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

GM32-Ex

In-situ Gas Analyzer, Probe Version

Installation, Operation, Maintenance

Summary of Contents for GM32 EX

Page 1: ...O P E R A T I N G I N S T R U C T I O N S GM32 Ex In situ Gas Analyzer Probe Version Installation Operation Maintenance...

Page 2: ...ent or parts of this document is only permissible within the limits of the legal determination of Copyright Law Any modifica tion shortening or translation of this document is prohibited without the e...

Page 3: ...ntification 16 3 2 Product characteristics 16 3 2 1 Device versions 16 3 2 2 Device variants 17 3 2 3 Options 17 3 3 SOPAS ET PC program 17 3 4 Reference cycle 18 3 5 Check cycle 18 3 6 Layout and fun...

Page 4: ...efault values for interfaces 42 6 4 Electrical connection of SR unit 44 6 5 Connecting the potential equalization 44 6 6 Connecting the potential equalization to the SR unit 45 6 7 Connecting the conn...

Page 5: ...ed enclosure system 75 9 5 Swiveling out and removing the SR unit 75 9 6 Visual inspection 76 9 7 Cleaning the window 77 9 8 Check replace the desiccant cartridge 78 9 9 Replacing the activated charco...

Page 6: ...r receiver unit Ex version 103 12 7 Dimension drawings Open measuring probe GMP 104 12 8 Dimension drawings Connection unit Version 2G 105 12 9 Dimension drawings Mounting flange DN125 105 12 10 Weath...

Page 7: ...ning 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 may be required at certai...

Page 8: ...mbols Symbol Significance Hazard general Hazard by voltage Hazard in potentially explosive atmospheres Hazard by explosive substances mixtures Hazard by toxic substances Hazard by unhealthy substances...

Page 9: ...eral Information on product condition with regard to Explosion Protection Direc tive ATEX 2014 34 EU Important technical information for this product Important information on electrical or electronic...

Page 10: ...when the SR unit is swiveled out Overpressure in the gas duct can cause hot and or noxious gases to escape when the SR unit is swiveled out b Swivel the SR unit out only when you have taken suitable s...

Page 11: ...rted the SR unit can drop when swiveled out b Check that the hinge pin is completely pressed down before the SR unit is swiv eled out CAUTION Damage when device is dropped Its weight and size make the...

Page 12: ...afety of a system The person setting the system up is responsible for the safety of the system in which the device is integrated 2 SAFETY INFORMATION 12 O P E R A T I N G I N S T R U C T I O N S GM32...

Page 13: ...it right 5 Type plate GM32 Ex2G 3G 6 Sampling point name optional 7 Danger sign UV light SR unit intermediate enclosure 8 Type plate GM32 Ex2G 3G 9 Warning sign Hot surface GM32 Ex connection unit 1 2...

Page 14: ...ou are not sure whether the device corre sponds to the state defined during project planning or to the delivered system documentation Correct use b Use the device only as described in Intended use The...

Page 15: ...ptional Technical Information GM32 Operating Instructions of the Ex purge air supply Optional Operating Instructions Modular I O System Final inspection record CD ROM with SOPAS ET For ATEX category 2...

Page 16: ...32 is an in situ measuring system which means measuring is done directly in the gas carrying duct Measuring components SO2 NO NO2 and NH3 device specific as well as the ref erence variables temperatur...

Page 17: ...panel Measured values operational state and malfunction messages are displayed in clear text on a monitor QAL3 Tool CUSUM chart 3 2 3 Options I O modules Analog Out Digital Out Digital In Analog In S...

Page 18: ...rnal zero point reflector is swiveled in time controlled in adjustable intervals The emitted light is reflected back in the sender receiver unit to the detector the zero spec trum is evaluated with th...

Page 19: ...igital input option Signal output during the output Output_control values optional digital output or OPC inter face Output sequence 1 Zero values for 90 s 2 Reference values for 90 s Display of zero a...

Page 20: ...e GM32 Ex Probe version comprises Sender receiver unit Contains optical and electronic subassemblies Function The concentration calculation of the sample gas is performed according to the absorption s...

Page 21: ...r modify any components to or on the device unless described and specified in the official manufac turer information Otherwise the approval for use in potentially explosive atmospheres becomes void w...

Page 22: ...set protective gas feed is activated until the rated pressure is reached again 3 7 1 1 Safety functions for pressurized enclosures GM32 Ex category 3G Malfunction of pressurized enclosure An alarm si...

Page 23: ...rigger an alarm signal when the pressurized enclosure is not in the correct operating state malfunction For GM32 Ex category 2G Ex control unit FS850S switches the main power supply of the GM32 Ex and...

