SICK GM700 Ex Operating Instructions Manual
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
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.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
CONTENTS
1 About this document........................................................................ 7
1.1 Function of this document....................................................................... 7
1.2 Scope of application................................................................................. 7
1.3 Target groups (and document structure)................................................. 7
1.4 Further information................................................................................... 7
1.5 Data integrity............................................................................................. 7
1.6 Symbols and document conventions...................................................... 8
1.6.1 Warning symbols...................................................................... 8
1.6.2 Warning levels / Signal words................................................. 8
1.6.3 Information symbols................................................................ 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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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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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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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.
b
1.5 Data integrity
SICK AG uses standardized data interfaces such as, for example, standard IP technol‐
ogy, in its products. The focus here is on product availability and features.
SICK AG always assumes that the customer is responsible for the integrity and confi‐
dentiality of data and rights involved in connection with using the products.
In all cases, the customer is responsible for the implementation of safety measures
suitable for the respective situation, e.g., network separation, firewalls, virus protection
and patch management.
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1 ABOUT THIS DOCUMENT
1.6 Symbols and document conventions
1.6.1 Warning symbols
Table 1: Warning symbols
Symbol 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.
b
WARNING
Injury risk through incorrect lifting and carrying of the device
Injuries can occur due to the weight and projecting enclosure parts when the equip‐
ment tips over or drops.
Consider the device weight before lifting.
b
Observe the regulations for protective clothing (e.g., safety shoes, non-slip gloves).
b
Grip underneath the equipment when possible to carry it safely.
b
Do not use projecting parts on the device to carry the device.
b
Call in further personnel for assistance as required.
b
Use a hoist or transport equipment as an option.
b
Pay attention to the transport safety device.
b
Clear obstacles that could cause falls and collisions out of the way.
b
DANGER
Risk for system safety through work on the device not described in these Operating
Instructions
Carrying out work on the device not described in these Operating Instructions or associ‐
ated documents can lead to unsafe operation of the measuring system and therefore
endanger plant safety.
Only carry out the work on the device described in these Operating Instructions
b
and associated documents.
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.
b
Laser protection class 1: Wear laser protection glasses despite low radiation.
b
Observe national valid limit values and standards that refer to these for industrial
b
safety.
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‐
b
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
b
their technical training and knowledge as well as knowledge of the relevant regula‐
tions, can assess the tasks given and recognize the hazards involved.
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
b
power isolating switch/circuit breaker in accordance with DIN EN 61010.
Make sure the power isolating switch is easily accessible.
b
An additional separation device is mandatory when the power isolating switch can‐
b
not be accessed or only with difficulty after installation of the device connection.
The power supply may only be switched on again after work completion or for test
b
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.
b
b
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.
b
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
b
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
1
3
4
2 SAFETY INFORMATION
GM 700 Ex evaluation unit
Figure 3: Warning information on the EvU GMA700 front and right sides
1
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).
w
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.
b
Observe all safety instructions.
b
If anything is not clear: Please contact SICK Customer Service.
b
Document retention
These Operating Instructions:
Must be kept for reference.
b
Must be passed on to new owners.
b
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01
02
03
04 05
06
07
01
02
03
04 05
06
07
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
1
8
9
5
3
2
ß
4
6
7
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.
NH
3
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
1
Evaluation unit GM700-035xEX3G
2
Ex-p control FS840
3
Metallic connecting hose between sender/receiver unit and evaluation unit
4
Digital purge medium valve, 230 V, G3/8", 2 mm, Ex-p
5
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3 PRODUCT DESCRIPTION
Purge air fixture (without electronics)
6
GMP measuring probe (without electronics)
7
Temperature and pressure measurement
8
Purge air supply
9
Pressure switch for purge air monitoring
ß
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
18
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
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!
w
Location of Ex relevant subassemblies, see Chapter “Design
and Function”.
w
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.
w
Adhere to the maintenance intervals, see Chapter “Mainte‐
nance plan”.
w
After switching off the main power supply: Wait 20 minutes
before opening the enclosure.
