SICK GM32-Ex User manual

OPERATING INSTRUCTIONS
GM32-Ex
In-situ Gas Analyzer, Probe Version
Installation, Operation, Maintenance

Described Product
GM32 EX
Version with measuring probe
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Production location
SICK AG
Nimburger Str. 11
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, shortening 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
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............................................................................................. 8
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 Warnings on the device............................................................................ 13
2.3 Intended use............................................................................................. 14
2.3.1 Purpose of the device.............................................................. 14
2.3.2 Operation in potentially explosive atmospheres.................... 14
2.4 Responsibility of user............................................................................... 14
2.5 Further information................................................................................... 15
3 Product description........................................................................... 16
3.1 Product identification............................................................................... 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 function.................................................................................. 20
3.7 Explosion protection in accordance with ATEX....................................... 21
3.7.1 Function of the pressurized enclosure................................... 22
3.7.1.1 Safety functions for pressurized enclosures......... 22
3.7.1.2 Subassemblies used.............................................. 23
3.7.2 Connecting hose SR-unit - junction box................................. 24
3.7.3 Intrinsically safe measuring probe (GMP probe)................... 24
3.8 Ex purge air unit........................................................................................ 24
4 Transport and storage....................................................................... 25
4.1 Transport safety device............................................................................ 25
4.2 Storage...................................................................................................... 27
5 Mounting............................................................................................. 28
5.1 Information on installation in potentially explosive atmospheres......... 28
CONTENTS
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5.1.1 Safety of measuring probes suitable for Ex zones................ 28
5.2 Tools required............................................................................................ 28
5.3 Material required...................................................................................... 28
5.4 Preparing the sampling point................................................................... 29
5.5 Scope of delivery...................................................................................... 29
5.6 Installation sequence............................................................................... 30
5.6.1 Installation example................................................................ 30
5.6.2 Overview of the installation steps (duct-side preparation)... 31
5.6.3 Installing the flange with tube................................................ 31
5.6.4 Installing the connection unit................................................. 32
5.6.4.1 Installing the Ex interface relay (for version 2G)... 32
5.6.4.2 Protective gas outlet............................................... 33
5.6.5 Installing the Ex purge air unit................................................ 34
6 Electrical installation........................................................................ 35
6.1 Electrical installation safety information................................................. 35
6.2 Connection overview................................................................................ 37
6.2.1 Connection diagram for version 2G........................................ 37
6.2.2 Connection diagram for version 3G........................................ 38
6.3 Connecting interfaces ............................................................................. 38
6.3.1 Connecting I/O interfaces (option)......................................... 38
6.3.1.1 Connection diagram for variant 2G....................... 40
6.3.1.2 Connection diagram for variant 3G....................... 41
6.3.1.3 Default 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 connection hose to the SR-unit on the junction box.... 45
6.8 Connecting pressure, temperature and purge air monitor.................... 46
6.9 Preparing the power supply..................................................................... 47
6.10 Connecting the Ex peripherals (control unit).......................................... 48
7 Commissioning.................................................................................. 49
7.1 Safety information for start-up................................................................. 49
7.2 Material required ..................................................................................... 51
7.3 Overview of start-up steps....................................................................... 52
7.4 Installing the device flange on the purge air fixture............................... 53
7.5 Aligning the measuring probe in flow direction...................................... 54
7.6 Connecting protective gas to the SR-unit................................................ 54
7.6.1 Feeding protective gas............................................................ 55
7.7 Start-up of the purge air supply............................................................... 55
7.8 Installing the measuring probe in the gas duct...................................... 58
7.9 Installing the SR-unit on the device flange............................................. 59
7.10 Optical fine alignment of the SR-unit ..................................................... 60
7.11 Installing weatherproof covers (option)................................................... 61
CONTENTS
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8 Operation............................................................................................ 63
8.1 Safety......................................................................................................... 63
8.1.1 Check before start-up.............................................................. 63
8.2 Start-up procedures for GM32 Ex versions............................................. 63
8.3 GM32 operator panel............................................................................... 64
8.3.1 LEDs.......................................................................................... 65
8.3.2 Function buttons...................................................................... 65
8.3.3 Setting the display contrast.................................................... 66
8.3.4 Menu tree................................................................................. 67
8.3.4.1 Diagnosis................................................................. 68
8.3.4.2 Check cycle - results of last check cycle............... 68
8.3.4.3 Alignment check (option) - automatic optical
alignment check..................................................... 69
8.3.4.4 Adjustment.............................................................. 70
8.3.4.5 Maintenance mode - set Maintenance mode ...... 72
9 Maintenance...................................................................................... 73
9.1 Safety ........................................................................................................ 73
9.2 Maintenance plan..................................................................................... 74
