‐ ment on the device flange so that the light spot is positioned in the center of the target.

NOTE

It takes a few seconds before the light spot moves after adjusting the screws.

✓

Fine alignment is completed when the light spot is positioned in the center of the target, see Figure “Alignment tool on the SR-unit”. After successful alignment, push the lever of the alignment tool back to its original position and secure it with a quarter turn.

7.7 Optical fine alignment on the version for HCI measurement

DANGER

Observe laser warning information, see "Optical fine alignment for device versions for

NH3 and HF measurement", page 43.

NOTE

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

NOTE

The adjustment, including the warming up time, takes about 2.5 to 5 hours whereby the actual work is completed in less than 30 minutes

Devices with automatic check cycle perform the first check cycle after the warming up phase.

On the control unit:

1. Switch to Maintenance mode: a) Press button “maint”. b) Select “Maintenance mode” and select “On” in selection menu “Mode”. c) Select submenu item “Adjust Optical Alignment”.

✓

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

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7 COMMISSIONING

On the sender/receiver unit (XY adjustment with internal alignment tool)

1. First turn and then pull down the lever of the built-in alignment tool to bring the alignment tool into adjustment position, see "Optical fine alignment for device ver‐

sions for NH3 and HF measurement", page 43, Figure “Alignment tool lever”.

2. To do this, adjust the nuts for X and Y alignment on the device flange so that the measuring channel brightness reaches the maximum value.

✓

After successful alignment, push the lever of the alignment tool back to its original position and secure it with a quarter turn.

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

7.8 Two types of zero point checks

When removed:

SR-unit mounted on the measuring probe and aligned in ambient air corresponding to the requirements of the zero point conditions. The measuring probe is then fitted again.

Only for devices with GPP measuring probes: When fitted:

Devices with GPP measuring probes can be checked when fitted by feeding suitable zero gas (nitrogen, clean compressed air in instrument air quality 1). The sequence is equal to the check with span gas. This function can also be executed in intervals, con‐ trolled by the device. During this procedure, the probe can cool down and swivel, result‐ ing in a zero point error. This effect can be minimized by setting the gas flow to the required amount and limiting the duration needed for the check. For higher gas temper‐ atures (as from 200°C), the zero gas should be preheated to minimize the swivel effect. This can be achieved by feeding the zero gas via a heated sample gas line or passively with a ¼“ metal tube, which is pushed beneath the channel insulation for contact with the hot duct wall. Here, the preheating spiral that can be ordered from SICK can be used or a construction adapted for the installation.

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

Figure 25: Preheating spiral, Part No. 2065326

7.8.1 Selecting the ambient temperature range

Select the ambient temperature

On the evaluation unit

1. Select a suitable ambient temperature so that the heater of the SR-unit can stabi‐ lize the optics temperatures.

2. Activate parameter mode.

ISO8573 Class 2 for particle size, content of contamination and oil, H2O dew point

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3. Select menu Settings, then Ambient Temp.

4. Warning message “DEV TEMP” is output.

5. Select the temperature range according the Table that matches the ambient condi‐ tions at the measuring location, see "Possible ambient temperatures", page 89.

The device automatically determines the appropriate temperature for the optics heater. Wait approx. 30 minutes for the temperature to change before starting the zero adjust.

7.8.2 Carrying out zero adjust (on the measuring path free from sample gas)

NOTE

As far as supported by the device variant.

Preparation

Ambient temperature range selected.

•

Optical axis alignment completed, see "Optical fine alignment for device versions

•

for NH3 and HF measurement", page 43 and see "Optical fine alignment on the version for HCI measurement", page 45.

Connect the evaluation unit to the power supply.

•

Warm the measuring system up for approx. 2.5 - 5 hours. The exact warming up

•

time varies according to ambient conditions.

COMMISSIONING 7

Carry out zero adjust

1. Activate Calibration mode: Press button “cal”

2. Select “Zero-Adjust” in submenu item and confirm with “Enter”.

3. The zero adjust starts.

“Zero Measuring” is displayed.

When zero adjust has completed, either a positive confirmation or an error

message is displayed.

4. Adjustment successful:

Switch to Measuring mode or define further parameter settings.