Page 24: ...urge air fixtures Protects the windows of the SR unit from contamination and high gas tempera tures A purge air unit for connection to the SR unit The purge air is blown into the gas duct through the...

Page 25: ...ivel the flange fixture up Check the transport safety device for damage Remove the transport safety devices Removing the transport safety device of the measuring probe 3 Figure 6 Transport safety devi...

Page 26: ...e transport safety devices well protected from humidity and contamination 4 TRANSPORT AND STORAGE 26 O P E R A T I N G I N S T R U C T I O N S GM32 Ex 8015558 YYJ8 V1 7 2016 07 SICK Subject to change...

Page 27: ...damp cleaning cloths A mild cleaning agent can be used b Check the desiccant cartridges and replace if necessary see Check replace the desiccant cartridge page 78 b Protect the openings of the SR unit...

Page 28: ...on and maintenance IEC 60079 19 Equipment repair overhaul and reclamation 5 1 1 Safety of measuring probes suitable for Ex zones DANGER Risk of explosion with a measuring probe not suitable for Ex zon...

Page 29: ...ne the installation location for the con nection unit Observe maximum line lengths Provide the power supply for the connection unit Observe the power requirements page 101 Lay the signal lines Determi...

Page 30: ...ion option 1 Spacing approx 1 5 m 2 Space requirement to open the SR unit 3 SR unit 4 Flange with tube L 240 mm standard 5 Angle max 1 6 Attachment e g 4 steel pipes 50 x 5 mm for purge air unit 5 MOU...

Page 31: ...t depend ing on the plant condition b 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 tion...

Page 32: ...onnection unit for GM32 Ex 1 Connection cable only for version 2G The line lengths to the GM32 sender receiver unit are according to project plan ning b Install the connection unit using the 4 threade...

Page 33: ...It is important that protective gas can flow out of the protective gas outlet against the atmospheric pressure b Ensure the unhindered flow of the protective gas NOTE More information on protective g...

Page 34: ...is can result in inadequate provision with purge air and therefore a device failure b Ensure the purge air pressure is adequate to force the purge air into the gas duct b If you have questions concern...

Page 35: ...s used electrical accidents can occur when the specifi cations are not fully observed b Always observe the exact specifications in the Operating Instructions Technical Data Section when replacing a re...

Page 36: ...off cable inlets vapor proof virtually gas tight b 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 afterwa...

Page 37: ...ection unit From Ex p control unit 7 Connection of marked lines only via Ex relay 8 Connection unit sender receiver unit with connecting hose Order separately 5 m Part No 2057666 10 m Part No 2057667...

Page 38: ...nnection unit sender receiver unit with connecting hose Order separately 5 m Part No 2057666 10 m Part No 2057667 8 Differential pressure sensor connection unit On site 9 Pressure temperature input On...

Page 39: ...device b Lay all I O lines only from to explosion free zone b For category 2G Always use an Ex interface relay 1 Route the data lines through the M screw fittings 2 Connect the data line NOTE Descript...

Page 40: ...Gateway module 7 I O module 8 Ethernet bus 9 Fiber optics connection Connections of temperature sensor 3 wire circuit Pins 1 2 and 3 Connections of pressure sensor Pins 4 and 5 Purge air monitoring o...

Page 41: ...8 Fiber optics connection 9 Connections of temperature sensor 3 wire circuit Pins 1 2 and 3 Connections of pressure sensor Pins 4 and 5 Purge air monitoring of sender probe Pins 6 and 7 Purge air moni...

Page 42: ...3 14 14 24 24 Figure 15 Example I O module pin assignment Analog input Pin assignment Function AI 1 11 12 Temperature internally wired AI 2 21 23 Pressure internally wired AI 3 11 12 Humidity NOTE The...

Page 43: ...signment Function DI 1 11 12 Check_cycle DI 2 21 22 Maintenance DI 3 13 14 Output_control_values DI 4 23 24 Disable_check_cycle DI 5 11 12 1 Purge_air_status DI 6 21 22 1 DI 7 13 14 1 DI 8 23 24 1 1 O...

Page 44: ...unit 1 Plug the three connectors from the connecting hose to the SR unit 2 Push on the cover and screw tight 3 Connect the electric lines from the connection unit to the SR unit 4 For GMP probe Connec...

Page 45: ...d the junction box is part of the pressur ized enclosure It is under overpressure b Protect the connecting hose from possible damage 1 Lead the cable through the 2 M screw fittings see Figure below 2...

