SICK GM700 Ex Operating Instructions Manual

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GM700 Ex

Laser Gas Analyzer, Version with Measuring Probe

O P E R A T I N G I N S T R U C T I O N S

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Described product

GM700 Ex

Probe version

Version GM700-05, 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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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................................................................ 9

2 Safety information............................................................................ 10

2.1 Main operating information..................................................................... 10

2.2 Warning information on the device.......................................................... 13

2.3 Intended use............................................................................................. 14

2.3.1 Purpose of the device.............................................................. 14

2.4 Responsibility of user............................................................................... 14

3 Product description........................................................................... 16

3.1 Product identification............................................................................... 16

3.2 Product characteristics............................................................................ 16

3.3 Type plate.................................................................................................. 16

3.4 Device variants......................................................................................... 17

3.5 Pressure and temperature sensor........................................................... 17

3.6 Options...................................................................................................... 17

3.7 Layout and function.................................................................................. 17

3.7.1 Function of the pressurized enclosure................................... 18

3.8 Purge air unit............................................................................................. 18

3.9 Check cycle............................................................................................... 19

3.10 Explosion protection in accordance with ATEX....................................... 20

3.10.1 Operation in potentially explosive atmosphere...................... 20

3.10.2 Zone of use GM700 Ex 3G components................................ 21

3.10.3 Pressurized enclosure system................................................ 22

3.10.3.1 Safety functions...................................................... 22

3.11 Sender/receiver unit - evaluation unit connecting hose........................ 22

3.12 GMP measuring probe in detail............................................................... 23

4 Transport and storage....................................................................... 24

4.1 Transport protection................................................................................. 24

4.2 Storage...................................................................................................... 25

5 Mounting............................................................................................. 26

5.1 Information on installation in potentially explosive atmospheres......... 26

5.2 Tools required............................................................................................ 27

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CONTENTS

5.3 Material required...................................................................................... 27

5.4 Preparing the sampling point................................................................... 27

5.5 GM700 Ex scope of delivery.................................................................... 28

5.6 Installation sequence............................................................................... 28

5.6.1 Installation example................................................................ 28

5.6.2 Overview of installation steps (duct-side preparation).......... 29

5.6.3 Installing the flange with tube................................................. 29

5.6.4 Install the evaluation unit........................................................ 31

5.6.4.1 Install the FS840.................................................... 31

5.6.5 Installing the purge air unit..................................................... 33

6 Electrical installation........................................................................ 34

6.1 Electrical installation safety information................................................. 34

6.2 Connection overview................................................................................ 36

6.2.1 Lines......................................................................................... 37

6.3 Connecting interfaces ............................................................................. 38

6.3.1 Connect I/O interfaces............................................................ 38

6.3.1.1 GM700 Ex 3G terminal connection diagram........ 38

6.3.1.2 Electrical connection of the evaluation unit EvU.. 40

6.4 Connecting the connecting hose to the SR-unit on the EvU.................. 41

6.5 Connecting pressure, temperature and purge air monitor ................... 41

6.6 Preparing the power supply...................................................................... 41

6.7 Connecting the FS840 Ex overpressure control..................................... 42

6.8 Electrical connection of SR-unit............................................................... 44

6.9 Connecting the potential equalization..................................................... 44

6.9.1 Connecting the potential equalization on the SR-unit........... 45

6.9.2 Connecting the potential equalization on the measuring

probe........................................................................................ 45

6.9.3 Potential equalization - evaluation unit and Ex control unit.. 46

7 Commissioning.................................................................................. 47

7.1 Safety information on commissioning..................................................... 47

7.2 Prerequisites for successful commissioning.......................................... 47

7.3 Material required ..................................................................................... 48

7.4 Overview of commissioning steps........................................................... 48

7.5 Zero adjust................................................................................................ 49

7.6 Fitting the SR-unit on the measuring probe............................................ 49

7.7 Aligning the measuring probe in flow direction...................................... 51

7.8 Feeding protective gas............................................................................. 52

7.8.1 Connecting the protective gas on the SR-unit....................... 52

7.8.2 Switch the pressurized enclosure on...................................... 54

7.9 Optical fine alignment of the sender/receiver unit ............................... 54

7.10 Installing the weatherproof cover ........................................................... 55

7.11 Starting measuring operation.................................................................. 56

7.11.1 Operating states...................................................................... 57

7.11.2 Select the ambient temperature range.................................. 57

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CONTENTS

8 Operation............................................................................................ 58

8.1 Safety......................................................................................................... 58

8.1.1 Check before commissioning.................................................. 58

8.2 Operating and display elements (evaluation unit).................................. 58

8.2.1 Function buttons...................................................................... 59

8.3 Menu tree of the evaluation unit............................................................. 60

8.3.1 Menu tree Measuring.............................................................. 60

8.3.2 Menu tree Diagnosis............................................................... 60

8.3.3 Menu tree Parameter.............................................................. 61

8.3.4 Menu tree Calibration.............................................................. 63

8.3.5 Menu tree Maintenance.......................................................... 63

8.4 Operating using the serial interface........................................................ 64

8.4.1 Significance of command line elements................................ 64

8.4.2 Setting for serial interfaces..................................................... 64

8.4.3 Serial interface command - MEAS ......................................... 64

8.4.4 Serial interface commands - Diag.......................................... 65

8.4.4.1 Table with warning messages................................ 65

8.4.4.2 Call up the Table with error messages.................. 65

8.4.4.3 View the device configuration................................ 65

8.4.4.4 Check the system state and configuration........... 65

8.4.4.5 Call up diagnostic data........................................... 65

8.5 Setting the display contrast..................................................................... 65

9 Maintenance...................................................................................... 67

9.1 Safety......................................................................................................... 67

9.2 Maintenance plan..................................................................................... 69

9.2.1 Expendable, wearing and spare parts.................................... 70

9.3 Preparatory work....................................................................................... 70

9.4 Function test of the pressurized enclosure system................................ 70

9.4.1 Maintenance work on the FS840........................................... 71

9.4.2 Repair work on the FS840...................................................... 71

9.5 Removing the sender/receiver unit......................................................... 71

9.6 Visual check of the sender/receiver unit and evaluation unit............... 72

9.7 Cleaning the optical interfaces................................................................ 73

9.8 Etalon tool................................................................................................. 74

9.9 Filter box measurement to check the measuring channels (for dry

gases)........................................................................................................ 75

9.10 Checking the evaluation unit................................................................... 77

9.11 Cleaning the purge air unit....................................................................... 78

10 Troubleshooting................................................................................. 79

10.1 Safety......................................................................................................... 79

10.2 Monitoring and diagnostic system........................................................... 80

10.3 Device not functioning.............................................................................. 81

10.4 Evaluation unit not functioning................................................................ 81

10.4.1 Communication fault between evaluation unit and receiver 82

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CONTENTS

10.5 Ex operation malfunction......................................................................... 82

10.6 Error messages......................................................................................... 82

10.6.1 Error messages........................................................................ 82

10.6.2 Warning messages.................................................................. 84

10.7 Repairing inadequate purge air supply................................................... 85

10.8 Corrosion on flange.................................................................................. 85

11 Decommissioning............................................................................. 86

11.1 Safety information for decommissioning................................................ 86

11.2 Decommissioning Ex-relevant subassemblies....................................... 87

11.3 Removing the device................................................................................ 87

11.4 Preparing the device ready for shipping.................................................. 88

11.5 Environmentally compatible disposal ..................................................... 89

12 Technical data.................................................................................... 90

12.1 System: GM700 Ex version 3G / zone 2................................................. 90

12.2 Sender/receiver unit................................................................................ 90

12.3 Measuring probe....................................................................................... 91

12.4 Evaluation unit Ex version I/O module.................................................... 91

12.5 Technical data for pressurized enclosure system................................... 92

12.5.1 Technical data energy supply.................................................. 92

12.5.2 Limit values for terminal assignment FS840......................... 92

12.5.3 Technical data for Protective gas............................................ 92

12.5.4 Technical data for enclosure................................................... 92

12.5.5 Pressurized enclosure system settings.................................. 92

12.6 Dimension drawings: Sender/receiver unit............................................ 94

12.7 Dimension drawings: Open measuring probe (GMP)............................. 95

12.8 Dimension drawing, purge air unit........................................................... 96

12.9 Dimension drawings, evaluation unit with pressurized enclosure sys‐

tem FS840................................................................................................ 97

12.10 Dimension drawings: Mounting flange DN125....................................... 97

12.11 Dimension drawing, weatherproof cover, sender/receiver unit............. 98

13 Annex.................................................................................................. 99

13.1 Conformities.............................................................................................. 99

13.2 Electrical protection.................................................................................. 99

13.3 Ex certifications........................................................................................ 99

13.4 Possible ambient temperatures............................................................... 99

13.4.1 Ambient temperature ranges.................................................. 99

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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

•

3G / Zone 2

Manual, Pressurized enclosure FS840 and purge medium valve

•

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 Meaning

Hazard (general)

Hazard by voltage

Hazard in potentially explosive atmospheres

Hazard by explosive substances

Hazard by inflammable substances

1.6.2 Warning levels / Signal words

DANGER

Risk or hazardous situation which will result in severe personal injury or death.

WARNING

Hazard by oxidizing substances

Hazard by laser radiation

Hazard by toxic substances

Hazard by noxious substances

Hazard by high temperature

Hazard for the environment/nature/organic life

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

Hints

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1.6.3 Information symbols

Table 2: Information symbols

Symbol Significance

ABOUT THIS DOCUMENT 1

Information on consistency of the product relative to Guideline 2014/34/EU (ATEX)

Important technical information for this product

Important information on electric or electronic functions

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2 SAFETY INFORMATION

2 Safety information

2.1 Main operating information

Work on the device

WARNING Risk of explosion

Work on the device assumes an Ex free zone at the installation location otherwise there is an explosion risk.

Ensure the work area is Ex free when working on the device.

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.

DANGER Risk of explosion through incorrect performance of maintenance work

Incorrect performance of maintenance work in potentially explosive atmospheres can cause serious injuries to people and damage during operation.

Maintenance and commissioning tasks as well as checks should only be carried

•

out by experienced/trained personnel with knowledge of the rules and regulations for potentially explosive atmospheres, especially: – Ignition protection types – Installation procedures – Zone classification Standards to be applied:

•

– IEC 60079‑14, Annex F: Knowledge, expertise and competence of responsi‐

ble persons, craftsmen and designers – IEC 60079-17: Electrical installations inspection and maintenance – IEC 60079-19: Equipment repair, overhaul and reclamation

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SAFETY INFORMATION 2

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.

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 as well as gas temperatures over 200°C:

Regularly check the functionality of the reverse flow safeguard fitted in the mea‐

suring probe.

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.

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.

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.

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2 SAFETY INFORMATION

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.

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.

Contamination of device through purge air failure

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

Always observe the exact specifications in the Operating Instructions (Technical Data Chapter) when replacing a removable power line.

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 the safety of a system

ATTENTION Responsibility for the safety of a system

The person setting the system up is responsible for the safety of the system in which the device is integrated.

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2.2 Warning information on the device

112 2

S/R unit

Figure 1: Warning information on the sender/receiver unit

SR-unit, front side

1 Danger sign: Laser radiation

2 Type plate GM700 Ex

SR-unit, right side

1 Danger sign: Laser radiation

2 Type plate GM700 Ex

SAFETY INFORMATION 2

Figure 2: Laser symbol on device

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2 SAFETY INFORMATION

GM 700 Ex evaluation unit

Figure 3: Warning information on the EvU GMA700 front and right sides

2 3 4

Protective gas warning

•

Protective gas outlet

•

Risk of suffocation when using inert gases

•

20 minutes waiting time before opening the enclosure

General warning: Warning of danger area

Warning sign: Pull power plug before opening the device

Type plate

2.3 Intended use

2.3.1 Purpose of the device

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

NOTICE Responsibility for the safety of a system

The plant operator may not make any technical changes to the GM700 system. Every change voids the EU type approval.

Intended 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).

If you are not sure whether the device corresponds to the state defined dur‐

ing project planning or to the delivered system documentation: Please con‐

tact SICK Customer Service.