5. Adjustment not possible:

The flashing “Malfunction” LED indicates that one or more error messages are pending.

Switch to Diagnosis mode, press button “diag”.

Viewing error messages, see "Error messages", page 72.

Clear malfunction.

7.8.3 Zero point check with GPP measuring probe

Material required

Gas hoses:

•

Teflon hose (PTFE), type 650 P 0707, 1/4"

Steel pipe 1.4571, 1/4"

Zero gas: Instrument air, class 2

•

Pressure reducer

•

Supply line 1/4" with cutting-clamping ring connection (Swagelok)

•

Using a gas hose: Inner sleeve (Part No. 5309138)

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7 COMMISSIONING

Connect zero gas (instrument air) to “Zero gas” gas inlet

Figure 26: Swagelok screw fitting on gas inlet “Zero gas”

Cap nut

Clamping rings

Inner bushings

Gas pipe (open end)

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

Take off the cap nut from the gas inlet.

Place the cap nut and clamping rings on the open end of the gas pipe.

Insert the pipe in the open screw fitting.

Tighten the nut with a 9/16" open end wrench. Connect zero gas (instrument air) to 3rd gas inlet “N2 purging or dyn. zero”.

2 Connect instrument air to the instrument air supply.

Connect the pressure reducer to the instrument air supply.

Connect the gas hose from the probe to the pressure regulator outlet.

Set pressure reducer to 250 kPa.

Carry out the zero point check

On the evaluation unit

1. Switch Maintenance mode off:

Mode: Off

Press the meas button to start Measuring mode.

✓

The analyzer now starts Measuring mode.

2. Check for error or warning messages, especially on the status LEDs.

3. If error messages are displayed, clear according to the error messages, see "Error

messages", page 72.

4. Set parameters, special times and measuring range, see "Menu tree Parameter",

page 59.

7.9 Repositioning the probe reflector

Reposition the probe when the measuring probe must be realigned in flow direction (e.g. from vertical to horizontal direction) but the SR-unit must sit vertically.

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Figure 27: GMP measuring probe flow direction

30°

Fitting the probe: Horizontal measuring gap

Fitting the probe: Vertical measuring gap

Reflector unit on GMP measuring probe

COMMISSIONING 7

In accordance with the probe rotation (e.g. at 90°), the reflector in the probe end must be turned in the opposite direction to this rotation (e.g. –90°) so that the alignment of the optical beam path to SR-unit is maintained.

1. Loosen the 3 screws on the probe end (screws with nuts remain on the reflector enclosure).

2. Turn the cover 30° to the right (1.).

3. Pull the reflector unit out (2.).

Figure 28: Reflector on the GMP measuring probe and reflector position marking (Allen screw)

Screws

Allen screw to mark the reflector alignment

Slotted screw

Screw connection for reflector holder

1. Loosen and remove the screw connections on the reflector holder.

2. Take both holders and the wedge with the graphite seals out.

3. Take the hollow triple with the triple holder out, position it in the new probe align‐ ment in the appropriate position (e.g. –90°).

4. Swap the Allen and slotted screws: Screw the Allen screw in the triple holder groove.

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756543

8 9

7 COMMISSIONING

NOTE

The Allen screw shows the position of the hollow triple. It must always point towards the connector on the SR-unit so that the alignment is correct.

Exchanging

Spring

Allen screw to mark the reflector alignment

Slotted screw

Screw connection for reflector holder

Sealing ring

Holder (triple-side)

Wedge window

Graphite sealing ring

Holder (flange-side)

Allen screw

Allen and slotted screw positions on reflector enclosure swapped

Hollow triple repositioned (e.g. –90°)

1. Assemble the reflector component in reverse sequence (insert reflector and turn to the left to the stop; approx. 30°)

2. Fasten the reflector unit to the probe end.

Figure 29: Fitting the reflector unit

Allen screw to mark the reflector alignment

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7.10 Fitting the measuring probe on the flange with tube

Prerequisite

1. Observe all safety information for work on the gas duct, see "Safety information on

commissioning", page 40 and see "Main operating information", page 10.