Page 46: ...monitor 2 1 3 Figure 20 Connections of pressure temperature and purge air monitor 1 Temperature sensor 2 Pressure sensor 3 Purge air monitoring Pin assignment in connection unit see Connecting I O in...

Page 47: ...nit max power input page 101 Purge air units see Technical Data of purge air unit Mark the disconnecting device as disconnecting device for the GM32 Ex 3 For category 3G w Route the power cable throug...

Page 48: ...N All electrical connections must be connected using Ex approved relays Ex peripheral connection for category 3G 1 2 3 4 1 Ex p valve control line prewired 2 Ex control unit FS850S 3 L1 to terminal 17...

Page 49: ...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 Damage to eyes and skin by U...

Page 50: ...y with difficulty after installation of the device connec tion b The power supply may only be activated again after the end of the work or for test purposes by personnel carrying out the work under co...

Page 51: ...Material required Part No Required for 19 mm open end wrench Aligning the flanges Optical cleaning cloth without detergents 4003353 Cleaning the window Personal protective equipment For protection whe...

Page 52: ...tial equalization to the SR unit page 45 see Connecting the potential equalization page 44 7 Electrical connection of SR unit see Electrical connection of SR unit page 44 8 GMP probe Start up of the p...

Page 53: ...olts on the device flange 2 Pull the sealing ring over the flange of the purge air fixture and hang it loosely over the purge air unit 3 Push the device flange onto the purge air fixture 4 Position th...

Page 54: ...lange to align the probe 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 mus...

Page 55: ...air supply CAUTION Risk of device damage caused by inadequate purge air pressure The purge air supply protects the measuring system from contamination and overheat ing If the purge air pressure is in...

Page 56: ...st accidental switching off to all switching devices where the purge air supply can be switched off 2 6 5 7 4 3 1 Figure 25 Installing the GM32 Ex purge air unit 1 Purge air fixture 2 Hose adapter 3 S...

Page 57: ...st that may have entered the purge air hose 4 Switch the power supply off again Connecting the purge air supply 1 Pull the spiral hose over the hose adapter top and pressure monitor socket bot tom and...

Page 58: ...obe with purge air fixture or flange attachment without SR unit in the flange with tube on the duct side 2 Screw the measuring probe with purge air fixture or flange attachment tight to the flange wit...

Page 59: ...The advantage of installa tion on the left is the unhindered access to the device display when working on the swiveled out flange 2 Insert the hinge pin from above in the hinge NOTICE If the hinge pi...

Page 60: ...escription in SOPAS ET Manual Leave this work to a skilled per son familiar with SOPAS ET With operating unit see Alignment adjust manual optical alignment 7 COMMISSIONING 60 O P E R A T I N G I N S T...

Page 61: ...e upwards and remove it from the cover w Remove the bottom mounting ring w Place installation plate onto the rubber band of the purge air fixture from the top w Position the mounting ring on the side...

Page 62: ...lation plate w Position the cover on the installation plate from the top w Engage the locks and close again 3 4 7 COMMISSIONING 62 O P E R A T I N G I N S T R U C T I O N S GM32 Ex 8015558 YYJ8 V1 7 2...

Page 63: ...55 8 2 Start up procedures for GM32 Ex versions Start up procedure for GM32 category 3G 1 Switch the main power supply of the pressurized enclosure system on at an exter nal source 2 The pressurized...

Page 64: ...e 30 Operating and display elements with example menu 1 Status bar 2 Current menu 3 Current menu index 4 Display of values 5 Current menu branch 6 Significance of function buttons menu dependent 7 Fun...

Page 65: ...the function buttons is shown on the display Display Function Back Return to the higher level menu Press Save to store any changes made Otherwise the changes are lost Diag Diag is shown only when ther...

Page 66: ...22 Back Save 64 1 2 3 41 Figure 31 Menu to set the contrast with setting example 1 Current setting 2 Graphic for current setting 3 Setting range 2 Select until the desired setting is reached 3 Save t...

Page 67: ...see Diagnosis page 68 1 1 4 Check cycle see Check cycle results of last check cycle page 68 1 2 Alignment check see Alignment check option automatic optical alignment check page 69 1 3 Adjustments 1...

Page 68: ...ring malfunctions see Error messages Current According to setting Maintenance request mainte nance request mes sage Irregularities e g gas temperature too high devi ation from check cycle too high tha...

Page 69: ...ue of the assigned analog output 8 3 4 3 Alignment check option automatic optical alignment check This menu serves to view the values of automatic optical alignment NOTICE b Perform this check only wh...