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SAFETY INFORMATION 2

Special local conditions

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

These Operating Instructions:

Must be kept for reference.

Must be passed on to new owners.

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02 03

04 05

02 03

04 05

3 PRODUCT DESCRIPTION

3 Product description

3.1 Product identification

Product name GM700 Ex

Device version Measuring Probe Version

Manufacturer SICK AG

Type plates

3.2 Product characteristics

■

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: NH3, NH3 + H2O

■

Measuring principle: Diode laser spectroscopy (TDLS)

Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany

Sender/receiver unit: On right side

•

Control unit: On right side

•

On measuring probe: On purge air fixture

•

3.3 Type plate

Sender/receiver unit

No. Variable

01 Type code

02 Material number

03 Serial number

04 Min. gas temperature

05 Max. gas temperature

06 QR code

07 Month/year

Evaluation unit and connection unit

No. Variable

01 Type code

02 Material number

03 Serial number

04 Min. gas temperature

05 Max. gas temperature

06 QR code

07 Month/year

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3.4 Device variants

Sender/receiver unit

Table 3: Type code identification

Variants Measured components

Ex zone 2: GMM700-0513EX3G

•

Ex zone 2: GMM700-0913EX3G

•

Connection unit

Table 4: Type code identification

Version

Ex zone 2: GMA700-035X EX3G

•

3.5 Pressure and temperature sensor

A p/T sensor serves to measure pressure and temperature, see "Installation example",

page 28 and page 36.

NH3 / H2O

PRODUCT DESCRIPTION 3

3.6 Options

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

•

Weatherproof cover

•

Purge air unit

•

3.7 Layout and function

Figure 4: GM700 Ex layout and function

Sender/receiver unit GM700-0xxEX3G

Evaluation unit GM700-035xEX3G

Ex-p control FS840

Metallic connecting hose between sender/receiver unit and evaluation unit

Digital purge medium valve, 230 V, G3/8", 2 mm, Ex-p

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3 PRODUCT DESCRIPTION

Purge air fixture (without electronics)

GMP measuring probe (without electronics)

Temperature and pressure measurement

Purge air supply

Pressure switch for purge air monitoring

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: NH3, NH3 + H2O as well as reference values temperature and pressure

•

Measuring principle: Diode laser spectroscopy (TDLS) (laser protection class 1)

•

To maintain measuring reliability, a permanent air flow (optics purge air) protects and keeps the optics free

•

from soot and dust particles as well as condensate and moisture condensation Ignition protection type “pressurized enclosure” is effective when using the GM700 Ex in Zone 2 potentially

•

explosive atmospheres. All relevant enclosures of the sender/receiver unit and connection unit connected together via a pressure-proof metal hose are purged with a protective gas. The protective gas can be air suc‐ tioned in from the non-potentially explosive atmosphere or an inert gas.

3.7.1 Function of the pressurized enclosure

Purpose of the pressurized enclosure

The pressurized enclosure ensures Ex atmosphere cannot enter the device from out‐ side. To this purpose, the gas analyzer enclosure is filled with a protective gas. Apart from that, it is ensured that the gas pressure inside the gas analyzer enclosure is higher than the surrounding air pressure.

Functionality during operation

The pressurized enclosure system functions in “leakage compensation” mode: An over‐ pressure is generated in the device in relation to the atmosphere after pre-purging has completed. If the protective gas pressure sinks below the minimum pressure set, pro‐ tective gas feed is activated until the selected overpressure is reached again.

Safety functions

If the maximum permitted overpressure is exceeded or the maximum permitted under‐ pressure underrun, the Ex control unit switches an alarm contact which must be perma‐ nently evaluated (responsibility of plant operator, see FS840 Pressurized Enclosure Manual).

3.8 Purge air unit

•

The purge air unit must be in an Ex-free area and suction Ex-free purge air

The purge air unit supplies filtered ambient air to the measuring probe

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”.

•

NOTE

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

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3.9 Check cycle

PRODUCT DESCRIPTION 3

Cyclic check cycle for zero and sensitivity checks

Start a check cycle via

Timer trigger: Configurable 0 ... 1440 minutes (= 1 day), see menu “Settings /

•

Check Cycle” External digital input signal (Di 1)

•

Purpose of check cycle

■

Checking the zero point and span point without feeding span gases.

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.

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.

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PRODUCT DESCRIPTION

3.10 Explosion protection in accordance with ATEX

3.10.1 Operation in potentially explosive atmosphere

3G / Zone 2: Connection unit and sender/receiver unit

The GM700 Ex complies with ATEX Directive 2014/34/EU with the following characteristics: X II 3/-G Ex pzc op is [ia] IIC T4 Gc/-

•

Special conditions (X identification):

•

A measuring function for explosion protection is not part of the

EC type approval

Explosion protection relating to optical radiation in the measuring

•

channel The explosion protection relating to optical radiation in the measur‐ ing channel is satisfied in accordance with the temperature range (-20°... +60 °C) specified by ATX/IECEx. The plant operator must evaluate Ex atmospheres possibly present for exhaust gas temper‐ atures exceeding this range separately and take suitable protective measures!

Location of Ex relevant subassemblies, see Chapter “Design and Function”.

Do not remove, add or modify any components to or on the device unless described and specified in the official manufac‐ turer information. Otherwise the approval for the device for use in potentially explosive atmospheres becomes void.

Adhere to the maintenance intervals, see Chapter “Mainte‐ nance plan”.

After switching off the main power supply: Wait 20 minutes before opening the enclosure.

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3.10.2 Zone of use GM700 Ex 3G components

DI/DO/

AI/AO

230 /

115 V

GM700 Ex ATEX 3G

Ex p [op is]

p/t

Ex ia

Ex m

Ex p/ Ex i

Ex na nc

Non Ex

ã ä

DIV 1

DIV 2

Non Ex

Non Ex3GNon ExZone 2Zone 1

Zone 0

PRODUCT DESCRIPTION 3

Figure 5: Zone of use GM700 Ex 3G components

Components

Control station / measuring station

Sender/receiver unit

Measuring beam

Ex-p valve

Evaluation unit

Overpressure control

ß à á â ã ä å

p/T sensor

p sensor for purge air unit

Pressure controller for optics purge air as selected by the plant operator

Lines

Purge air hose, optics

Connecting hose, Ex-p

Pressure controller for optics purge air as selected by the plant operator

Ex-p error case signal

Service interface

Ex-p protective gas feed, from plant operator

Feed, optics purge air

Measuring channel

Measuring channel, Ex-free

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3 PRODUCT DESCRIPTION

3.10.3 Pressurized enclosure system

Ignition protection type, pressurized enclosure for Zone 2

Purging

All relevant enclosures of the sender/receiver unit and connection unit connected together via a pressure-proof metal hose are purged with a protective gas. Purging before starting the device safely removes any possible ignitable mix.

Controlling the overpressure in the enclosure

Control by the purge medium valve SVD.L.2.-AI00 G3/8"-300L Ex-p of the FS840 ensures that the complete enclosure is always kept at an overpressure of at least 0.8 mbar against the atmosphere after pre-purging; this prevents an ignitable gas mix pen‐ etrating the device.

Protective gas types

Instrument air suctioned in from the area outside the potentially explosive atmos‐

•

phere Inert gas

•

NOTE

The temperature of the protective gas must not be higher than 50°C.

More information, see "Technical data for Protective gas", page 92, and Pressurized Enclosure Operating Instructions.

3.10.3.1 Safety functions

Alarm signal of pressurized enclosure in case of malfunction

Ex control unit FS840 for Category 3G: The Ex control unit FS840 provides a falling edge when the pressurized enclosure is not in the correct operating state (malfunction).

WARNING Risk of explosion through incorrect parameter settings

Incorrect parameter setting can cause an explosion with fatal consequences.

Only authorized persons are allowed to change the parameters.

NOTICE

The operating company is responsible for the evaluation of the alarm signal. See the Pressurized Enclosure System Manual.

3.11 Sender/receiver unit - evaluation unit connecting hose

The following is applicable for the connecting hose between sender/receiver unit and evaluation unit:

It is part of the pressurized enclosure

•

It contains electrical connection lines

•

It is under overpressure

•

It must be connected to the potential equalization system

•

To ensure potential equalization, the mechanical screw fittings of the hose attach‐

•

ment on GMM700 and GMA700 are secured additionally with sprocket discs. These sprocket discs may not be removed.

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3.12 GMP measuring probe in detail

open Close

PRODUCT DESCRIPTION 3

Figure 6: GMP measuring probe description

Reflector

Measuring gap: Exposed measuring path

Purge air outlet: Air outlet in the duct 90° to gas flow direction (directed purge air)

Lever (locking device of the opening to sample gas)

Differential pressure sensor for purge air

Lever and locking device in “open” position

NOTE

Further characteristics of the GMP measuring probe, see "Measuring probe", page 91 and page 95.

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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 7: Transport safety device on the SR-unit

Remove the front cover of the sender/receiver unit

Figure 8: 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

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4.2 Storage

TRANSPORT AND STORAGE 4

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 sender/receiver-unit and measuring probe from atmos‐

pheric influences, preferably with the original transport safety devices.

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 Information on installation in potentially explosive atmospheres

Project planning for measuring channel

NOTICE

Observe information in Chapter “Main operating information”.

NOTICE

Hazard when exceeding the temperature classes for hot gas ducts

Temperature class T4 (max. 135 °C), for which the explosion protection of this device is designed, can be exceeded on hot gas ducts.

Plan appropriate thermal insulation of the duct and the flanges during project

planning/assembly. When necessary, ensure adequate ventilation or cooling.

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.

DANGER Risk of explosion through incorrect installation

Incorrect assessment of the installation location as well as all further installation work in potentially explosive atmospheres can cause serious injuries to people and damage during operation.

Installation, commissioning, maintenance and inspection may only be carried out

•

by skilled persons having knowledge of the relevant rules and regulations for potentially explosive atmospheres, especially: – Ignition protection types – Installation regulations – Zone classification Standards to be applied:

•

– IEC 60079-14, Annex F: Knowledge, skills and competencies of responsible

persons, operatives and designers – IEC 60079-17: Electrical installations inspection and maintenance – IEC 60079-19: Equipment repair, overhaul and reclamation

Local work safety regulations must be observed

•

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Page 27

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.

Ex-suitable measuring probe

DANGER Risk of explosion with a measuring probe not suitable for Ex zones

Measuring probes not approved for operation in potentially explosive atmospheres can cause an explosion.

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

MOUNTING 5

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

Only use the GMP measuring probe included in the scope of delivery from SICK.

5.3 Material required

Material Required for

Personal protective equipment Protection when working at the sampling point

Tubes for protective gas Protective gas feed line, see "Connecting the protective gas

5.4 Preparing the sampling point

The operating company is responsible for preparing the sampling point

NOTICE

Basis for determining the sampling point:

Preceding project planning (e.g., based on the SICK application questionnaire)

•

Regulations of the local authorities

•

Responsibility of the operator

Determine sampling point

•

Preparing the sampling point

•

Feed and drain for protective gas

•

on the SR-unit", page 52.

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ø133

5 MOUNTING

DANGER Risk of explosion through suctioning optics purge air from an Ex zone

Zone separation is no longer ensured when the purge air supply to purge the optics is suctioned in from an Ex zone. This can lead to an explosion.

Always make sure the air for the purge air supply is suctioned in from an Ex-free

zone and ensure sufficient tightness of the purge air path when it passes through an Ex atmosphere.

NOTICE

Observe zone separation, see "Zone of use GM700 Ex 3G components", page 21.

5.5 GM700 Ex scope of delivery

Check the scope of delivery according to the order confirmation/delivery note.