2. Remove the flange cover and store safely.

3. Provide all materials and auxiliary means at the installation location.

DANGER Risk of injury when the device drops down

The weight and size make it hard to handle the SR-unit with installed measuring probe. This increases the risk that the measuring device is damaged when dropped.

Install the SR-unit and the measuring probe singly.

Carry out assembly work on parts of the device together with another person when

necessary.

Fit the measuring probe with pre-fitted purge air fixture on the flange with tube.

Fit the purge air fixture on the flange with tube with 4 x M16 screws as shown in

the Figure.

COMMISSIONING 7

Figure 30: Fitting the measuring probe with pre-fitted purge air fixture on the flange with tube (on the duct)

M16 screw

Washer

Flange

Flange seal

Flange with tube

Washer

Spring washer

Nut

NOTE

Fitting the GMP and GPP measuring probes on the flange with tube is identical.

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7 COMMISSIONING

7.11 Putting the purge air unit into operation

NOTE

Electrical connections for the purge air unit, see Purge air unit Operating Instructions.

Preparation

Switch the power supply for the purge air unit on for a short time to check the function and to remove any dust that may have penetrated the purge air hose.

Figure 31: Purge air connection on the purge air fixture of the measuring probe

Purge air hose connection (purge air bracket)

On the purge air fixture of the measuring probe:

1. Connect the purge air hose of the purge air unit with a hose clamp to the purge air bracket connection of the fitting.

2. Switch the purge air supply on.

✓

Purge air supply is now activated and protects the measuring system against cont‐ amination and overheating. Purge air feed must never be switched off when the SR-unit and reflector are on the sample gas duct.

NOTICE

Attach clearly visible warning information against unintentional switching off on all switching devices with which the purge air units can be switched off.

7.12 Fitting the sender/receiver unit on the intermediate housing

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

necessary.

1st step: Separate the sender/receiver unit and the intermediate enclosure

1 Loosen the quick-release fasteners. 2 Pull the hinge pin upwards.

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COMMISSIONING 7

2nd step: Fit the sender/receiver unit on the intermediate enclosure

4 Insert the SR-unit in the hinge. 5 Insert the pin from the top downwards through the hinge. 6 Close the quick-release fasteners.

Figure 32: Fitting the GM700 sender/receiver unit on the intermediate housing

Quick-release fasteners of the sender/receiver unit

Intermediate housing

Hinge pin

7.13 Installing the weatherproof cover

Installing the weatherproof cover of the sender/receiver unit:

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

Lay the weatherproof cover upside down on the floor.

Open and unhinge the locking bolts on both sides.

Pull the installation plate upwards and remove it from the cover.

Remove the bottom mounting ring.

Place the installation plate onto the rubber band of the purge air fixture from the top.

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

Screw the bottom mounting ring to the top mounting ring.

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7 COMMISSIONING

1 2 3

Mounting ring

Locking bolts

Installation plate

Top mounting ring

Bottom mounting ring

2 Place the weatherproof cover on the installation plate.

Position the cover on the installation plate from the top.

Engage the locking bolts and close again.

7.14 Starting measuring operation

NOTE

The device is delivered from the factory with the parameter settings specified by the customer when ordering. When these parameter specifications match the parameters during commissioning, measuring operation can be started after fine optical alignment by pressing the “meas” button. The device can be configured to meet the plant condi‐ tions when required.

Start Operating mode:

1 Switch Maintenance mode off, menu path: see "Menu tree Maintenance",

page 61.

2 Set Mode to“Off”. 3 Press “meas”.

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Checking status LEDs, error and warning messages

NOTE

Quick check of Measuring screens on the LC display of the evaluation unit:

When error or warning messages are present:

7.14.1 Operating states

Message on EvU display Meaning

INIT Initializing the evaluation unit

INITIALISATION

SIGNAL_ADJUST Adjusting amplification to changed transmission

MEASURING

MEASURING LL

MEASURING LD Measuring operation; Beam length tracked (line locking

MAINTENANCE Maintenance mode (no measurement)

DOWNLOAD

COMMISSIONING 7

Using the Operating Instructions, see "Operating and display elements (evaluation

unit)", page 56.