Page 70: ...l point and X Y values are shown on the screen NOTE The focal point is in the center of the crosshair when the following tolerances are shown X 0 05 0 05 Y 0 05 0 05 2 Perform the optical alignment Ad...

Page 71: ...he sender lamp page 80 NOTE Recommendation Start check cycle after each manual alignment and maintenance work 3 The values for the light energy V1 V4 must be in the range 250 500 and approximately hav...

Page 72: ...held MAINTENANCE REQUEST Maintenance Back Maintenance mode activ Stay in Maintenance mode display of held measured value Press the Back but ton Exit Maintenance mode current measured value display Pr...

Page 73: ...rts for the in situ measuring device GM32 Ex have been checked by SICK for ATEX suitability The use of different spare parts and expend able parts increases the risk of an explosion and the ATEX certi...

Page 74: ...nt check page 69 6M Check the pressurized enclosure system see Function test of the pressurized enclo sure system page 75 Protective gas Condition availability pres sures see Checking the protective g...

Page 75: ...closure system is described in the Pressurized Enclosure Manual If work is performed which is not described in this manual the risk of explosion of the measuring system increases and the ATEX certific...

Page 76: ...uick release fasteners of the SR unit 3 Swivel the SR unit out 1 1 Quick release fasteners 2 2 Hinge pin 2 Removing the SR unit b Hold the unit b Pull out the hinge pin b Take the SR unit off 9 6 Visu...

Page 77: ...ng out and removing the SR unit page 75 2 Clean the window with an optical cleaning cloth and demineralized water NOTICE Do not use cleaning agents 3 Close the SR unit again 4 Set the lever on the pur...

Page 78: ...ight blue The desiccant cartridge is dry White Replace the desiccant cartridge 3 Replacing the desiccant cartridge w Unscrew the desiccant cartridge w Screw in the new desiccant cartridge 4 Close the...

Page 79: ...the SR unit page 75 2 Place the SR unit in a clean dry place with little dust 3 Loosen six screws see Figure 4 Take the cover off to the rear 5 Replace the used activated charcoal bag with a new one...

Page 80: ...al connections are established and the power supply is switched on This is also valid for plug connections b Disconnect the GM32 Ex and any connected devices from the voltage supply Preparation work 1...

Page 81: ...r lamp Pull out lamp slightly to the rear 7 Push blue ring on both hose fittings and pull off hose 8 Remove the cap from the new sender lamp 9 Plug in the two tube ends to the hose fittings 10 Plug in...

Page 82: ...urge air unit is not immediately functional b Remove the SR unit from the gas duct swiveling out is sufficient for short time work Cleaning the purge air unit 1 Put the purge air unit out of operation...

Page 83: ...wer cable Then contact service technicians of the manufacturer or correspondingly trained skilled persons to have the device repaired If safe operation of the device is no longer possible w Put the de...

Page 84: ...the device repaired 2 If caused by acute external influence Locate the heat source and protect the device provisionally against heat Unusual noises Inside the device 1 Check malfunction indications a...

Page 85: ...em GM32 Ex category 3G Output of an alarm signal There is no automatic switch off NOTE See Pressurized Enclosure System Manual TROUBLESHOOTING 10 8015558 YYJ8 V1 7 2016 07 SICK O P E R A T I N G I N S...

Page 86: ...st gases used Are setpoint values correct b If the answer to both questions is Yes contact SICK Service to have a calibration performed Analyzer is contaminated b Report to manufacturer s Technical Se...

Page 87: ...ge exceeded b Check the calibration range All measured values blink The lever for the dia phragm is set to closed b Set the lever to open see Installing the SR unit on the device flange page 59 TROUBL...

Page 88: ...ailure 1 1 1 Men Diag Failure Measuring Back 1 1 04 29 01 57 System Mirror adj end 1 3 4 2 1 Message number number of messages 2 Date dd mm time hh mm ss 3 Initiator 4 Error message NOTE All error mes...

Page 89: ...tside the valid range Hardware defect Electronics not adjustable amplification too high Visor no signal Failure All 4Q signals below threshold parameter Check alignment reflector contamination Lamp fa...

Page 90: ...eviation Cycle peak position Maint The check of the position of the peak of the NO cell showed an excess deviation Check limit value parameter setting Defective NO cell Cycle peak width Maint The chec...

Page 91: ...reflector Communication error to optic head and or reflector System Systemstart Xtended This message is entered during each system start Shows when last system start was made Zero adjust Xtended The...

Page 92: ...ended Absorption in active measuring path above warning threshold Standard setting of warning thresh old 1 8 extinction units Check Window dirty see Fenster reinigen Dust content in sample gas too hig...