5.6 Installation sequence

5.6.1 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 9: Assembly example, all dimensions in mm

Components

Evaluation unit with Ex-p control FS840

GM700 Ex sender/receiver unit

GMP measuring probe

Purge air unit

Pressure and temperature sensor (installation location according to project planning)

Ex-p control FS840

Dimensions

Max. distance SR-unit -EvU: 4 m, 8 m, depending on hose length

Duct wall - SR-unit: depending on flange with tube length + measuring probe length

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

Min. flange length in gas duct: 20 mm

Flange with tube length: Standard 240 mm

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

Vertical clearance fastening drill holes - purge air supply assembly plate: 470 mm

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

Miscellaneous

Working platform

5.6.2 Overview of installation steps (duct-side preparation)

Step Procedure Reference

1 Fit flange with tube. see "Installing the flange with tube",

2 Install evaluation unit. see "Install the evaluation unit",

3 Fit purge air unit or units. see "Installing the purge air unit",

4 Observe protective gas outlet (evaluation

unit).

5 Connect pressure, temperature and purge air

monitor.

6 Connect protective gas feed to sender/

receiver unit.

MOUNTING 5

page 29

page 31.

page 33.

see "Install the FS840", page 31.

see "Connecting pressure, temperature and purge air monitor ", page 41.

see "Connecting the protective gas on the SR-unit", page 52.

Information on installing the measuring probe in the gas duct

CAUTION

Device damage through fitting the measuring probe too early on the gas duct

Unsuitable ambient conditions or the atmosphere in the measuring channel can dam‐ age the measuring system and make commissioning impossible.

Carry out the commissioning steps as described in the Commissioning Chapter.

5.6.3 Installing the flange with tube

DANGER Hazard through hot, explosive or toxic flue gases

Hot and/or noxious gases can escape during assembly work on the gas duct depending on plant conditions.

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.

DANGER Hazard through hot, toxic and corrosive flue gases

Hot and/or noxious gases can escape during assembly work on the gas duct depending on plant conditions.

Switch the plant off when working on the gas duct

or the plant operator determines the safety measures to be observed during work on

the plant when switched on based on an evaluation of the danger involved.

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5 MOUNTING

CAUTION Device damage through incorrect/missing insulation of the duct when the measuring channel is hot

When the measuring channel is hot, plan the duct and flange insulation so that

the device is protected against 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 10: "Top" marking on flange with tube

Marking “Top”

3 Attach the flange with tube.

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.

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5.6.4 Install the evaluation unit

MOUNTING 5

Figure 11: Assembly brackets GMA700 Ex 3G

see figure 40, page 97

NOTICE

Do not yet connect the evaluation unit electrically.

5.6.4.1 Install the FS840

Assembly information

When setting up outdoors, it is recommended to protect the explosion-proof device against direct atmospheric influences, e.g., with a protective roof.

Ensure the protective gas inlet and outlet are in a horizontal axis.

Brackets

•

Drill holes: Ø 8 mm

•

Screws: M6

Fasten the connection unit with 4 M6 screws as shown in the dimension drawing.

Refer to the dimension drawings for the dimensions.

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5 MOUNTING

Figure 12: Protective gas outlet

Protective gas outlet: Thread G1"

Reference opening (M5 inner thread)

Protective gas quality

Instrument air or inert gas

•

Compressed air, class 533 according to ISO 8573-1

•

Solid matter 40 µm (class 1)

•

Pressure dew point ≤ 20 °C (class 3)

•

Oil quality ≤ 0.01 mg/m3 (class 1)

•

The air quality may possibly have to be better depending on the requirements of the devices fitted in the pressurized enclosure.

Protective gas outlet

It is important that protective gas can flow out of the protective gas outlet against the atmospheric pressure.

Ensure the unhindered flow of the protective gas.

Reference opening

The reference opening must be located in the Ex area.

Make sure the opening is always clear.

Line lengths for protective gas supply

Large pressure losses occur during the purge phase (high purge medium throughput) depending on the supply line diameter. Consider this when dimensioning the supply line:

Reference values: With 4 mm line diameter (inner diameter), a pressure loss of 500 mbar per meter must be calculated during purging with 2 l/s.

The pressure losses are noticeable when the purge medium flow rate is too low so that the device is possibly not completely pre-purged.

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NOTE

More information on protective gas,

see "Technical data for Protective gas", page 92.

•

5.6.5 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.

MOUNTING 5

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6 ELECTRICAL INSTALLATION

6 Electrical installation

6.1 Electrical installation safety information

NOTICE

Observe information in Chapter “Main operating 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. 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.

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.

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.

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ELECTRICAL INSTALLATION 6

Ex information

DANGER Risk of explosion through incorrect performance of maintenance work

Incorrect performance of maintenance work in potentially explosive atmospheres can cause serious injuries to people and damage during operation.

Maintenance and commissioning tasks as well as checks should only be carried

•

– IEC 60079‑14, Annex F: Knowledge, expertise and competence of responsi‐

ble persons, craftsmen and designers – IEC 60079-17: Electrical installations inspection and maintenance – IEC 60079-19: Equipment repair, overhaul and reclamation

DANGER The Ex certification becomes void when line inlets and plugs without approval are used

The line inlets and plugs are part of the Ex protection and therefore require approval.

Do not replace line inlets or plugs with other types.

Line inlet dimensions, see "Dimension drawings, evaluation unit with pressurized

enclosure system FS840", page 97.

DANGER Risk of explosion through non-Ex conform installation of the lines to the device

Incorrect installation of the supply lines (power supply, signal and communication lines) through Ex zones can lead to an electrostatic charge. This creates an increased risk of explosion.

Install all lines in accordance with EN61010-1 and EN60079-14.

Protect lines against electrostatic charges.

WARNING Risk of explosion through incorrect or non-existing grounding

To avoid an explosion due to electrostatic discharge, 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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1 2

6 7

6 ELECTRICAL INSTALLATION

DANGER Risk of explosion through incorrect connection of the external sensors

The explosion protection is endangered when the external sensors p/T (in the stack) as well as the optics purge air monitor (on the purge air fixture) are not connected to the intrinsically safe terminals provided in the connection unit.

Always connect the external sensors p/T (in the stack) as well as the optics purge

air monitor (on the purge air fixture) to the intrinsically safe terminals specified in the connection unit for this purpose. Observe the intrinsically safe connection values for the Ex barriers fitted in the

evaluation unit in the Operating Instructions delivered.

DANGER Risk of explosion through unsuitable screw fittings and lines

Only use lines (according to EN60079-14) with suitable outer diameters.

Close off cable inlets “vapor-proof” (virtually gas-tight).

Protect lines against electrostatic charges.

Only open those cable inlets to be used for installing cables. Keep the plugs. Refit

the original plug when a cable inlet must be closed again afterwards.

Electromagnetic compatibility

NOTE

This is a Class A product. This device can cause radio interference in household envi‐ ronments and therefore the user must take suitable measures when necessary.

6.2 Connection overview

Observe zone separation, see "Zone of use GM700 Ex 3G components", page 21.

Figure 13: GM700 Ex 3G / zone 2 connection diagram

Power supply

Warning signal, Ex-p control FS840

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Service interface

3 12

I/O signal lines

Protective gas supply

Connection line, pressure sensor

Connection line, temperature sensor

Connection line, purge air monitor, pressure switch

Connection line, purge medium valve SVD.L.2.-AI00 G 3/8“-300L Ex p

Metallic connecting hose between sender/receiver unit and evaluation unit

6.2.1 Lines

ELECTRICAL INSTALLATION 6

Figure 14: Evaluation unit, version 3G

No. Line opening size Line diameter (clamping

range)

M16 x 1.5 5 - 11 mm 6 Nm 5

M20 x 1.5 10 - 14 mm 10 Nm 1

M16 x 1.5 5 - 10 mm 6 Nm 4

Table 5: Lines

Lines Remark

Power supply From customer: 3 x 1.5 mm

Evaluation unit power supply From customer: 3 x 1.5 mm

Evaluation unit - sender/receiver unit with con‐ necting hose

Differential pressure sensor (measuring probe)

- evaluation unit

Pressure/temperature input From customer, intrinsically safe I/O connec‐

Service interface From customer, RS232

Inputs/outputs From customer: Terminal connections: 6 x

Evaluation unit - temperature sensor From customer

Evaluation unit - pressure sensor From customer

In accordance with project planning

5 m

•

10 m

•

From customer, intrinsically safe I/O connec‐ tion

tion

0,75 mm

Tightening torque Qty.

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Table 6: Technical data, M screw fittings

Outer thread M20 x 1.5 M16 x 1.5

Thread length 6 mm

Height 23 mm

Page 38

6 ELECTRICAL INSTALLATION

Outer thread M20 x 1.5 M16 x 1.5

Cable diameter 10 ... 14 mm 6 ... 10 mm

Key width 24 mm 20 mm

Continuous service temperature -20 ... 95 °C

Material Nickel-plated brass

6.3 Connecting interfaces

6.3.1 Connect I/O interfaces

CAUTION

Never lay power supply cables directly next to signal cables.

DANGER Risk of explosion through non-Ex conform installation of the lines to the device

Incorrect installation of the supply lines (power supply, signal and communication lines) through Ex zones can lead to an electrostatic charge. This creates an increased risk of explosion.

Install all lines in accordance with EN61010-1 and EN60079-14.

Protect lines against electrostatic charges.

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 default setting and may not be modified.

6.3.1.1 GM700 Ex 3G terminal connection diagram

Figure 15: Connection diagram of connection unit for variant 3G / Ex zone 2

Power supply

Connections of temperature sensor (3-wire circuit): Pins 1,2 and 3

Connections of pressure sensor: Pins 4 and 5

Pressure monitor for purge air monitoring: Pins 6 and 9

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ELECTRICAL INSTALLATION 6

Connection area for intrinsically safe components

NOTICE PAY CLOSE ATTENTION TO THE CONNECTION VALUES ON TERMINALS 1-9

In area5, the intrinsically safe connections for temperature 2, pressure 3 and a digital input 4 to connect the pressure monitor are provided. Only connect intrinsically safe simple operating means with suitable connection data to these terminals in accordance with the Table below. Otherwise the explosion protection of the connected sensors is not ensured. Only connect intrinsically safe devices with appropriate connection data to these termi‐ nals.

Table 7: Connection data for intrinsically safe connections

Termi‐

Inlet sizes Gas

nal

1 Inlet, temperature sensor

PT100, 3-wire circuit RMA42

2 IIB ≤ 360 nF ≤ 2 mH k.A.

group

IIC ≤ 27.3 V ≤ 22.1mA151mWk.A. 8 nF 75 μH ≤ 85 nF ≤ 500 μH k.A.

Uo Io Po Ui Ci1Li Co

3 IIB ≤ 530 nF ≤ 5 mH k.A.

4 Analog input, pressure sen‐

sor 4-20 mA RMA42

5 IIB ≤ 683 nF ≤ 17 mH k.A.

IIC ≤ 27.3 V ≤ 96.5mA659mWk.A. 8 nF 75 μH ≤ 88 nF ≤ 4 mH k.A.

IIA ≤ 2 280 nF ≤ 34 mH k.A.

6 Digital input, pressure switch

1 KCD2-SR-Ex

7 IIB ≤ 16.8 µF ≤ 486.3 mH 1628

IIC 10.5V 17.1mA45mW12 V 0 0 2.41 µF ≤ 121.5 mH 801

IIA ≤ 75 µF ≤ 972.7 mH 1628

8 Digital input, pressure switch

2 KCD2-SR-Ex

9 IIB ≤ 16.8 µF ≤ 486.3 mH 1628

IIC 10.5V 17.1mA45mW12 V 0 0 ≤ 2.41 µF ≤ 121.5 mH 801

IIA ≤ 75 µF ≤ 972.7 mH 1628

Max. inner capacity

Max. inner inductivity

Max. outer capacity

Max. outer inductivity

L/R ratio (inductivity/resistance)

μH/ Ω

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Page 40

+ – + – + –

4 2+

230 V AC;

50 Hz (3 x 1.5

)

1 2 3

Power +5V +24V

Power CAN +24V + – H L GND

Digital inAnalog i n

0.. 20mA 100 100 100

40...60Hz

AO1 AO2 AO3DI1 DI2 AI1 AI2 AI3

Sensor

DO1 DO2 DO3

Digital out AC/DC 48V 30VA 1A

Analog out

0.. 20mA

Sensor

Fuse 2.5 AT 250V

PE N L1

contrast

PE N L1

CAN H

CAN L

--- +++

6 4 3

7 8

DI3

6 ELECTRICAL INSTALLATION

6.3.1.2 Electrical connection of the evaluation unit EvU

Figure 16: Electrical connection of the evaluation unit

GM700 Ex evaluation unit

Connections on circuit board

2 3 4 5 6 7 8

Power supply GM700

Fuse, 2.5 2,5 AT, 250 V

CAN GM700

Analog outputs: 0 ... 20 mA (6 x 0.75 mm2)

Digital outputs 48 V AC/DC; 60 VA, 1 A (6 x 0.75 mm2)

1 = digital output (NC contact) for malfunction

2 = digital output (NO contact) for maintenance request

3 = digital output (NO contact) for function check

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ELECTRICAL INSTALLATION 6

6.4 Connecting the connecting hose to the SR-unit on the EvU

NOTICE

The connecting hose between the SR-unit and the evaluation unit is part of the pressur‐ ized enclosure. It is under overpressure.