Determine and clear the error cause using the Operating Instructions, see "Serial

interface commands - Diag", page 62, and the Error and Warning Message

Tables, see "Error messages", page 72 and see "Warning messages", page 74. If the error cause cannot be cleared: Contact SICK Service.

Initializing the SR-unit

Measuring operation

Measuring operation with active tracking of the laser beam length (line locking)

done)

Download new software (for Service purposes only)

7.14.2 Select the ambient temperature range

NOTICE Temperature stabilization: 30 minutes

The device stabilizes the temperature after the temperature is modified.

Warning message “DEV TEMP” is output during temperature stabilization.

•

1 Activate Parameter mode. 2 Menu path: Setting -> Ambient Temp. 3 Select the temperature range from the Table that matches the ambient conditions

best at the measuring location, see "Possible ambient temperatures", page 89.

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maintcalpardiag

GM 700

Evaluation Unit

CO CO

H2O

mg/ m

236

Ref. conditions

Hum: wet

Measuring

Operation

Service

Warnin

Malfunction

GM700

Evaluation Unit

NH3

mg/ m

236

Operation

Service

Warning

Malfunction

GM 700

Evaluation Unit

NH3

mg/ m

236

Ref. conditions

Hum: wet

Enter meas

diag par cal maint

Measuring

Operation

Service

Warning

Malfunction

GM 35

Evaluation Unit

CO CO

H2O

mg/ m

236

Ref. conditions

Hum: wet

Enter meas

diag par cal maint

Measuring

Enter meas

maintcalpardiag

Operation

Service

Warning

Malfunction

Ref. conditions Hum: wet

1 2

8 OPERATION

8 Operation

8.1 Safety

WARNING Hazard for persons and plant through unsafe operation of the measuring system

If the device is or could be in an unsafe state:

Put the device out of operation.

Disconnect the device from the main supply voltage and signal voltage.

Secure the device against unallowed or unintentional start-up.

NOTE

More information concerning the detection of unsafe operating states, see Chapter “Visual check”.

8.1.1 Check before start-up

Before every start-up

Check all enclosures are closed

– Enclosure cover – Cable inlets – Enclosure openings

8.2 Operating and display elements (evaluation unit)

Figure 33: GM700 operator panel

GM700 evaluation unit, cast metal enclosure

GM700 evaluation unit, sheet steel enclosure

Display for

•

All current measured values

•

Computed value

•

Menu navigation

Status LEDs to signal operating and malfunction states

Function buttons for menu navigation and input

5 6

Function buttons for menu selection

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LEDs

Table 11: Significance of LEDs

LED Significance / possible cause

Measuring mode

•

The device is switched on, power voltage is available

•

OPERATION

Service mode

•

SERVICE

Warning message

•

At least one warning message pending

•

Reading warning messages, see Diagnosis mode (diag)

Warning

MALFUNCTION

•

Device malfunction

•

At least one malfunction message pending

•

Reading malfunction messages, see Diagnosis mode (diag)

•

OPERATION 8

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meas

8 OPERATION

8.3 Menu tree of the evaluation unit

NOTE Menu texts are shown in English.

8.3.1 Menu tree Measuring

Menu level Explanation

Measuring

8.3.2 Menu tree Diagnosis

Current measured values depending on

•

device version Reference variables (wet, dry)

•

Menu level

Diagnosis Diagnosis

Malfunction Current error messages (plain text)

Warning Current warning messages (plain text)

Sensor values Displays diagnostic values and control values

GM700 Sensor values

GM700

Cross-Duct: OH Cross Duct: Reflector

Current monitored sensor values (amplification setting, internal temperature control, control val‐ ues, etc.)