20
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3.10.2 Zone of use GM700 Ex 3G components
DI/DO/
AI/AO
230 /
115 V
ß
à
GM700
Ex ATEX 3G
á
Ex p
[op is]
p/t
Ex ia
Ex m
6
Ex p/ Ex i
Ex na
nc
8
5
1
3
4
â
Non Ex
ã ä
æ
9
å
DIV 1
DIV 2
Non Ex
1G
2G
Non Ex3GNon ExZone 2Zone 1
Zone 0
2
7
PRODUCT DESCRIPTION 3
Figure 5: Zone of use GM700 Ex 3G components
Components
Control station / measuring station
1
Sender/receiver unit
2
Measuring beam
3
Ex-p valve
4
Evaluation unit
5
Overpressure control
6
8
7
9
ß
à
á
â
ã
ä
å
æ
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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21
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.
b
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:
22
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
3
2
open Close
4
6
1
5
PRODUCT DESCRIPTION 3
Figure 6: GMP measuring probe description
Reflector
1
Measuring gap: Exposed measuring path
2
Purge air outlet: Air outlet in the duct 90° to gas flow direction (directed purge air)
3
Lever (locking device of the opening to sample gas)
4
Differential pressure sensor for purge air
5
Lever and locking device in “open” position
6
NOTE
Further characteristics of the GMP measuring probe, see "Measuring probe", page 91
and page 95.
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3
1
2
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.
24
Figure 7: Transport safety device on the SR-unit
Remove the front cover of the sender/receiver unit
1
Figure 8: Transport safety device on the GMP measuring probe
2 plastic protective caps to cover the optics
1
Remove the protective stickers
2
Set the locking device to the "close" position
3
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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.
b
Wear the specified protective clothing for all work with a contaminated measuring
b
probe.
Clean all components of the measuring system with slightly damp cleaning cloths.
b
Use a mild cleaning agent here.
Protect the openings of the sender/receiver-unit and measuring probe from atmos‐
b
pheric influences, preferably with the original transport safety devices.
Pack all components for storage or transport. Preferably use the original packing.
b
Store all components of the measuring system in a dry, clean room.
b
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5 MOUNTING
5 Mounting
5.1 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
b
planning/assembly.
When necessary, ensure adequate ventilation or cooling.
b
Correct installation
DANGER
Risk for system safety through work on the device not described in these Operating
Instructions
Carrying out work on the device not described in these Operating Instructions or associ‐
ated documents can lead to unsafe operation of the measuring system and therefore
endanger plant safety.
Only carry out the work on the device described in these Operating Instructions
b
and associated documents.
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
26
Local work safety regulations must be observed
•
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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.
b
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.
b
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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27
1
2
4
6
3
5
7
8
à
ä
9
ß
á
â
ã
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
b
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
1
GM700 Ex sender/receiver unit
2
GMP measuring probe
3
Purge air unit
4
Pressure and temperature sensor (installation location according to project planning)
5
Ex-p control FS840
6
Dimensions
Max. distance SR-unit -EvU: 4 m, 8 m, depending on hose length
7
Duct wall - SR-unit: depending on flange with tube length + measuring probe length
8
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Minimum clearance (center) - working platform: 1300 - 1500 mm
9
Min. flange length in gas duct: 20 mm
ß
Flange with tube length: Standard 240 mm
à
Minimum clearance flange (center) to purge air supply: > 700 mm
á
Vertical clearance fastening drill holes - purge air supply assembly plate: 470 mm
â
Horizontal clearance fastening drill holes - purge air supply assembly plate: 470 mm
ã
Miscellaneous
Working platform
ä
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.
b
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
b
their technical training and knowledge as well as knowledge of the relevant regula‐
tions, can assess the tasks given and recognize the hazards involved.
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
b
or
the plant operator determines the safety measures to be observed during work on
b
the plant when switched on based on an evaluation of the danger involved.
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29
1
200
18
4
5
°
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
b
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”
1
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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