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SICK GM700 Ex Operating Instructions Manual Download Page 8

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

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

1.6.2

Warning levels / Signal words

DANGER

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

WARNING

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

CAUTION

Hazard or unsafe practice which could result in less severe or minor injuries.

Notice

Hazard which could result in property damage.

Note

Hints

1 

ABOUT THIS DOCUMENT

8

O P E R A T I N G   I N S T R U C T I O N S | GM700 Ex

8019532/100Q/V1-1/2018-08 | SICK

Subject to change without notice

Summary of Contents for GM700 Ex

Page 1: ...O P E R A T I N G I N S T R U C T I O N S GM700 Ex Laser Gas Analyzer Version with Measuring Probe...

Page 2: ...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...

Page 3: ...ariants 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 prote...

Page 4: ...trol 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 o...

Page 5: ...ta 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 pressurize...

Page 6: ...echnical 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 syst...

Page 7: ...ved 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 Operat...

Page 8: ...igh temperature Hazard for the environment nature organic life 1 6 2 Warning levels Signal words DANGER Risk or hazardous situation which will result in severe personal injury or death WARNING Risk or...

Page 9: ...of the product relative to Guideline 2014 34 EU ATEX Important technical information for this product Important information on electric or electronic functions ABOUT THIS DOCUMENT 1 8019532 100Q V1 1...

Page 10: ...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 endang...

Page 11: ...plant conditions b 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 th...

Page 12: ...the specifications for replacement of a removable power cable have not been adequately observed b Always observe the exact specifications in the Operating Instructions Technical Data Chapter when rep...

Page 13: ...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 Figure 2 Laser symbol on device SAFETY INFORMATION 2 80195...

Page 14: ...OTICE 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 d...

Page 15: ...e Operating Instructions b Read and observe these Operating Instructions b Observe all safety instructions b If anything is not clear Please contact SICK Customer Service Document retention These Oper...

Page 16: ...ns measuring is done directly in the gas carrying duct Measuring components NH3 NH3 H2O Measuring principle Diode laser spectroscopy TDLS 3 3 Type plate Sender receiver unit 01 02 03 04 05 06 07 No Va...

Page 17: ...e page 28 and page 36 3 6 Options Cover plate for purge air fixture of the sender receiver unit Weatherproof cover Purge air unit 3 7 Layout and function 1 8 9 5 3 2 4 6 7 Figure 4 GM700 Ex layout and...

Page 18: ...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...

Page 19: ...ng 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 except...

Page 20: ...nge 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...

Page 21: ...ion unit 6 Overpressure control 7 p T sensor 8 p sensor for purge air unit 9 Pressure controller for optics purge air as selected by the plant operator Lines Purge air hose optics Connecting hose Ex p...

Page 22: ...essurized 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...

Page 23: ...direction directed purge air 4 Lever locking device of the opening to sample gas 5 Differential pressure sensor for purge air 6 Lever and locking device in open position NOTE Further characteristics...

Page 24: ...transport safety device Figure 7 Transport safety device on the SR unit 1 Remove the front cover of the sender receiver unit 3 1 2 Figure 8 Transport safety device on the GMP measuring probe 1 2 plast...

Page 25: ...ing probe b Clean all components of the measuring system with slightly damp cleaning cloths Use a mild cleaning agent here b Protect the openings of the sender receiver unit and measuring probe from a...

Page 26: ...b 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 installa...

Page 27: ...with tube 19 mm jaw wrench Flange screw fitting Screwdriver Connections Allen key Connections 5 3 Material required Material Required for Personal protective equipment Protection when working at the...

Page 28: ...on 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...

Page 29: ...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 a...

Page 30: ...ng must point upwards vertically irrespective of the gas duct angle The tube must project at least 30 mm into the gas duct 1 200 18 45 Figure 10 Top marking on flange with tube 1 Marking Top 3 Attach...

Page 31: ...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 a...

Page 32: ...e the unhindered flow of the protective gas Reference opening The reference opening must be located in the Ex area b Make sure the opening is always clear Line lengths for protective gas supply Large...

Page 33: ...e 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 8019532...

Page 34: ...ecifications for replacement of a power line have not been adequately observed b Always observe the exact specifications in the Operating Instructions Technical Data Chapter when replacing a power lin...

Page 35: ...place line inlets or plugs with other types b Line inlet dimensions see Dimension drawings evaluation unit with pressurized enclosure system FS840 page 97 DANGER Risk of explosion through non Ex confo...

Page 36: ...rew fittings and lines b Only use lines according to EN60079 14 with suitable outer diameters b Close off cable inlets vapor proof virtually gas tight b Protect lines against electrostatic charges b O...

Page 37: ...1 5 mm2 Evaluation unit power supply From customer 3 x 1 5 mm2 Evaluation unit sender receiver unit with con necting hose In accordance with project planning 5 m 10 m Differential pressure sensor meas...

Page 38: ...Install all lines in accordance with EN61010 1 and EN60079 14 b Protect lines against electrostatic charges 1 Route the data lines through the M screw fittings 2 Connect the data line NOTE The analog...