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OPERATION 8

8.3.3 Menu tree Parameter

Menu level Explanation

Parameters Parameter

Settings Parameter settings/display of system compo‐

nents

Physical Unit

Component

Average Avg. Time 0 ... 300 s

Meas. Distance Active 200 ... 8000 mm

Gas temperature

Pressure

Humidity Subst. Subst.: 0 ... 93.0 %Vol

Unit mg/m3, ppm

t: actual, 25 °C, 20 °C, 0 °C

•

Ref. condition

p: actual, 1013 mbar

•

Hum.: wet, dry

•

Source Probe, Subst. Analog In

Subst. –100 ... 2000 °C

Unit °C, °F, K

Source Probe, Subst. Analog In

Subst. 600 ... 15000 hPa

Live Zero 0, 4 mA

Component: e.g., NH3, - -, p, T

Analog Out

Output 1

Output 2

Output 3

Range low: 0 ... 999999

Range high: 0 ... 999999

Cycle Out: No, Yes

Component: e.g., NH3,, - -, p, T

Range low: 0 ... 999999

Range high: 0 ... 999999

Cycle Out: No, Yes

Component: e.g., NH3,, - -, p, T

Range low: 0 ... 999999

Range high: 0 ... 999999

Cycle Out: No, Yes

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8 OPERATION

Menu level Explanation

Unit: °C, K, °F

Input 1 T

Analog In

Input 2 p

Regress Funct. Span 0.50 ... 1.99

Zero ±999

Ambient Temp. Range

t (Feed Test Gas) Period d (days), only when purge cell is included

Check cycle Period 0 ... 24 h

Enable Yes, No

Live Zero: 0, 2, 4 mA

Range low: 0 ... 15000

Range high: 0 ... 15000

Unit: hPa

Range low: 0 ... 15000

Range high: 0 ... 15000

0 ... 50 °C

•

–10 ... 40 °C

•

–20 ... 30 °C

•

–30 ... 20 °C

•

–40 ... 10 °C

•

Repet. 0 ... 24 h (only GPP)

t (purge) 0 ... 900 s; purge time until the process gas con‐

Zero Adjust

centration is zero

t (delay) 0 ... 1800 s; delay until gas enters again

Delta T 0 ... 999 °C; temperature difference at which a

zero adjust is carried out

Device Serial Number Head _ _ _ _ _ _ _ _

Laser _ _ _ _ _ _ _ _

EvU _ _ _ _ _ _ _ _

Software Revision

■

GMM700-X

■

XXXXXXX XXXX

■

GMM700/DSP

■

XXXXXXX XXXX

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8.3.4 Menu tree Calibration

Menu level Explanation

Calibration Calibration

Check cycle Start CCY (Check Cycle) Check cycle for test purposes, e.g., after mainte‐

nance

Zero Adjust Start ZeroAdjust

Zero point determination, e.g., during commis‐ sioning or maintenance tasks based on the zero path

Zero Adj. Stack Start ZeroAdjust Only GPP probe: Zero point determination with

Password (1234)

measuring device on gas duct Zero gas must be connected to the GPP probe.

Box measuring Start Meas. Check of measuring components with span gas

via a filter box

OPERATION 8

8.3.5 Menu tree Maintenance

Menu level Explanation

Maintenance

Maint. Mode Mode: Off, On Maintenance operation: On, Off

Adj. Opt. Align. Opt. Alignment Displays optical alignment of SR-unit

AO 1: 4 mA

Test Analog Out

Tests the analog outputsAO 2: 4 mA

AO 3: 12.5 mA

Test Analog In

AI 1: 0 mA

Tests the analog inputs

AI 2: 0 mA

AI 3: 0 mA

Relay 1: On (Off)

Test Relay

Tests the relay outputsRelay 2: On (Off)

Relay 3 Off (On)

DI 1: Open

Test Digital In

Tests the digital inputsDI 2: Open

DI 3: Open

Push Diag

RS232 Outputs the complete parameter set via the

RS232 Service interface

Reset System Restarts the measuring system

Reset Parameter

Resets parameters to factory settings a All settings are overwritten!

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8 OPERATION

8.4 Operating using the serial interface

NOTE Menu texts are shown in English.

8.4.1 Significance of command line elements

Table 12: Significance of command line elements

Element Meaning Text style used

SAMPLE Shows the name of the command or utility pro‐

gram.

{variable} Shows several options from which the user

must select one, more or all.

[option] Shows optional elements. Small letters in [square brack‐

. , : ; Punctuation marks are part of the command

and to be inserted as such.

<cr> Stands for pressing Enter (on the computer

keyboard).