Protect the connecting hose against possible damage.

1 Lead the cable through the M screw fittings, see Figure below. 2 Connect the cable in the connection unit. 3 Tighten screws on the terminal strip. 4 Push on the connector housing and screw tight.

Figure 17: Connecting the connecting hose of the SR-unit on the EvU

M screw fitting

Connector housing

6.5 Connecting pressure, temperature and purge air monitor

NOTE

Purge air monitor - pressure controller for purge air monitoring

Wiring layout, see "Connection overview", page 36.

•

Terminal assignment, see "GM700 Ex 3G terminal connection diagram", page 38.

•

Observe the Operating Instructions of the sensors and the purge air monitor.

•

6.6 Preparing the power supply

1 Check that the connection lines meet the requirements:

– Cross-section: 3 x 1.5 mm

2 Plan a disconnecting device for

– Evaluation unit (see "Evaluation unit Ex version I/O module", page 91). – Optics purge air units (see technical data of the optics purge air unit). – Mark the disconnecting device as disconnecting device for the GM700 Ex.

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6 ELECTRICAL INSTALLATION

3 Connect power cable and lines:

w w

4 Tighten the M screw fitting.

Figure 18: Power connection in the evaluation unit, power supply 230V / 50 Hz

NOTICE

The PE connection must always be connected to the protective ground of the system.

Route the power cable through the M screw fitting.

Connect the lines in the connection unit.

6.7 Connecting the FS840 Ex overpressure control

Electrical safety

The local electrical installation regulations must be observed.

Risk of explosion

DANGER Risk of explosion through incorrect settings for the pressurized enclosure

The pressurized enclosure is a central safety part of the device. All work is described in this Manual and the relevant specified documents. If work is performed which is not described in this Manual, the risk of explosion of the measuring system increases and the ATEX certification for the device becomes void.

Carry out all work skillfully and in accordance with the delivered documentation.

Unsafe measuring operation

CAUTION Risk of unsafe measuring operation through loss of degree of protection IP65

Ineffective seals of the connection unit and insufficient closed openings for unused line inlets can lead to loss of degree of protection IP65. Penetration by dust or moisture can lead to unsafe operation of the FS840.

Close off unused openings for line inlets with impact resistant sealing plugs that

have been checked against self-loosening and turning. Check the seals on the Ex-e enclosure for damage and replace as necessary.

Tighten the terminals, especially in the Ex-e area.

Check the terminals for discoloration. This could indicate increased temperatures.

Check the gland screw fittings, sealing plugs and flanges for leak tightness and

tight seat.

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Terminal assignment

ELECTRICAL INSTALLATION 6

Figure 19: Connecting the Ex overpressure control

Terminals

Table 8: Terminal assignment

Terminals Designation

1, 2 Signal contact 1

3, 4 Signal contact 1

5, 6 Connection for purge medium valve

7, 8 – power supply (feed)

9, 10 + power supply (feed)

Table 9: Terminals with higher safety in the FS840

Tightening torques Wire cross-sections rigid / flexible

Min. 0.3 Nm Min. 0.3 mm

Max. 0.4 Nm Max. 2.5 mm

NOTICE

Always maintain the limit values on the respective terminals. Refer to the Technical Data or the Test Certificate for the limit values. The fitted valve fuse must correspond to the specified fuse value of the purge medium valve used.

Limit values, see "Limit values for terminal assignment FS840", page 92.

NOTE

Further information on the pressurized enclosure system, see "Pressurized enclosure

system settings", page 92 and FS840 Operating Instructions.

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6 ELECTRICAL INSTALLATION

6.8 Electrical connection of SR-unit

NOTICE

The connecting hose between the SR-unit and the evaluation unit is part of the pressur‐ ized enclosure. It is under overpressure.

Protect the connecting hose against possible damage.

Figure 20: Connection of connecting hose with the SR-unit

Connect the connecting hose to the SR-unit:

1 Connect the connecting hose plug on the SR-unit. 2 Push on the cover and screw tight.

6.9 Connecting the potential equalization

NOTICE

A potential equalization not connected properly or missing can lead to malfunctions in device operation.

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6.9.1 Connecting the potential equalization on the SR-unit

Figure 21: Connecting the potential equalization on the SR-unit

Screw the grounding conductor (4 mm2) of the plant ground tight to the screw ter‐

minal.

ELECTRICAL INSTALLATION 6

6.9.2 Connecting the potential equalization on the measuring probe

Figure 22: Potential equalization on the GMP measuring probe

Potential equalization connection

Screw the grounding conductor tight on the screw terminal.

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6 ELECTRICAL INSTALLATION

6.9.3 Potential equalization - evaluation unit and Ex control 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.

Connect the grounding conductor on the Ex control unit FS840

Screw the potential equalization (4 mm2) of the plant ground tight to the screw ter‐

minal.

Figure 23: Potential equalization on Ex control unit and evaluation unit

Potential equalization connection on Ex control unit

Potential equalization connection on evaluation unit

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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 national and local requirements regarding setting up and

•

operating devices in potentially explosive atmospheres. 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:

Please contact SICK Customer Service or your local representative.

COMMISSIONING 7

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 non-existing grounding

During installation and maintenance work, it must be ensured that the protective grounding to the devices and/or lines involved is effective in accordance with EN 61010-1.

System safety

ATTENTION Responsibility for the safety of a system

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 Ex

•

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7 COMMISSIONING

Operating Instructions, purge air supply

•

Gönnheimer Pressurized Enclosure FS840 and Purge Medium Valve Manual

•

Final inspection protocol

•

Table 10: 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 11: Technical data of the measuring point

Measuring range

Limit values

Inputs and outputs to be used



7.3 Material required

Not contained in the scope of delivery

Optical alignment tool

•

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 Overview of commissioning steps

Table 12: Commissioning steps

Step Procedure Reference

1 Remove the transport safety devices. see "Transport protection", page 24

2 Fit the SR-unit on the measuring probe.

3 Carry out zero adjust. see "Zero adjust", page 49

4 Put the purge air supply into operation.

5 Align the measuring probe in flow direc‐

tion.

6 Connect the protective gas. see "Connecting the protective gas on the

see "Fitting the SR-unit on the measuring probe.", page 49

see "Installing the purge air unit", page 33

see "Aligning the measuring probe in flow direction", page 51

SR-unit", page 52

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7.5 Zero adjust

COMMISSIONING 7

Step Procedure Reference

7 Connect the potential equalization. see "Connecting the potential equalization

on the SR-unit", page 45

8 Electrical connection of SR-unit. see "Electrical connection of SR-unit",

page 44

9 Switch the measuring system on.

10 Optional: Fit the weatherproof cover. see "Installing the weatherproof cover ",

Prerequisite

1. Clean ambient atmosphere, free from sample gas, protected against weather.

2. Bracket for the measuring probe

NOTICE

Position the measuring probe bracket within reach of the metal hose between EvU and SR-unit.

see "Optical fine alignment of the sender/ receiver unit ", page 54 see "Starting measuring operation", page 56

page 55

7.6

Preparation

1 Switch the power supply of the evaluation unit on. 2 Wait for the 2.5 - 5 hours warming up time of the SR-unit (depending on ambient

conditions) to elapse.

NOTE

Signal output on the EvU when the warming up time is not reached yet:

1 LED: "Warning" is yellow. 2 Display: Message "DEV Temp" is output.

Carry out zero adjust

1 Align the optical beam path after the warming up phase, see "Optical fine align‐

ment of the sender/receiver unit ", page 54.

2 Select in menu cal:

– Zero Adjust – manual zero adjust (measuring path free from sample gas) – Activate Calibration mode (button “cal”), carry out menu item Zero Adjust.

3 Confirm the prompt.

Zero Measuring is displayed whilst zero point adjustment executes.

Fitting the SR-unit on the measuring probe.

The flange fixture can be removed before installing the SR-unit.

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1 2 3 4

5 6

7 COMMISSIONING

Figure 24: Fastening the GMP measuring probe on the SR-unit

SR-unit flange fixture (detachable)

Cup springs (10 per fastening)

Sealing ring

Centering disc and self-locking nut

Threaded pin of flange fixture

Device flange

Cross-section of the connection fitted between the SR-unit and measuring probe

Figure 25: Cross-section of the connection fitted between the SR-unit and measuring probe

1 2 3 4 5 6

Gap = 3 ±0.5 mm

Hose clamps

Sealing ring

10 cup springs

Spherical washer

Self-locking nut

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COMMISSIONING 7

1 Put 10 cup springs each, back-to-back, onto the three threaded bolts on the flange

fixture of the SR-unit.

2 Pull the sealing ring over the flange of the purge air fixture and hang it loosely over

the purge air unit.

3 Carefully push the measuring probe with the device flange onto the three threaded

bolts of the flange fixture fitted with cup springs.

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. 3 ± 0.5 mm remains. This gap is important for adjustment of the optical alignment.

6 Fit the sealing ring over the gap. 7 Push two hose clamps over the sealing ring and screw tight.

8 Refit the flange fixture back on the SR-unit when it was removed beforehand.

Insert the hinge pins back in and close the quick release fasteners.

9 Set the lever on the probe flange to the “open” position to open the locking device

on the probe towards the sample gas.

7.7 Aligning the measuring probe in flow direction

Flow direction aligned at the factory

NOTE

When the gas flow direction is already known during project planning, the installation angle of the of the measuring probe is already set accordingly when delivered.

A sticker marks the setting.

Figure 26: Flow direction marking

Device flange

1 2 3

Flow direction sticker

Mounting ring screws (4 pcs.)

Measuring probe, aligning

The measuring probe can be adjusted by turning the device flange.

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7 COMMISSIONING

1 Loosen the 4 screws on the mounting ring (see Figure). 2 Rotate the device flange to the following position:

– The measuring gap must point in flow direction. – The device flange must be positioned so that the SR-unit can be fitted in a

vertical position.

3 Tighten the screws on the mounting ring again to fasten the device flange in this

position.

7.8 Feeding protective gas

NOTICE

The pressurized enclosure requires a permanent supply of protective gas to ensure the Ex protection function.

Feed the protective gas via the protective gas connection.

Further information concerning protective gas: – Requirements for protective gas, see "Technical data for Protective gas",

page 92.

– Protective gas outlet: see "Install the FS840", page 31.

7.8.1 Connecting the protective gas on the SR-unit

The protective gas connection is located underneath the enclosure of the sender/ receiver unit.

Figure 27: Connection for protective gas on GM700 Ex

Protective gas inlet:

•

Thread G3/8" or

•

hose connection for 8 mm diameter

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COMMISSIONING 7

NOTICE

Only use protective gas corresponding to the specifications, see "Technical data for Pro‐

tective gas", page 92.

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7 COMMISSIONING

7.8.2 Switch the pressurized enclosure on

1 Switch the main power supply of the pressurized enclosure system on (at an exter‐

nal source).

2 The pressurized enclosure system starts pre-purging the enclosure with protective

gas. The Ex control unit signals the end of the pre-purge phase.

3 Switch the main power supply of the measuring system on (at an external source).

7.9 Optical fine alignment of the sender/receiver unit

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: Disconnect the power supply before opening

the device.