9.2.1 Consumable parts, expendable parts and spare parts........ 74
9.3 Preparation work...................................................................................... 74
9.4 Checking the protective gas feed............................................................ 75
9.4.1 Function test of the pressurized 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 charcoal bag..................................................... 78
9.10 Replacing the sender lamp...................................................................... 80
9.11 Cleaning the purge air unit....................................................................... 82
10 Troubleshooting................................................................................. 83
10.1 Safety......................................................................................................... 83
10.2 Visual inspection....................................................................................... 84
10.3 Device not functioning.............................................................................. 84
10.4 Overpressure monitoring failure.............................................................. 84
10.5 Measured values clearly incorrect........................................................... 86
10.6 Sample gas penetrating........................................................................... 86
10.7 Corrosion on measuring probe or flange................................................. 86
10.8 Measured value blinks............................................................................. 87
10.9 Error messages......................................................................................... 88
10.9.1 Example of an error message................................................. 88
10.9.2 Error messages........................................................................ 89
10.10 Inadequate purge air supply.................................................................... 95
10.11 Malfunctions on the connection unit...................................................... 95
CONTENTS
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11 Decommissioning............................................................................. 96
11.1 Safety information on shutting down...................................................... 96
11.2 Shutting down subassemblies with explosion relevance....................... 97
11.3 Removing the device................................................................................ 99
11.4 Environmentally compatible disposal ..................................................... 99
12 Technical data.................................................................................... 100
12.1 System: GM32 Ex version........................................................................ 100
12.2 GM32 Ex sender/receiver unit................................................................ 101
12.3 Measuring probe....................................................................................... 101
12.4 Connection unit, Ex version I/O module.................................................. 101
12.5 Electric isolation of evaluation unit ........................................................ 102
12.6 Dimension drawings: Sender/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 Weatherproof cover.................................................................................. 106
12.11 Technical data of pressurized enclosure system.................................... 106
12.11.1 Technical data - protective gas............................................... 106
12.11.2 Technical data Enclosure data................................................ 106
12.11.3 Pressurized enclosure system settings.................................. 106
13 Annex.................................................................................................. 108
13.1 Conformities.............................................................................................. 108
13.2 Electrical protection.................................................................................. 108
13.3 Ex certifications........................................................................................ 108
14 Index.................................................................................................... 109
CONTENTS
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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 valid only for the gas in-situ measuring device with the
designation GM32 EX probe version.
They are not valid for the other gas in-situ measuring devices from SICK.
1.3 Target groups (and document structure)
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 may be required at certain times during installation and maintenance.
Please observe the information at the beginning of the respective Sections.
1.4 Further information
•Optional: 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 2G and 3G:
•Pressurized enclosure system F850S Manual
•Ex relay SR852 (interface relay) Manual (only for category 2G)
NOTICE
Observe all supplied documents.
ABOUT THIS DOCUMENT 1
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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.
1.6 Symbols and document conventions
1.6.1 Warning symbols
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
Hazard by ultraviolet radiation (UV light)
Hazard by high temperature
Hazard for the environment/nature/organic life
Table 1: Warning symbols
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
1 ABOUT THIS DOCUMENT
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Hazard which could result in property damage.
Note
Hints
1.6.3 Information symbols
Symbol Significance
Information on product condition with regard to explosion protection (gen‐
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 functions
Table 2: Information symbols
ABOUT THIS DOCUMENT 1
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2 Safety information
2.1 Main operating information
Noxious UV radiation
DANGER
Damage to eyes and skin by UV radiation
The in-situ gas measuring device GM32 emits UV radiation when the SR-unit or reflec‐
tor unit is opened during operation. Exposure of the unprotected skin and eyes to radia‐
tion is dangerous to health.
bDisconnect the power supply of the device before opening the device.
bWear suitable protective goggles and protective gloves when work on the open
device with the power supply connected is performed.
Noxious gas
WARNING
Risk to health through contact with toxic gases
The modules and equipment contain enclosed, potentially dangerous gases that can
escape should a defect or leak occur. Should a leak occur, the concentrations within
the enclosed equipment can rise up to 40 ppm.
■NO: 2 ml maximum total volume
bOnly open the device when good ventilation is available, especially when a leak of
one of the device components is suspected.
DANGER
Hazard by gas escaping 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.
bSwivel the SR-unit out only when you have taken suitable safety measures.
bSet the lever on the purge air fixture to the “Close” position".
Electrical safety through power isolating switches properly installed
WARNING
Endangerment of electrical safety during installation and maintenance work when the
power supply is not switched off
bBefore starting the work on the device, ensure the power supply can be switched
off using a power isolating switch/circuit breaker in accordance with DIN EN
61010.
bMake sure the power isolating switch is easily accessible.
bAn additional disconnecting device is mandatory when the power isolating switch
cannot be accessed or only with difficulty after installation of the device connec‐
tion.
bThe power supply may only be activated again after the end of the work or for test
purposes by personnel carrying out the work under consideration of valid safety
regulations.
2 SAFETY INFORMATION
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