CAPITAL LETTERS

Small letters in {round brack‐ ets}

ets]

Small letters

8.4.2 Setting for serial interfaces

Table 13: Standard setting for serial interface

Parameter Description / value

Baud rate 9600 Baud

Data bits 7

Parity Even parity

Stop bits 1

Protocol No protocol

Interface line 1:1

Connection 2-2 / 3-3 / 5-5

8.4.3 Serial interface commands - Meas

Table 14: Serial interface command for measuring

Serial interface command Description

GM700<<GOTO MEAS meas / measuring operation

8.4.3.1 Serial interface command - MEAS

Start measuring operation/switch to measuring operation

Syntax:

GM700<<GOTO MEAS

8.4.4 Serial interface commands - Diag

8.4.4.1 Table with warning messages

Call up the Table of warning messages.

Syntax:

GM700<<DIS WTBL

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8.4.4.2 Error messages Table

Call up the Table with error messages

Syntax:

GM700<<DIS MTBL

8.4.4.3 View the device configuration

Call up the list of the device configuration

Syntax:

GM700<<DIS CONFIG

8.4.4.4 Check the system state and configuration

Output of the current system state and configuration

Syntax:

DIS DEV PARA

8.4.4.5 Call up diagnostic data

OPERATION 8

Command “DIS MERB” calls up the diagnostic data.

Syntax:

GM700<<DIS MERB

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9 MAINTENANCE

9 Maintenance

9.1 Safety

CAUTION Risk of device damage when the optics purge air is switched off too soon

Hot and contaminated gas can cause device damage when the optics purge air is switched off when the SR-unit and the measuring probe are still in the gas duct.

WARNING Endangerment of electrical safety during installation and maintenance work when the power supply is not switched off

b b

Switch off the purge air unit only after removal of the SR-unit from the gas duct.

Before starting the work on the device, ensure the power supply can be switched off using a power disconnector switch/circuit breaker in accordance with DIN EN 61010-1:2010. Make sure the power disconnector switch is easily accessible. An additional disconnecting device is mandatory when the power disconnector switch cannot be accessed or only with difficulty after installation of the device connection. 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.

DANGER Risk of injury by electrical accident

■

If the device has to be opened for setting or service work:

First disconnect the device from all voltage sources.

■

If the opened device must remain under voltage during work:

Have the work done by skilled persons familiar with potential risks. If it is nec‐ essary to remove or open internal components, live parts could be exposed.

■

If any liquid has penetrated electrical device components:

Put the device out of operation and interrupt the power voltage at an external point (e.g. disconnect the power cable). Then contact service technicians of the manufacturer or correspondingly trained skilled persons to have the device repaired.

■

If safe operation of the device is no longer possible:

Put the device out of operation and secure against unauthorized start-up.

■

Do not interrupt the protective conductor connections inside or outside the device.

WARNING Health risk through contact with toxic gases

The modules and devices contain enclosed, potentially dangerous gases that can escape should a defect or leak occur. If a leak occurs, the concentrations inside the enclosed device can increase up to 25 ppm.

■

NH3: 17 ml max. total amount

■

HF: 6 ml max. total amount

Check the state of the seals on the device/module regularly.

Only open the device when good ventilation is available, especially when a leak of

one of the device components is suspected.

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WARNING Risk of chemical burns/poisoning through caustic/toxic residues on components with sample gas contact

After the device has been decommissioned or removed from the measuring channel, process gas residues can exist as deposits on components with sample gas contact (e.g., gas filter, gas-carrying lines etc.). These residues can be odorless or invisible depending on the gas mixture in the duct. Without protective clothing, contact with such contaminated components can lead to severe burns or poisoning.

Take appropriate protective measures for work (e.g., by wearing a safety mask, pro‐

tective gloves and acid resistant clothes). In case of contact with skin or the eyes, rinse immediately with clear water and

consult a doctor. Decontaminate all contaminated components according to regulations after disas‐

sembly.

9.2 Maintenance plan

Table 15: Maintenance intervals

Inter‐

val

1W = Weekly, 1M = Monthly, 3M = Every 3 months, 6M = Every 6 months, Y = Yearly

MAINTENANCE 9

Maintenance work Reference

Check that measured values in the control area are plausible

Visual inspection of system

Clean window

Check optical alignment

Check ambient temperature range

Check and/or clean the purge air unit

Check analyzer with span gas Normally carried out by SICK Service.