Prerequisite

The power supply of the evaluation unit is switched on.

•

The device is in Maintenance mode.

•

Components of the alignment tool on the GM700

Figure 28: Components of the alignment tool on the SR-unit

Visor of the optical alignment tool

LED display for rough optical alignment

Alignment tool lever

Y-alignment: Vertical

X-alignment: Horizontal

Carry out optical fine alignment of the SR-unit

1 First turn the lever of the built-in alignment tool (3) and then pull it down to bring it

to the adjustment position, (see Figure above).

2 Look through visor (1) on the right enclosure side diagonally from above to the mir‐

ror with the target.

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COMMISSIONING 7

3 Align the position of the red light spot. To do this, adjust the nuts for the X and Y

alignment on the device flange so that the light spot in positioned in the center of the target, see "Optical fine alignment of the sender/receiver unit ", page 54.

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

position and secure it with a quarter turn.

Figure 29: Point for correct fine adjustment

Target for the alignment tool for the Cross-Duct version

Target for the alignment tool for the probe version

7.10 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.

7.11 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 63.

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:

7.11.1 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 58.

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

interface commands - Diag", page 65, and the Error and Warning Message

Tables, see "Error messages", page 82 and see "Warning messages", page 84. 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)

7.11.2 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 99.

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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 commissioning

Before every start-up

Check all enclosures are closed:

– Enclosure cover – Cable inlets – Enclosure openings

NOTICE

Permanent feed of protective gas must be ensured, see "Feeding protective

gas", page 52.

8.2 Operating and display elements (evaluation unit)

DANGER

Risk of explosion through releasing the Ex protection

The operating elements of the evaluation unit GMA700 can only be used when the eval‐ uation unit is opened. The zone separation is no longer ensured when the evaluation unit is opened in the Ex zone during operation. This creates an explosion risk.

The Ex-p system generates a warning signal that the Ex protection is not effective.

To operate the measuring system via the operating elements:

Ensure an Ex-free atmosphere exists when opening the GMA700.

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Page 59

NH3

mg/ m

236

Measuring

GM700

Evaluation Unit

Ref. conditions Hum: wet

Figure 30: GM700 operator panel

Display

•

All current measured values

•

Computed values

•

Menu navigation

Status LEDs to signal operating and malfunction states

Function buttons for menu navigation and input

Function buttons for menu selection

OPERATION 8

LEDs

Table 13: Significance of LEDs

LED Significance / possible cause

OPERATION

SERVICE

Warning

MALFUNCTION

8.2.1 Function buttons

Measuring mode

•

The device is switched on, power voltage is available

•

Service mode

•

Warning message

•

At least one warning message pending

•

Reading warning messages, see Diagnosis mode (diag)

•

Device malfunction

•

At least one malfunction message pending

•

Reading malfunction messages, see Diagnosis mode (diag)

•

Button Function

MEAS Back to the Measuring screen from any menu. All inputs that have not been ter‐

minated with Save are discarded.

The current function of the function buttons is shown on the display.

Display Function

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Back Returns to next higher level menu.

Page 60

meas

8 OPERATION

Display Function

Diag To display warning and/or error messages (plain text) and retrieve sensor values:

Press this button.

Enter Call up/start/confirm selected menu function.

Select Select function/character.

Start Start procedure.

In a selection list: Move cursor upwards.

During input: Next character.

Move cursor downwards.

Move cursor to the left.

Move cursor to the right.

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

Current measured values: Depending on

•

device version Reference variables (wet, dry)

•

8.3.2 Menu tree Diagnosis

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

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 percent by volume

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

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

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

•

NOTICE

[1]

These temperature ranges are not allowed

for Ex applications.

[1]

t (Feed Test Gas) Period 0 ... 3666 d (t = days), only when permanent cell

is included

Check cycle Period 0 ... 24 h

Enable Yes, No

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

Service Not defined

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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 (preliminary)

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 É Do not use on GM700 Ex! This causes erroneous zero point determination.

Box measuring Start Meas. Check of measuring components with test gas via

a filter box

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

nance

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

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8 OPERATION

Menu level Explanation

Reset System Restarts the measuring system

Reset Parameter

8.4 Operating using the serial interface

NOTE Menu texts are shown in English.

NOTICE

Operating is only possible via the serial interface during operation in Ex area. Local operating via the evaluation unit is possible when the Ex protection is not effective.

8.4.1 Significance of command line elements

Table 14: 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).

Resets parameters to factory settings a All settings are overwritten!

CAPITAL LETTERS

Small letters in {round brack‐ ets}

ets]

Small letters

8.4.2 Setting for serial interfaces

Table 15: Standard setting for serial interface

Parameter Description / value

Baudrate 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 command - MEAS

Start measuring operation/switch to measuring operation

Syntax:

GM700<<GOTO MEAS

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8.4.4 Serial interface commands - Diag

The serial interface is only used when fast access to the menu in the EvU is not possi‐ ble due to Ex protection. The following Chapters explain a selection of commands the user will need to analyze a problem when errors occur.

8.4.4.1 Table with warning messages

Call up the Table of warning messages.

Syntax:

GM700<<DIS WTBL

8.4.4.2 Call up the Table with error messages

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

OPERATION 8

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

Command “DIS MERB” calls up the diagnostic data.

Syntax:

GM700<<DIS MERB

8.5 Setting the display contrast

The rotary potentiometer for setting the display contrast is located above the “Digital Out” terminal block.

Use a 2 mm precision screwdriver to adjust the display contrast setting.

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8 OPERATION

Figure 31: Rotary potentiometer for display contrast

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9 Maintenance

9.1 Safety

Ex safety

WARNING Risk of explosion

Some of the work described in this Chapter assumes an Ex free zone.

DANGER Risk of explosion through incorrect performance of maintenance work

Incorrect performance of maintenance work in potentially explosive atmospheres can cause serious injuries to people and damage during operation.

•

MAINTENANCE 9

Wait 20 minutes after switching off the main power supply before opening the enclosure.

Maintenance and commissioning tasks as well as checks should only be carried out by experienced/trained personnel with knowledge of the rules and regulations for potentially explosive atmospheres, especially: – Ignition protection types – Installation procedures – Zone classification Standards to be applied: – IEC 60079‑14, Annex F: Knowledge, expertise and competence of responsi‐

ble persons, craftsmen and designers – IEC 60079-17: Electrical installations inspection and maintenance – IEC 60079-19: Equipment repair, overhaul and reclamation

DANGER Risk of explosion when using spare and wearing parts not approved for the Ex zone

All spare parts and expendable parts for the in-situ gas measuring device have been checked by SICK for ATEX suitability. The use of different spare parts and expendable parts increases the risk of an explosion and the ignition protection can no longer be ensured.

Use only original spare parts and expendable parts from SICK.

DANGER Risk of explosion through residual voltages and hot surfaces in the device

When the device is switched off, residual voltages and hot surfaces represent an increased risk of explosion when the device is open.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

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DANGER Hazard for health through contact with inert protective gas

Inert protective gas can emerge uncontrolled when the device is opened directly after switching off. Direct contact with inert protective gas is a high health risk, including risk of suffocation.

Interrupt the inert gas feed before opening the device so that only the volume of

inert gas in the device can escape. Ensure good ventilation and air exchange.

Never open the device when the room is too small.

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 purge air is switched off when the device is still in the gas duct.

Do not switch the purge air unit off as long as the device is still in the gas duct.

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.

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.

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.

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 disconnecting device is mandatory when the disconnector switch is

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

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MAINTENANCE 9

Contamination through gas residues

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.

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

Swiveling the SR-unit or reflector unit (on Cross-Duct version) open can lead to contact with toxic and/or hot gases with overpressure 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 in the device flange of the SR-unit and

reflector (for Cross-Duct version) and have it available. Attach the cover to the device flange opening immediately after swiveling the SR-

unit open (reflector unit, for Cross-Duct version).

9.2 Maintenance plan

Table 16: Maintenance intervals

Interval

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

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 purge air unit.

Check the pressurized enclosure system.

Protective gas: Condition, availability, pres‐ sures.

see "Call up diagnostic data", page 65

see "Visual check of the sender/receiver unit and evaluation unit", page 72

.see "Cleaning the optical interfaces",

page 73

see "Optical fine alignment of the sender/ receiver unit ", page 54

see "System: GM700 Ex version 3G / zone 2", page 90

See Operating Instructions of purge air unit

see "Function test of the pressurized enclo‐ sure system", page 70

see "Feeding protective gas", page 52

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9 MAINTENANCE

9.2.1 Expendable, wearing and spare parts

Recommendation for two years operation

Table 17: Expendable and spare parts for two years operation

Part Qty. Part number

Pressure compensation element 1 5312881

Optics cleaning cloth 8 4003353

Filter insert for purge air unit 8 5328662

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 Function test of the pressurized enclosure system

All maintenance work for the pressurized enclosure system is described in the Pressur‐ ized Enclosure Manual.

DANGER Risk of injury through electric voltage

Switch the power supply off before working on terminals and laying lines.

Observe the installation regulations according to VDE DIN 57 165 and Test Certifi‐

cates BVS 15 ATEX E 048 X and IECEx BVS 15.0037 X.

WARNING Risk of explosion through unauthorized parameter changes

The parameters for the pressurized enclosure system are protected with a parameter password and cannot be changed. Unauthorized changing of parameters can cause an explosion with fatal consequences.

Never change parameters without authorization.

DANGER Risk of explosion when the maintenance of the pressurized enclosure is incorrect

The pressurized enclosure is a central part of the ATEX certification of the device. All maintenance work is described in the Pressurized Enclosure Manual. If work is per‐ formed which is not described in this Manual, the risk of explosion of the measuring system increases and the ATEX certification becomes void.

Also observe the maintenance instructions in the Pressurized Enclosure Manual.

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DANGER Risk of explosion through incorrect settings for the pressurized enclosure

Carry out all work skillfully and in accordance with the delivered documentation.

Checking the protective gas feed

NOTE

Keep the device in operation during the check.

1 Interrupt protective gas feed to the device.

The Ex control unit should signal an error state after a few minutes.

2 Start protective gas feed again.

The Ex control unit should now reset the error state and start the pre-purge phase.

9.4.1 Maintenance work on the FS840

MAINTENANCE 9

Maintenance FS840

Inspect the inlet and outlet of the FS840 regularly for contamination / corrosion.

Correct cleaning in good time by Gönnheimer Elektronic GmbH as a precautionary

measure against failure of a control unit.

9.4.2 Repair work on the FS840

NOTE

Repairs on the FS840 as well as accessories may only be carried out by Gönnheimer Elektronic GmbH.

9.5 Removing the sender/receiver unit

DANGER Hazard for health through contact with inert protective gas

Inert protective gas can emerge uncontrolled when the device is opened directly after switching off. Direct contact with inert protective gas is a high health risk, including risk of suffocation.

Interrupt the inert gas feed before opening the device so that only the volume of

inert gas in the device can escape. Ensure good ventilation and air exchange.

Never open the device when the room is too small.

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9 MAINTENANCE

Figure 32: Opening the GM700 Ex sender/receiver unit and removing the intermediate enclosure

Quick-release fasteners of the sender/receiver unit

Intermediate enclosure

Hinge pin

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.

Remove the intermediate enclosure

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

9.6 Visual check of the sender/receiver unit and evaluation unit

Inspect the enclosures of the sender/receiver unit and evaluation unit for mechan‐

ical damage. Clean the respective enclosures if contaminated.

b b

b b b b

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 flanges and screw fittings for tight seat.

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9.7 Cleaning the optical interfaces

DANGER Risk of explosion through residual voltages and hot surfaces in the device

When the device is switched off, residual voltages and hot surfaces represent an increased risk of explosion when the device is open.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

Materials required Part number

Optics cleaning cloth 4003353

Demineralized water

MAINTENANCE 9

Figure 33: Optical interfaces on the SR-unit

Sender/receiver unit GM700 Ex (open, without intermediate enclo‐

sure)

Target

1 Switch device off and open, see "Removing the sender/receiver unit", page 71. 2 Flap the target holder upwards and check the sender/receiver unit window under‐

neath for contamination.