Page 39: ...Co3 Lo4 H 1 Inlet temperature sensor PT100 3 wire circuit RMA42 IIC 27 3 V 22 1 mA 151 mW k A 8 nF 75 H 85 nF 500 H k A 2 IIB 360 nF 2 mH k A 3 IIB 530 nF 5 mH k A 4 Analog input pressure sen sor 4 2...

Page 40: ...I3 5 Figure 16 Electrical connection of the evaluation unit 1 GM700 Ex evaluation unit 2 Connections on circuit board 3 Power supply GM700 4 Fuse 2 5 2 5 AT 250 V 5 CAN GM700 6 Analog outputs 0 20 mA...

Page 41: ...e 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 diagra...

Page 42: ...on for the device becomes void b Carry out all work skillfully and in accordance with the delivered documentation Unsafe measuring operation CAUTION Risk of unsafe measuring operation through loss of...

Page 43: ...5 mm2 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 specifie...

Page 44: ...necting 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...

Page 45: ...the screw ter minal 6 9 2 Connecting the potential equalization on the measuring probe 1 Figure 22 Potential equalization on the GMP measuring probe 1 Potential equalization connection b Screw the gr...

Page 46: ...nductor on the Ex control unit FS840 b Screw the potential equalization 4 mm2 of the plant ground tight to the screw ter minal 1 2 Figure 23 Potential equalization on Ex control unit and evaluation un...

Page 47: ...ng when the SR unit of the device is swiveled open during installation work for test purposes and the laser beam is activated b Never look directly into the laser aperture when opening the SR unit b L...

Page 48: ...ring 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...

Page 49: ...pply 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...

Page 50: ...Device flange Cross section of the connection fitted between the SR unit and measuring probe 1 2 3 4 5 6 Figure 25 Cross section of the connection fitted between the SR unit and measuring probe 1 Gap...

Page 51: ...sh 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 w Insert the hinge pins back in and close the quick release faste...

Page 52: ...x protection function b Feed the protective gas via the protective gas connection Further information concerning protective gas Requirements for protective gas see Technical data for Protective gas pa...

Page 53: ...ve gas corresponding to the specifications see Technical data for Pro tective gas page 92 COMMISSIONING 7 8019532 100Q V1 1 2018 08 SICK O P E R A T I N G I N S T R U C T I O N S GM700 Ex 53 Subject t...

Page 54: ...ct 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 1 2 3...

Page 55: ...ersion 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 w Lay the weatherpro...

Page 56: ...ry 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 optic...

Page 57: ...ication to changed transmission MEASURING Measuring operation MEASURING LL Measuring operation with active tracking of the laser beam length line locking MEASURING LD Measuring operation beam length t...

Page 58: ...rmanent 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 op...

Page 59: ...e SERVICE Service mode Warning Warning message At least one warning message pending Reading warning messages see Diagnosis mode diag MALFUNCTION Device malfunction At least one malfunction message pen...

Page 60: ...wn in English 8 3 1 Menu tree Measuring meas Menu level Explanation Measuring Current measured values Depending on device version Reference variables wet dry 8 3 2 Menu tree Diagnosis Menu level Diagn...

Page 61: ...ubst 100 2000 C Pressure Source Probe Subst Analog In Subst 600 15000 hPa Humidity Subst Subst 0 93 0 percent by volume Analog Out Live Zero 0 4 mA Output 1 Component e g NH3 p T Range low 0 999999 Ra...

Page 62: ...anent cell is included Check cycle Period 0 24 h Zero Adjust Enable Yes No Repet 0 24 h only GPP t purge 0 900 s purge time until the process gas con centration is zero t delay 0 1800 s delay until ga...

Page 63: ...cycle Check CycleStart CCY Check Cycle Check cycle for test purposes e g after mainte nance 8 3 5 Menu tree Maintenance Menu level Explanation Maintenance Maint Mode Mode Off On Maintenance operation...

Page 64: ...riable Shows several options from which the user must select one more or all Small letters in round brack ets option Shows optional elements Small letters in square brack ets Punctuation marks are par...

Page 65: ...4 3 View the device configuration Call up the list of the device configuration Syntax GM700 DIS CONFIG 8 4 4 4 Check the system state and configuration Output of the current system state and configura...

Page 66: ...Figure 31 Rotary potentiometer for display contrast 8 OPERATION 66 O P E R A T I N G I N S T R U C T I O N S GM700 Ex 8019532 100Q V1 1 2018 08 SICK Subject to change without notice...

Page 67: ...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 an...

Page 68: ...ircuit breaker b 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 b Make sure the power isolating swi...

Page 69: ...ce must follow the protective measures mandatory in operation Pay special attention to protective masks and protective gloves b Prepare a suitable cover for the opening in the device flange of the SR...

Page 70: ...g on terminals and laying lines b 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...

Page 71: ...on the FS840 Maintenance FS840 b Inspect the inlet and outlet of the FS840 regularly for contamination corrosion b Correct cleaning in good time by G nnheimer Elektronic GmbH as a precautionary measur...