Control and track the laser working point during measurement

see "Call up diagnostic data", page 63.

see "Visual check", page 67.

see "Cleaning the optical interfaces", page 67.

see "Optical fine alignment for device versions for NH3 and HF measurement", page 43, see

"Optical fine alignment on the version for HCI measurement", page 45.

see "Ambient temperature ranges with test cell"

and see "Ambient temperature ranges (closed

cell)", page 89.

see "Cleaning the purge air unit", page 69

and purge air unit Operating Instructions.

Normally carried out by SICK Service.

9.2.1 Maintenance protocol

The following data should be recorded:

Maintenance dates

•

Work done

•

Special observations

•

Required consumables and spare parts

•

9.2.2 Expendable, wearing and spare parts

Recommendation for two years operation

Table 16: Expendable and spare parts for two years operation

Part Part number

GM700 sender/receiver unit

8022447/0000/2018-01 | SICK OP E RA T IN G I N ST R UC T IO N S | GM700

Subject to change without notice

9 MAINTENANCE

Part Part number

Spare parts set, mounting kit, flange (2 pcs.) 2039628

GPP measuring probe

Sealing tape for flange, Neoprene/Teflon for GPP 2064871

Spare parts set, seal GPP700 (2 pcs.) 2032919

Seal between probe and flange (2 pcs.) 4032310

Spare parts set, GPP700 reflector, enclosed 2092801

GMP measuring probe

Triple, gold-coated 2076492

Sealing ring, GMP and SLV (2 pcs.) 2083220

Seal between probe and flange 4032310

Diverse

Filter element, micro, top element for SLV unit (4 pcs.) 5306091

Optics cloths (2 pcs.) 4003353

9.3 Preparatory work

NOTE Some maintenance tasks will cause the measuring device to switch to malfunction

Activate Maintenance mode before starting the work.

NOTE

Ensure good accessibility to the device in accordance with valid accident preven‐

tion regulations. Provide suitable work platforms/pedestals.

NOTE

A zero path must be available for zero adjust.

9.4 Removing the SR-unit from the intermediate housing

Figure 34: Opening the GM700 Ex sender/receiver unit and removing the intermediate housing

Quick-release fasteners of the sender/receiver unit

Intermediate housing

Hinge pin

O PE R AT I NG IN S TR U CT I ON S | GM700 8022447/0000/2018-01 | SICK

Subject to change without notice

9.5 Visual check

MAINTENANCE 9

1 Switch device off. 2 Open the SR-unit enclosure by releasing the quick-release fasteners. 3 Immediately attach the cover on the device flange opening.

Removing the intermediate housing

1 Hold the unit tight. 2 Pull out the hinge pin. 3 Remove the sender/receiver unit.

All device components

Check SR-unit housing for mechanical damage.

Clean the respective enclosures (all components) if contaminated.

Check all cables for damage. Pay attention to chafe marks and kinks on cable

ducts. Check all hose fittings for tight seat.

Check all electrical connections are free from corrosion and have a tight seat.

Check grounding conductors are free from corrosion.

Check flange and screw fittings for tight seat.

Evaluation unit

Visual check of surfaces:

•

– Enclosure and fastening – Opening and closing the front door – Clean the inspection window – Check for moisture outside and inside the enclosure Electrical check:

•

– LED – Tight seat of line connections Damage on the evaluation unit (e.g., LC display failure):

Contact SICK Service.

9.6 Cleaning the optical interfaces

WARNING Risk of injury through uncontrolled escape of process gas when the gas duct is opened when under overpressure

Swiveling the SR-unit open can lead to contact with toxic and/or hot gases with over‐ pressure in the duct.

All persons at the gas duct during opening of the device must follow the protective

measures mandatory in operation. Pay special attention to protective masks and protective gloves. Prepare a suitable cover for the opening on the device flange of the SR-unit and

keep it available. Immediately place the cover on the opening of the device flange once the SR-unit

has been opened.

8022447/0000/2018-01 | SICK OP E RA T IN G I N ST R UC T IO N S | GM700

Subject to change without notice

MAINTENANCE