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9 MAINTENANCE

Figure 34: Flap the target holder upwards

Target holder

3 If required: Clean the window with an optical cleaning cloth and demineralized

water.

9.8

Etalon tool

NOTICE

Do not use cleaning agents. Residues can falsify measuring results.

4 Close the enclosure immediately after cleaning to protect the cleaned optical inter‐

faces against moisture and dust.

The laser beam must be readjusted once a year.

Prerequisite:

Etalon maintenance tool, Part No. 2049984

•

Adjustment software

•

Training by SICK

•

Figure 35: Etalon tool

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Test gas conc. [ppm o. vol. %] =

Meas. range [ppm o. vol. %] x active meas. path [m]

0.15 m max. filter chamber length

Test gas conc. [ppm o. vol. %] =

3 Desired

= test gas conc. [ppm] x 0,769 x

353 1013

273

Meas. range [ppm o. vol. %] x active meas. path [m]

act. air pressure [hpa]

L [mm]

Chamber

x 0,001

0.15 m max. filter chamber length

MAINTENANCE 9

9.9 Filter box measurement to check the measuring channels (for dry gases)

WARNING Risk of explosion during filter box measurement in the Ex zone

The filter box is not designed for operation in the Ex zone.

Filter box measurement may only be carried out in an Ex-free environment.

Observe the relevant Operating Instructions when using the filter box.

Components required

Table 18: Components required for filter box measurement

Components required Part number

Reflector enclosure with built-in gold-coated hollow triple

Filter box with adapter plate for the GM700

Zero gas

Determining the necessary test gas concentration

1 General calculation:

2030206

2 Calculating setpoint values for all 6 chamber lengths:

Table 19: Test gas concentration for NH3 of the respective filter chamber length

Test gas concentration

Filter cham‐

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

ber lengths

Installing the filter box

1 Provide the filter box with adapter plate and reflector enclosure. 2 Remove the intermediate enclosure from the sender/receiver unit:

Swivel the intermediate enclosure of the device open.

Remove pin.

Remove the intermediate enclosure.

Store the intermediate enclosure dry and clean during the filter box measure‐

ment.

3 Fit the filter box in the device:

Insert the filter box in the SR-unit hinge.

Insert and fasten the hinge.

Swivel the filter box on the SR-unit in and lock with the locking device

4 Attach the reflector for the device on the filter box:

Fasten the reflector enclosure to the filter box with 4 screws.

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1 2

3 4

MAINTENANCE

Figure 36: Fit the filter box on the measuring device

1 2 3 4 5 6

Carry out filter box measurement

1 Switch filter box on.

NOTE

The warming-up phase takes about 2.5 hours.

2 Make the settings on the filter box:

w w

3 Make the settings on the EvU:

w w w

The measuring device starts a zero adjust and then switches to operating mode “Box measuring”.

4 Connect the test gas on the filter box.

5 Measure the individual chambers and/or chamber combinations of the filter box

w w

6 Leave operating mode “Box measuring” on the EvU with the return button.

Gas filter box

Reflector enclosure

Adapter plate for SR-unit

Sender/receiver unit

Intermediate enclosure

Set the sample gas chamber to “Zero gas”.

Set the “Measuring/Purging” valve to “Purging”.

Switch to Calibration mode with button “cal”.

Select menu “Box measuring” -> “gas”.

Enter password “1 2 3 4”.

Set the primary pressure to approx. 1000 hPa (1 bar)

Set the valves for the respective filter chambers to “Test gas”

Set the valve measure/purge to “Purging” for 2 to 3 minutes (until the mea‐

sured value has stabilized to a level).

Then set the valve to “Measuring”.

The overpressure from the purge phase now dissipates.

When the measured value has stabilized again, read off and note the value.

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MAINTENANCE 9

9.10

Valve “Zero” for zero gas

Valve “Measuring/ Purging” for purging and measuring operation

Valve “Test gas” for switching the single measuring chambers

On/Off switch

Power supply connection

Gas connection “Zero gas”

Gas connection: Measuring chamber 75 mm

Gas connection: Measuring chamber 50 mm

Gas connection: Measuring chamber 25 mm

Pump ON/OFF switch

Temperature displays “Preheater” and “Cell temp.”

1 Disassemble the filter box with plate and reflector from the SR-unit and store

safely.

2 Fit the SR-unit back on measuring point properly again.

Checking the evaluation unit

NOTICE

Observe safety information, see "Safety information on commissioning", page 47.

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DANGER Risk of explosion through residual voltages and hot surfaces in the device

When the device is switched off, residual voltages and hot surfaces represent an increased risk of explosion when the device is open.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

The evaluation unit must be checked regularly depending on ambient conditions:

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.

9.11 Cleaning the purge air unit

Materials required Part number

Air filter 5328662

CAUTION Contaminated purge air supply can damage the measuring system

Inadequate cleaning of the purge air supply can cause blocking of tubes or filters. The measuring system can no longer be protected from contaminated sample gas.

Regularly check and clean the purge air supply.

NOTE

Further information on maintenance and cleaning can be found in the Data Sheet of the purge air unit.

NOTE

The filter of the purge air unit must be replaced at the latest when the low-pressure sensor on the filter outlet triggers.

Preparation

For prolonged maintenance work on the purge air supply: Remove the SR-unit and

•

reflector unit from the gas duct For short maintenance work on the purge air supply: Swivel SR-unit and reflector

•

unit from the gas duct

Cleaning the purge air unit

1. Put the purge air unit out of operation and completely remove the purge air hoses.

2. Replace the air filter in the purge air unit and clean the inside of the purge air unit..

3. Completely swivel open the SR-unit and the reflector so that dust that was possibly blown through the purge air hose is not deposited on the windows.

4. Put the purge air unit back into operation. .

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10 Troubleshooting

10.1 Safety

Prerequisites

DANGER Risk of explosion through residual voltages and hot surfaces in the device

When the device is switched off, residual voltages and hot surfaces represent an increased risk of explosion when the device is open.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

WARNING Risk of explosion

Some of the work described in this Chapter assumes an Ex free zone.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

TROUBLESHOOTING 10

DANGER Risk of explosion through incorrect performance of maintenance work

Incorrect performance of maintenance work in potentially explosive atmospheres can cause serious injuries to people and damage during operation.

Maintenance and commissioning tasks as well as checks should only be carried

•

– IEC 60079‑14, Annex F: Knowledge, expertise and competence of responsi‐

ble persons, craftsmen and designers – IEC 60079-17: Electrical installations inspection and maintenance – IEC 60079-19: Equipment repair, overhaul and reclamation

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.

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10 TROUBLESHOOTING

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

Electrical safety

DANGER Electrical accident through bare, live lines

When uninstalling, unsecured, live lines can lead to serious accidents.

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.

Switch the power supply to the device off before starting uninstallation.

If power supply is required during uninstallation: Secure all live lines during unin‐

stallation work so that nobody can be injured.

DANGER Hazard by voltage

Lines in the subassemblies of the measuring system are live and can cause serious injuries through electric shock when touched.

Disconnect the subassemblies or lines involved from the power supply during

installation, maintenance and repair work.

10.2 Monitoring and diagnostic system

The device has an integrated system that continually checks the operating state of the SR-unit and the control unit. Corresponding messages are displayed for deviations from the normal state and recorded in the devices for later evaluation. Messages for the two system components are categorized into error messages and warning messages depending on the anticipated effects:

Significance of warning messages

Measuring results are not (yet) directly influenced by a deviating system state.

•

Observance and clearance of the cause(s), e.g., through maintenance measures,

•

are necessary to prevent subsequent errors or device damage

Significance of malfunction messages

Measuring operation is no longer possible or no longer reliable.

•

NOTE

Warning and error messages are stored in the built-in message memory of the control unit.

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TROUBLESHOOTING 10

10.3 Device not functioning

Table 20: Device not functioning

Possible cause Action

Power supply not connected. 1 Check power cable and connections.

Check power supply (e.g. socket, external disconnecting device).

Main power supply has failed.

Internal operating temperatures are incorrect.

Internal software not functioning. Can only occur with complex internal malfunctions or after strong external influences

Ex control unit does not switch on. 1 Protective gas feed interrupted or too low.

1 Check whether error messages exist.

(e.g., strong electromagnetic interfering pulse).

1 Switch device off and then back on again after a few seconds.

2 Ex control unit displays an error (see Pressurized Enclosure Manual).

10.4 Evaluation unit not functioning

WARNING Risk of explosion

Some of the work described in this Chapter assumes an Ex free zone.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

Table 21: Device not functioning

Error indication Possible cause Action

Malfunction LED blinks, (Warning LED possibly on)

Evaluation unit not responding

Plain-text error messages indicate possible causes.

Operating voltage not set correctly.

Power supply on evaluation unit incorrect. 1 Provide power supply from plant.

Defective fuse.

Cause cannot be determined. 1 Disconnect all system components from

Error occurs again.

24V/5V supply defective. 1 Check 24V/5V supply.

1 Trigger Diagnostic mode by pressing the

2 Call menu Malfunction (and/or Warning). 3 Check and clear the specified malfunction.

1 Check operating voltage set. 2 If necessary, replace fuse.

2 Check/reconnect connections on the sys‐

1 Check fuses in the evaluation unit. 2 Exchange when necessary.

2 Check the CAN bus cable from the evalua‐

2 Exchange evaluation unit and/or electron‐

3 Contact Service.

“diag” button.

tem components

the power supply and reconnect one at a time.

tion unit to the SR-unit resp. terminal box.

Replace the last component connected, contact Service.

ics board module.

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10 TROUBLESHOOTING

Error indication Possible cause Action

Display output: Corrupt Parameters: Reset Memory

10.4.1 Communication fault between evaluation unit and receiver

Inconsistent data detected in parameter memory 1 Press Enter.

2 If necessary, reconfigure the parameters.

3 Exchange the evaluation unit. 4 Contact SICK Service.

Error message: "Sensor Communication"

The receiver sends data continually to the evaluation unit, an error message is gener‐ ated automatically when no data is received there.

Check following connections:

1 Evaluation unit -> receiver. 2 Cable connection on the plug-in terminal in the evaluation unit. 3 Cable to receiver. 4 Outer plug-in connector on receiver. 5 Inner plug-in connector in receiver.

A system restart is carried out. This resets the parameters to the factory settings.

If the error message appears again:

10.5

Ex operation malfunction

An Ex control device malfunction causes an alarm signal to be displayed for the GM700 Ex Category 3G. There is no automatic switch-off.

Possible cause Action

Protective gas feed interrupted Check protective gas feed

Enclosure of sender/receiver unit or enclosure of evaluation unit is leaky

Check screw fittings and seals

NOTE

Clearing pressurized enclosure malfunctions, see Manual FS840 and purge medium valve.

10.6 Error messages

10.6.1 Error messages

WARNING Risk of explosion

Some of the work described in this Chapter assumes an Ex free zone.

Wait 20 minutes after switching off the main power supply before opening the enclosure.

Table 22: Error Table: Malfunction message

Error message Description Possible cause/clearance

System

DSP: BOOT ERROR DSP…Digital Signal Processor

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Error during start process

b X Observe safety information for Ex-free zone!

Restart device.

– Press maint button to activate mainte‐

nance. – Trigger menu Reset System or – switch device off and on again. If not successful, contact Service.

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TROUBLESHOOTING 10

Error message Description Possible cause/clearance

DSP: INV PARA Incompatible software (SR-unit)

Invalid values entered.

DSP: NO RESP Electronics communication problem (SR-unit).

EEPROM: CONTROL Invalid microcontroller parameters (SR-unit).

EEPROM: LASER Invalid laser parameters.

FIT: DIV BY 0 Error during signal evaluation:

Incorrect parameter values.

•

Hardware defect.

•

FIT: NO CONV Error during signal evaluation:

Incorrect parameter values.

•

Hardware defect.

•

FIT: S MATRIX Error during signal evaluation:

Incorrect parameter values.

•

Hardware defect.

•

Incompatible device Incompatible software (SR-unit).

INIT: NO LINE Incompatible software (SR-unit).