Page 72: ...9 6 Visual check of the sender receiver unit and evaluation unit b Inspect the enclosures of the sender receiver unit and evaluation unit for mechan ical damage b Clean the respective enclosures if c...

Page 73: ...enclosure Materials required Part number Optics cleaning cloth 4003353 Demineralized water 1 2 Figure 33 Optical interfaces on the SR unit 1 Sender receiver unit GM700 Ex open without intermediate enc...

Page 74: ...lose the enclosure immediately after cleaning to protect the cleaned optical inter faces against moisture and dust 9 8 Etalon tool The laser beam must be readjusted once a year Prerequisite Etalon mai...

Page 75: ...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 Table 19 Test gas concentration for NH3 of the respective filter chamber lengt...

Page 76: ...ice starts a zero adjust and then switches to operating mode Box measuring 4 Connect the test gas on the filter box w Set the primary pressure to approx 1000 hPa 1 bar 5 Measure the individual chamber...

Page 77: ...9 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...

Page 78: ...measuring system can no longer be protected from contaminated sample gas b Regularly check and clean the purge air supply NOTE Further information on maintenance and cleaning can be found in the Data...

Page 79: ...aintenance 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 espec...

Page 80: ...nin 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 touche...

Page 81: ...ng Error indication Possible cause Action Malfunction LED blinks Warning LED possibly on Plain text error messages indicate possible causes 1 Trigger Diagnostic mode by pressing the diag button 2 Call...

Page 82: ...gnal 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...

Page 83: ...start device see above b If not successful contact Service LD PELT ERROR LD laser diode Temperature measurement on Peltier element defec tive b Possible hardware defect b Restart device see above b If...

Page 84: ...ble 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 a...

Page 85: ...ion 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 b Pull the purge air hose...

Page 86: ...idual voltages and hot surfaces represent an increased risk of explosion when the device is open b Wait 20 minutes after switching off the main power supply before opening the enclosure Gas WARNING Ri...

Page 87: ...is still in the gas duct b 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 t...

Page 88: ...e for repair b 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 devic...

Page 89: ...semblies 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 recharg...

Page 90: ...age 99 temperature change maximum 10 C h Storage temperature 20 C 50 C Ambient humidity 85 relative humidity non condensing Conformities CE Directives Standards 2014 34 EU ATEX EN 60079 0 2012 EN 6007...

Page 91: ...rsion I O module Description Serves to connect the power supply and the data and signal cables at the customer location Degree of protection IP 65 Analog outputs 3 outputs 0 4 20 mA 500 Electrically i...

Page 92: ...nstrument air or inert gas in accordance with ISO8573 1 Solid particles Class 1 Water Class 3 pressure dew point 20 C Oil content Class 1 0 01 mg m3 Connections Inlet Thread G 3 8 or hose connection f...

Page 93: ...alve 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...

Page 94: ...79 338 13 31 45 1 77 M12 R 3 0 5 3 1 2 0 2 79 7 3 14 305 12 01 33 1 30 9 0 228 6 9 00 8 mm or G Figure 37 GM700 Ex 3G sender receiver unit all dimensions in mm 12 TECHNICAL DATA 94 O P E R A T I N G I...

Page 95: ...dimensions in mm GMP measuring probes Measuring gap L3 active measuring path 250 500 750 1 000 1 250 1 750 Probe length nominal L1 L2 900 935 296 46 1 500 1 644 1 004 5 754 5 504 5 254 5 2 000 2 128...

Page 96: ...59 570 22 44 31 1 22 40 1 57 287 11 30 1 0 0 3 9 40 1 57 43 1 69 200 7 87 Figure 39 Dimensions purge air unit all dimensions in mm inch 12 TECHNICAL DATA 96 O P E R A T I N G I N S T R U C T I O N S...

Page 97: ...9 20 0 79 435 17 13 483 5 19 04 15 0 59 24 0 94 122 4 80 267 7 10 54 8 0 31 50 8 0 3 1 M20 M20 M16 M16 M16 M16 M20 M16 M16 M16 M16 Figure 40 Evaluation unit all dimensions in mm 12 10 Dimension drawin...

Page 98: ...r for sender receiver unit 576 3 525 8 25 2 507 8 297 2 4 0 636 4 Figure 42 Weatherproof cover for sender receiver unit all specifications in mm 12 TECHNICAL DATA 98 O P E R A T I N G I N S T R U C T...

Page 99: ...ng 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...

Page 100: ...ature ranges 0 50 273 323 32 122 1 X Attention These ranges may not be used for Ex applications 13 ANNEX 100 O P E R A T I N G I N S T R U C T I O N S GM700 Ex 8019532 100Q V1 1 2018 08 SICK Subject t...

Page 101: ...ANNEX 13 8019532 100Q V1 1 2018 08 SICK O P E R A T I N G I N S T R U C T I O N S GM700 Ex 101 Subject to change without notice...

Page 102: ...xico Phone 52 472 748 9451 E Mail mario garcia sick com Netherlands Phone 31 0 30 229 25 44 E Mail info sick nl New Zealand Phone 64 9 415 0459 0800 222 278 tollfree E Mail sales sick co nz Norway Pho...

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