Page 93: ...uring each system start Shows when last system start was made Zero adjust Xtended The start of an adjustment is recorded in the logbook Shows when last adjustment was made Boxmeasuring Xtended The sta...

Page 94: ...ended Absorption in active measuring path above warning threshold Standard setting of warning thresh old 1 8 extinction units Check Window dirty see Fenster reinigen Dust content in sample gas too hig...

Page 95: ...y Measures if purge air supply is inadequate If the purge air unit is not immediately functional w Remove the SR unit from the gas duct For a short malfunction w Swiveling out the SR unit is sufficien...

Page 96: ...ching off it is possible that residual amounts of protective gas emerge uncontrolled This means that the device represents an increased risk of explosion and when inert protective gases are used a ris...

Page 97: ...work on the open device with the power supply connected is performed Electricity Observe all safety information in the Commissioning and Electrical Installation Sec tions see Electrical installation...

Page 98: ...m the main power supply there will be no message via the analyzer when the purge air supply fails b Install suitable monitoring or b remove the respective subassemblies 11 DECOMMISSIONING 98 O P E R A...

Page 99: ...ay it down 4 Switch the purge air supply off and disconnect the purge air hose on the device flange 5 Close the flanges on the gas duct with a lid Information on storage see Storage page 27 11 4 Envir...

Page 100: ...ested is not T V tested for suitability Response time Open measuring probe GMP 5 s adjustable T V tested for suitability 30 s adjusted Precision NH3 0 7 ppm NO 0 8 ppm NO2 2 5 ppm SO2 0 3 ppm Relative...

Page 101: ...sions W x H x D See dimension drawings Weight Measuring probe 25 kg Purge air fixture 7 kg Material media contact Stainless steel 1 4571 optional Stainless steel 1 4539 Connections for auxiliary mate...

Page 102: ...x 158 mm Weight 16 kg Electrical connection Voltage 100 V 230 V Frequency 50 Hz 60 Hz Power input 260 W 12 5 Electric isolation of evaluation unit Connections SCU I O Relay contact PE 860 V AC Relay c...

Page 103: ...eceiver unit all specifications in mm NOTE The sender receiver unit housing can be swiveled to the left or right of the device flange max 180 105 TECHNICAL DATA 12 8015558 YYJ8 V1 7 2016 07 SICK O P E...

Page 104: ...ring gap L3 active measuring path 250 500 750 1 000 1 250 1 500 1 750 Probe length normal L1 900 935 296 1 500 1 644 1 004 5 754 5 504 5 254 5 2 000 2 128 1 489 1 239 989 739 489 239 2 500 2 628 1 988...

Page 105: ...on unit version 2G all specifications in mm Cable duct of connection unit Cable diameter M16 x 1 5 5 10 mm M20 x 1 5 10 14 mm 12 9 Dimension drawings Mounting flange DN125 240 178 125 133 8 14 240 500...

Page 106: ...nnection for 8 mm diameter Outlet Thread G 1 Consumption Max 0 6 l min Inlet temperature 20 55 C 4 131 F Primary pressure Max 2500 hPa 2 5 bar 36 psi relative Min 2000 hPa 2 bar 30 psi relative 12 11...

Page 107: ...g Valve control Proportional valve P valve Operating mode Leakage compensation purging not continuous Purge amount 500 l 30000 in3 Nominal purge pressure 10 mbar 0 145 psi relative Minimum pressure in...

Page 108: ...ertification of automated measuring systems Part 3 EN60068 Shock and vibration 13 2 Electrical protection Insulation Class of protection 1 in accordance with EN 61140 Insulation coordination Overvolta...

Page 109: ...on unit 102 Explosion protection 21 Ex purge air unit 24 56 F F850S parameters 107 Feeding protective gas 55 Flow direction aligned at the factory 54 for category 2G 48 for category 3G 48 Function but...

Page 110: ...tive gas connection 54 Pull the installation plate 61 R Removing the measuring system 99 Replacing the activated charcoal bag 78 Replacing the sender lamp 80 S Safety information 49 Screw the groundin...

Page 111: ...INDEX 14 8015558 YYJ8 V1 7 2016 07 SICK O P E R A T I N G I N S T R U C T I O N S GM32 Ex 111 Subject to change without notice...

Page 112: ...ail mario garcia sick com Netherlands Phone 31 30 2044 000 E Mail info sick nl New Zealand Phone 64 9 415 0459 0800 222 278 tollfree E Mail sales sick co nz Norway Phone 47 67 81 50 00 E Mail sick sic...

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SICK GM32 EX, Operating Instructions Manual

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