LD: PELT ERROR LD…laser diode

LD: TEMP ERROR Laser wavelength adjustment outside allowed range.

MEAS: M PLAUS Measuring results from measuring channel not plausi‐

MEAS: R PLAUS Measuring results from measuring channel not plausi‐

MEAS: REF CONC (only for device with closed cell)

Sensor communication SR-unit not connected correctly.

SIG: DARK VALUE Dark values of receiver element too high:

SIG: K HIGH Monitoring channel signal too high.

SIG: K LOW Monitoring channel signal too low.

SIG: M HIGH Measuring channel signal too high.

Temperature measurement on Peltier element defec‐ tive:

Possible hardware defect.

Absorption line “lost”.

Laser diode defective.

ble:

Incorrect parameter values.

Strong signal interference.

Hardware defect.

ble:

Incorrect parameter values.

Strong signal interference.

Hardware defect.

Gas concentration in reference cell too low.

Possible hardware defect.

Check software version; contact Service if neces‐

sary. Correct erroneous values.

Restart device; see above.

If not successful, contact Service.

Restart device; see above.

If not successful, contact Service.

Restart device; see above.

If not successful, contact Service.

Check measuring distance, substitute for tem‐

perature and pressure parameters, correct when necessary. Restart device; see above.

If not successful, contact Service.

Check measuring distance, substitute for tem‐

perature and pressure parameters. Increase Average parameter

a Attention, these parameters may only be mod‐

ified by trained personnel. Restart device; see above.

If not successful, contact Service.

Check measuring distance, substitute for tem‐

perature and pressure parameters, correct when necessary. Restart device; see above.

If not successful, contact Service.

Check software version.

Contact Service.

Restart device; see above.

If not successful, contact Service.

Restart device; see above.

If not successful, contact Service.

Restart device; see above.

If not successful, contact Service.

Check measuring distance, substitute for tem‐

perature and pressure parameters. Increase Average parameter.

a Attention, these parameters may only be mod‐

ified by trained personnel. Restart device; see above.

If not successful, contact Service.

Restart device; see above.

If not successful, contact Service.

b X Observe safety information for Ex-free zone!

Exchange reference cell.

Contact Service.

Check CAN connection and repair if necessary.

Contact Service.

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10 TROUBLESHOOTING

Error message Description Possible cause/clearance

SIG: M LOW Measuring channel signal too low:

Optical interfaces (front window) of SR-unit or

reflector contaminated. Optical axes alignment too inaccurate.

Hardware defect.

SIG: R HIGH Reference channel signal too high.

SIG: R LOW Reference channel signal too low.

Zero gas measurement for NH

Z MEAS: RANGE Unallowed results during zero gas measurement:

Zero gas missing.

Optical interfaces (front window) of SR-unit or

reflector contaminated. Optical axes alignment too inaccurate.

Sensor Communica‐ tion???

Communication fault between evaluation unit and GM700 SR-unit

Clean front window, chapter 9.7.

Check optical alignment and correct if necessary,

chapter 7.9.

If not successful, contact Service.

Contact Service.

Check zero gas supply and repair if necessary.

Clean front window, chapter 9.7.

Check optical alignment and correct if necessary,

chapter 7.9.

Check connections:

b X Observe safety information for Ex-free zone!

Evaluation unit - SR-unit.

Lines to SR-unit.

Outer plug-in connectors on SR-unit.

Inner plug-in connectors in SR-unit.

NOTE

This Table also contains recommended solutions that can only be performed by specially trained personnel.

10.6.2 Warning messages

WARNING Risk of explosion

Some of the work described in this Chapter assumes an Ex free zone.

Wait 20 minutes after switching off the main power supply before opening the enclosure.

Table 23: Warning messages

Warning message Description Possible cause / clearance

Feed Test Gas No detectable sample gas concentration (see Interval).

FIT: LINEPOS Deviation of absorption line position:

Line during start process not aligned properly.

MEAS: REF CONC (only for device with closed cell)

DEV: TEMP Optic of SR-unit out of allowed temperature range:

Gas concentration in reference cell too low; measure‐ ment still possible.

Warm-up phase after switching on.

Ambient temperature too high.

Feed span gas. (GMK)

Wait until the warning message disappears after

a few minutes. Restart device

– Activate Maintenance mode with maint

button. – Trigger menu item Reset System or – switch device off and on again. If not successful, contact Service.

Plan and prepare reference cell replacement.

Wait until the temperature has stabilized.

Select different ambient temperature range.

Cool device.

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10.7 Repairing inadequate purge air supply

WARNING Risk of explosion

Some of the work described in this Chapter assumes an Ex free zone.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

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.

Indications of insufficient purge air supply

Unusual noises from the area of the purge air supply

•

On systems with pressure difference sensor: An appropriate error message occurs

•

Rise in enclosure temperature

•

Unusually rapid contamination of the window of the measuring device

•

TROUBLESHOOTING 10

Information for fast correction of faults

Air filter of purge air unit clogged?

•

Purge air hose slipped off or broken?

•

Power supply of the purge air unit failed?

•

Check the purge air unit

Pull the purge air hose on the sender/receiver unit: A strong air flow must be

noticeable. Reinstall the purge air hose immediately.

Measures for insufficient purge air supply

If the purge air unit is not immediately functional:

•

For a short malfunction:

•

Bring the purge air unit back to correct operation immediately.

•

Replace provisionally with a different purge air supply with at least the same purge

•

air throughput.

10.8 Corrosion on flange

Table 24: Corrosion on flange

Possible errors Possible causes Action

Corrosion on flange.

Remove SR-unit and measuring probe from the gas duct.

Swiveling the SR-unit out is sufficient

Unsuitable materials

Check project planning.

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11 DECOMMISSIONING

11 Decommissioning

11.1 Safety information for decommissioning

WARNING Risk of explosion

Some of the work described in this Chapter assumes an Ex free zone.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

Technical knowledge needed / requirements for decommissioning

NOTICE

You are basically familiar with the GM700.

•

You are well versed in the ATEX Directives.

•

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.

Risk of explosion

DANGER Risk of explosion through residual voltages and hot surfaces in the device

When the device is switched off, residual voltages and hot surfaces represent an increased risk of explosion when the device is open.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

Gas

WARNING Risk to health through contact with protective gas

Residual amounts of protective gas could emerge uncontrolled when the device is opened directly after switching off. This means that the device represents an increased health risk and a risk of suffocation when using inert protective gases.

Wait 20 minutes after switching off the main power supply before opening the

enclosure.

DANGER Hazard through gas escaping when the sender/receiver unit is swiveled out

Overpressure in the gas duct can cause hot and/or noxious gases to escape when the sender/receiver unit is swiveled out.

Swivel the sender/receiver unit out only when you have taken suitable safety mea‐

sures. Set the lever on the purge air fixture to the “Close” position".

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DECOMMISSIONING 11

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.

Electricity

Observe all safety information in Chapters Commissioning and Electrical installation.

see "Safety information on commissioning", page 47 and see "Electrical installation safety information", page 34.

Device damage

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 measuring device is still in the gas duct.

Do not switch the purge air unit off as long as the measuring device is still in the

gas duct.

11.2 Decommissioning Ex-relevant subassemblies

1 Disconnect the GM700 Ex from the main power supply. 2 Wait 20 minutes before opening the device. 3 Disconnect the Ex control unit from the power.

NOTE

The analyzer can remain on the gas duct as long as the purge air supply is in oper‐ ation.

CAUTION Device damaged caused by unnoticed purge air failure

After the GM700 Ex has been disconnected from the power, there is no message via the analyzer for a purge air failure.

Install suitable monitoring

or remove the respective subassemblies.

11.3 Removing the device

Material required Part number Required for

Flange cover -- Covering the flange

Personal protective equipment -- Protection when working on the stack or hot or

aggressive sample gases

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11 DECOMMISSIONING

Removing the measuring system

1 Disconnect all connection lines between connection unit and SR-unit and/or

reflector unit.

2 Remove the SR-unit and/or reflector unit, see "Removing the sender/receiver

unit", page 71.

CAUTION

■

Observe the information concerning removal of the SR-unit, see "Removing

the sender/receiver unit", page 71.

3 When necessary, unscrew and remove device flanges. 4 When necessary, unscrew and remove purge air fixtures on the flanges. 5 Switch purge air supply off and remove purge air hoses on device flanges. 6 Close the flanges on the gas duct with a lid.

Information on storage, see "Storage", page 25.

11.4 Preparing the device ready for shipping

Before shipping:

Contact your local SICK representative. The addresses are on the back cover of

the Operating Instructions. Your SICK representative can advise you whether the defective device can be

repaired locally or whether it would more advantageous for you to return the device for repair. Observe the following when returning the device to SICK:

Flat rates for repairs (concerning duration and costs)

Safety protection for the transport

Replacement devices or putting the device back into operation by SICK Ser‐

vice

NOTICE Correct device preparation for return delivery

Clean all device components.

Use the original packaging for the transport.

Complete the Non-Risk Declaration (NRD) and lay these clearly visible in the pack‐

aging.

Without the Non-Risk Declaration, the device will either be cleaned by a third-party com‐ pany at the customer's expense or the package will not be accepted.

Clean the device before returning

Prerequisite: Switch device free from voltage.

Clean surfaces and parts with media contact:

Remove loose contamination with compressed air.

Remove adhering contamination with a mild soap solution and a soft cloth.

NOTICE

Close the enclosure before cleaning so that no fluid can penetrate.

Clean optical surfaces, see "Cleaning the optical interfaces", page 73.

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11.5 Environmentally compatible disposal

The device should be disposed as industrial waste.

NOTICE

Observe relevant local conditions for disposal of industrial waste.

WARNING Disposal of subassemblies containing residual substances which are harmful to the environment

The following subassemblies could contain substances that have to be disposed of sep‐ arately:

Electronics: Capacitors, rechargeable batteries, batteries

•

Display: Liquid of LC-Display

•

DECOMMISSIONING 11

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12 TECHNICAL DATA

12 Technical data

12.1 System: GM700 Ex version 3G / zone 2

Measured variable NH3, NH3 / H2O

Measuring principle Diode laser Spectroscopy (TDLS)

Measuring path length 0.25 ... 1.5 m, depending on the application

Measuring ranges

Response time 1 s ... 360 s, adjustable

Precision

Process gas pressure Max. 1,100 mbar absolute

Process gas temperature –20 °C ... +250 °C, depending on device version

Ambient temperature –20 °C … +50 °C, depending on device configuration, see

Storage temperature -20 °C … +50 °C

Ambient humidity ≤ 85 % relative humidity; non-condensing

Conformities CE

Directives / Standards 2014/34/EU ATEX

Ex certifications

Control functions

•

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

•

"Ambient temperature ranges", page 99; temperature

change maximum ±10 °C/h

•

2014/30/EU EMC

•

2014/35/EU Low Voltage Directive

•

NH3: 0 ... 25 ppm / 0 ... 4,000 ppm H2O: 0 ... 5 ppm / 0 ... 40 Vol%

Zero point : ≤ ± 2 %, relative to upper measuring range value Sensitivity: ≤ ± 2 %, in maintenance interval (6 months), relative to upper measuring range value

EN 60079-0:2012 EN 60079-2:2014 EN 60079-11:2012 EN 60079-28:2015

EN 61326-1:2013 Emission and Immunity; Industrial Environment (Class A)

EN 61010-1:2010

Connection unit and sender/receiver unit: 3G / Zone 2 Process gas: Ex-free ATEX : X II 3/-G Ex pzc op is [ia] IIC T4 Gc/-

Automatic check cycle for zero and span point

12.2 Sender/receiver unit

Table 25: Technical data GM700 sender/receiver unit

Description Analyzer unit of measuring system

Degree of protection IP 65

Dimensions (W x H x D) 239 mm x 401 mm x 338 mm

Weight 14 kg

Power supply Supply via evaluation unit: 24 V DC

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TECHNICAL DATA 12

Connections for auxiliary sub‐ stances

12.3 Measuring probe

Open measuring probe (GMP)

Description Measuring probe in open design with integrated purge air

Process temperature -20 °C ... +250 °C

Process pressure Depending on purge air supply

Process gas moisture Non-condensing

Degree of protection IP65

Weight 25 kg

Dimensions (W x H x D) See dimension drawings.

Components fitted

Material, media contact Stainless steel 1.4571, optional: Stainless steel 1.4539

Connections for auxiliary sub‐ stances

Test gas: Swagelok 1/4″

•

Purge gas: Swagelok 1/4″

•

control system.

Flange fixture with connections for purge air and purge

•

air monitoring Flow monitor (purge air feed monitoring)

•

Purge air

12.4 Evaluation unit Ex version I/O module

Description Serves to connect the power supply and the data and signal

Degree of protection

Analog outputs 3 outputs:

Analog inputs 2 inputs:

Digital outputs 3 relay contacts:

Digital inputs 3 inputs:

Interfaces and bus protocol

RS-232 Proprietary Service interface

Display LC-Display

Input Arrow buttons

Material Sheet steel enclosure

Dimensions (W x H x D)

Weight ≤ 16 kg

Power supply

cables at the customer location.

IP 65

•

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

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

48 V AC, 1 A, 60 W / 48 V DC, 1 A, 30 W

24 V

Status LEDs:"Operation", "Service", "Warning" and "Malfunc‐ tion"

Evaluation unit: 300 mm x 483 mm x 138 mm

•

Pressurized enclosure FS840: 129 mm x 122 mm x

•

120 mm

Voltage: 230 V

•

Frequency: 50 Hz

•

Power input: ≤ 75 VA

•

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12 TECHNICAL DATA

12.5 Technical data for pressurized enclosure system

12.5.1 Technical data energy supply

Voltage 230 V

Frequency 50 Hz

12.5.2 Limit values for terminal assignment FS840

Terminal Voltage Current Output Remark

1, 2 Um = 250 V AC Im = 5 A at AC1 Pm= 1500 VA Signal contact 1

Um = 250 V AC Im = 1.2 A at AC15 Pm= 300 VA

Um = 30 V DC Im = 5 A at DC1 Pm= 150 W

3, 4 Um = 250 V AC Im = 5 A at AC1 Pm= 1500 VA Signal contact 2

Um = 250 V AC Im = 1.2 A at AC15 Pm= 300 W

Um = 30 V DC Im = 4 A at DC1 Pm= 150 W

5, 6 Connection for

7/8, 9/10 Um = 250 V AC Power supply

purge medium valve

12.5.3 Technical data for Protective gas

Protective gas

Protective gas Instrument air or inert gas in accordance with ISO8573-1

Connections

Inlet

•

Outlet

•

Consumption

•

Inlet temperature -20 ... +50 °C (-4 ... +122 °F)

Primary pressure

Max.:

•

Min.:

•

12.5.4 Technical data for enclosure

Free volume: 33 l (2014 in3)

Minimum overpressure:

Maximum overpressure: 1,800 Pa (18 mbar) (0.26 psi) (relative)

Solid particles: Class 1 Water: Class 3 (pressure dew point-20 °C) Oil content: Class 1 (≤0.01 mg/m3)

Thread G 3/8" or hose connection for 8 mm diameter

Thread G 1"

Typ. 0.2 l/min

2,500 hPa (2.5 bar) (36 psi) (relative)

2,000 hPa (2 bar) (30 psi) (relative)

80 Pa (0.8 mbar) (0.012 psi) (relative)

Pre-purging during commissioning

Typical pre-purge time: Approx. 6 minutes

12.5.5 Pressurized enclosure system settings

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TECHNICAL DATA 12

WARNING Risk of explosion through incorrect parameter settings

Incorrect parameter setting can cause an explosion with fatal consequences.

Only authorized persons are allowed to change the parameters.

Enclosure pressurization system used: Gönnheimer FS840 for use in Ex zone 2.

FS840 parameters Setting

Valve control Digital valve

Operating mode Constant purge flow

Purge volume, pre-purge 165 l (10 068 in3)

Nominal purge pressure 10 mbar (0.145 psi) (relative)

Minimum pressure in enclosure 0.8 mbar (0.012 psi) (relative)

Maximum pressure in enclo‐ sure

Nominal pressure in enclosure 2 mbar (0.03 psi) (relative)

Signal pressure 1.5 mbar (0.022 psi) (relative)

18 mbar (0.26 psi) (relative)

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Ø 239 (9.41)

188 (7.40)

45°

Ø 200

(7.87)

136.8 (5.39)

401 (15.79)

338 (13.31) 45

(1.77)

M12

R = 305.3

(12.02)

79.7 (3.14)

305 (12.01)

(1.30)

≤ 90°

228.6 (9.00)

Ø 8 mm or G⅜″

TECHNICAL DATA

12.6 Dimension drawings: Sender/receiver unit

Figure 37: GM700 Ex 3G sender/receiver unit (all dimensions in mm)

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12.7 Dimension drawings: Open measuring probe (GMP)

Ø 200

Ø 40

Ø 14

360

233,2

176,9

144

45°

Ø 254

Ø 200

Ø 18

Ø 215,8

45°

L2 L3

Ø 114,3

227

76,4

TECHNICAL DATA 12

Figure 38: GMP measuring probe (all dimensions in mm)

GMP measuring probes Measuring gap L3 (active measuring path)

250 500 750 1.000 1.250 1.750

Probe length,

L1 L2

nominal

900 935 296 46 -- -- -- --

1.500 1.644 1.004,5 754,5 504,5 254,5 -- --

2.000 2.128 1.489 1.239 989 739 489 --

All dimensions in mm

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550 (21.65)

470 (18.50)40 (1.57)

650 (25.59)

570 (22.44)

31 (1.22)

40 (1.57)

287 (11.30)

Ø 10 (0.39)

Ø 40 (1.57)

43 (1.69)200 (7.87)

12 TECHNICAL DATA

12.8 Dimension drawing, purge air unit

Figure 39: Dimensions, purge air unit (all dimensions in mm (inch))

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146.8 (5.78)

26.8 (1.06)

80.8 (3.18)

107.8 (4.24)

171 (6.73)

41 (1.61)

88.6 (3.49)

143.9 (5.67)

64.7 (2.55)

339.8 (13.38)

384.8 (15.15)

429.3 (16.90)

224.4 (8.83)

259.7 (10.22)

300 (11.81)

200 (7.87)

260 (10.24)129.3 (5.09) 20 (0.79)

435 (17.13)

483.5 (19.04)

15 (0.59)

24 (0.94)

122 (4.80)267.7 (10.54)

Ø 8 (0.31)

Ø 8

(0.31)

M20

M16 M16 M16 M16M20

M16M16

M16

Ø 240

Ø 178

Ø 125

Ø 133

240 / 500 / 1.000

3,6 – 4,0

Ø 200

Ø 18

45°

TECHNICAL DATA 12

12.9 Dimension drawings, evaluation unit with pressurized enclosure system FS840

12.10

Figure 40: Evaluation unit (all dimensions in mm)

Dimension drawings: Mounting flange DN125

Figure 41: Mounting flange DN125 (all specifications in mm)

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576,3 525,8

25,2

507,8

297

240

636,4

12 TECHNICAL DATA

12.11 Dimension drawing, weatherproof cover, sender/receiver unit

Weatherproof cover for sender/receiver unit

Figure 42: Weatherproof cover for sender/receiver unit (all specifications in mm)

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13 Annex

13.1 Conformities

Table 26: Ex-relevant directives and standards

ANNEX 13

Directive Harmonized standard Application

2014/34/EU ATEX EN 60079-0:2012 General requirements

EN 60079-2:2014 Pressurized enclosure Ex-p

EN 60079-11:2012 Protection through intrinsic safety

Ex i

EN 60079-28:2015 Optical radiation

2014/30/EU EMC EN 61326-1:2013 Emission

and Immunity; Industrial Envi‐ ronment (Class A)

2014/35/EU Low Voltage Directive

EN 61010-1:2010 Safety requirements for electrical

EN 60529:1991+ A1:2000 + A2:2013

EMC for electrical measuring devices

equipment for measurement, con‐ trol, and laboratory use

Degrees of protection provided by enclosures (IP code)

13.2 Electrical protection

Device corresponds to protection class 1 and requires a protective grounding (PE)

•

in accordance with EN 61140 Overvoltage protection in accordance with EN 61010-1

•

Contamination: The control unit operates safely in an environment up to contami‐

•

nation level 2 in accordance with EN 61010-1 (usual, non-conductive contamina‐ tion and temporary conductivity by occasional moisture condensation)

13.3 Ex certifications

3G / Zone 2: Connection unit and sender/receiver unit

X II 3/-G Ex pzc op is [ia] IIC T4 Gc/-

•

Special conditions (X identification)

A measuring function for explosion protection is not part of the EC type approval

•

13.4 Possible ambient temperatures

13.4.1 Ambient temperature ranges

Table 27: Possible ambient temperature ranges

Possible ambient temperature ranges

Degrees Centigrade (°C) Kelvin (K) Degrees Fahrenheit (°F)

–40 … 10

–30 … 20

–20 ... 30 253 ... 303 –4 ... 86

–10 ... 40 263 ... 313 14 ... 104

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233 … 283 –40 … 50

243 ... 293 –22 ... 68

Page 100

13 ANNEX

Possible ambient temperature ranges

0 ... 50 273 ... 323 32 ... 122

X Attention: These ranges may not be used for Ex applications!

100

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SICK GM700 Ex Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

O P E R A T I N G I N S T R U C T I O N S

Contents

1 About this document

1.1 Function of this document

1.2 Scope of application

1.3 Target groups (and document structure)

1.4 Further information

1.5 Data integrity

1.6 Symbols and document conventions

1.6.1 Warning symbols

1.6.2 Warning levels / Signal words

1.6.3 Information symbols

2 SAFETY INFORMATION

2.1 Main operating information

2.2 Warning information on the device

2.3 Intended use

2.3.1 Purpose of the device

2.4 Responsibility of user

3 PRODUCT DESCRIPTION

3.1 Product identification

3.2 Product characteristics

3.3 Type plate

3.4 Device variants

3.5 Pressure and temperature sensor

3.6 Options

3.7 Layout and function

3.7.1 Function of the pressurized enclosure

3.8 Purge air unit

3.9 Check cycle

3.10 Explosion protection in accordance with ATEX

3.10.1 Operation in potentially explosive atmosphere

3.10.2 Zone of use GM700 Ex 3G components

3.10.3 Pressurized enclosure system

3.10.3.1 Safety functions

3.11 Sender/receiver unit - evaluation unit connecting hose

3.12 GMP measuring probe in detail

4 TRANSPORT AND STORAGE

4.1 Transport protection

4.2 Storage

5 MOUNTING

5.1 Information on installation in potentially explosive atmospheres

5.2 Tools required

5.3 Material required

5.4 Preparing the sampling point

5.5 GM700 Ex scope of delivery

5.6 Installation sequence

5.6.1 Installation example

5.6.2 Overview of installation steps (duct-side preparation)

5.6.3 Installing the flange with tube

5.6.4 Install the evaluation unit

5.6.4.1 Install the FS840

5.6.5 Installing the purge air unit

6 ELECTRICAL INSTALLATION

6.1 Electrical installation safety information

6.2 Connection overview

6.2.1 Lines

6.3 Connecting interfaces

6.3.1 Connect I/O interfaces

6.3.1.1 GM700 Ex 3G terminal connection diagram

6.3.1.2 Electrical connection of the evaluation unit EvU

6.4 Connecting the connecting hose to the SR-unit on the EvU

6.5 Connecting pressure, temperature and purge air monitor

6.6 Preparing the power supply

6.7 Connecting the FS840 Ex overpressure control

6.8 Electrical connection of SR-unit

6.9 Connecting the potential equalization

6.9.1 Connecting the potential equalization on the SR-unit

6.9.2 Connecting the potential equalization on the measuring probe

6.9.3 Potential equalization - evaluation unit and Ex control unit

7 Commissioning

7.1 Safety information on commissioning

7.2 Prerequisites for successful commissioning

7.3 Material required

7.4 Overview of commissioning steps

7.5 Zero adjust

Fitting the SR-unit on the measuring probe.