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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Subject to change without notice

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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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:
bEnsure reverse flow is prevented by fitting a (trip) flap or a valve.
bRegularly check the functionality of the reverse flow safeguard.
WARNING
Endangerment of electrical safety through power cable with incorrect rating
When a removable power cable is used, electrical accidents can occur when the specifi‐
cations are not fully observed.
bAlways observe the exact specifications in the Operating Instructions (Technical
Data Section) when replacing a removable power cable.
Mechanical damage to equipment
CAUTION
If the hinge pin has not been correctly inserted, the SR-unit can drop when swiveled
out.
bCheck 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 SR-unit with installed probe hard to handle. This increases
the risk that the measuring device is damaged when dropped.
bInstall the SR-unit and the probe separately.
Contamination caused by purge air failure
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.
bWhen the purge air supply is faulty, immediately perform all actions described in
these Operating Instructions.
Device grounding
CAUTION
Device damage through incorrect or missing grounding
During installation and maintenance work, it must be ensured that the protective
grounding to the devices and/or lines involved is effective in accordance with EN
61010-1.
SAFETY INFORMATION 2
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Responsibility for system safety
ATTENTION
Responsibility for the safety of a system
The person setting the system up is responsible for the safety of the system in which
the device is integrated.
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2.2 Warnings on the device
GM32 Ex SR-unit
1
2
3
4
5
6
7
8
9
Figure 1: Sender/receiver unit from the front, the side and with the intermediate enclosure open
SR-unit, front
1 Warning sign protective gas:
°Protective gas outlet.
°Risk of suffocation when using inert gases.
°20 minutes waiting time before opening the
enclosure.
2 Warning sign: Pull power plug before opening the
device
3 Mandatory sign: Wear eye protection.
4 Warning sign: Do not disconnect when live.
SR-unit, 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 3
Figure 2: GM32 Ex connection unit
Connection unit for GM32 Ex, front
1 Warning sign protective gas:
°Protective gas outlet
°Risk of suffocation when using inert
gases
°20 minutes waiting time before open‐
ing the enclosure.
2 Warning sign: Pull power plug before open‐
ing the device.
3 General warning sign: Warning of danger
area.
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2.3 Intended use
2.3.1 Purpose of the device
The GM32 serves exclusively for emission and process monitoring of gases in industrial
plants.
GM32 measures continuously directly in the gas duct (in-situ).
2.3.2 Operation in potentially explosive atmospheres
The GM32 Ex corresponds to the ATEX category (according to ATEX 2014/34/EU):
•ATEX II 2G Ex px [op is] IIC T3 Gb
OR
•ATEX II 3G Ex pz [op is] IIC T3 Gc
NOTE
Complete information on operation in potentially explosive atmospheres: see "Explosion
protection in accordance with ATEX", page 21.
2.4 Responsibility of user
Designated 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 ( delivered System Documentation).
wContact SICK Customer Service if you are not sure whether the device corre‐
sponds to the state defined during project planning or to the delivered system
documentation.
Correct use
bUse the device only as described in "Intended use".
The manufacturer bears no responsibility for any other use.
bPerform the specified maintenance work.
bDo not attempt any work on or repairs to the device unless described in this Man‐
ual.
Do not remove, add or modify any components to or on the device unless descri‐
bed and specified in the official manufacturer information.
Failure to observe these precautions could result in:
°Voiding the manufacturer's warranty.
°The device could become dangerous.
°The approval for use in potentially explosive atmospheres is no longer valid.
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
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bRead and observe these Operating Instructions.
bObserve all safety instructions.
bIf anything is not clear: Please contact SICK Customer Service.
Retain documents
These Operating Instructions
bMust be available for reference.
bMust be passed on to new owners.
2.5 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.
SAFETY INFORMATION 2
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3 Product description
3.1 Product identification
Product name GM32 Ex
Device version Version with measuring probe
Manufacturer SICK AG
Erwin-Sick-Str. 1 D-79183 Waldkirch · Germany
Type plates •Sender/receiver unit: On the right side and on the intermedi‐
ate enclosure
•Connection unit: On the right side and inside
•GMP probe: On the purge air fixture
3.2 Product characteristics
■The in-situ gas analyzer GM32 serves for continuous measurement of gas concen‐
trations in industrial plants.
■GM32 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 temperature and pressure.
■Measuring principle: Differential Optical Absorption Spectroscopy (DOAS).
3.2.1 Device versions
Version Measured components Calculated components
All T, p --
GM32-1 SO2--
GM32-2 SO2, NO NOx
GM32-3 SO2, NO, NO2NOx
GM32-4 NO NOx
GM32-5 SO2, NO, NH3NOx
GM32-6 NO, NO2, NH3NOx
GM32-7 NO, NO2NOx
GM32-8 NO, NO2, (low NOx) NOx
GM32-9 SO2, NO, NO2, NH3NOx
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3.2.2 Device variants
“Basic” variant
•Reference cycle, see "Reference cycle", page 18: Correction of internal drifts.
Zero point check.
•Automatic mirror tracking: Automatic adjustment of optical axis.
•Logbook: System messages are recorded in a logbook.
•Network: Ethernet interface with OPC standard.
•Ethernet: 1 x fiber optics connection on connection unit.
“Pro” variant
As “Basic” variant. In addition:
•TÜV-tested for equipment subject to authorization:.
•Check cycle, see "Check cycle", page 18: Reference cycle (as in the “Basic” var‐
iant) followed by a cycle to check and output the zero and check point. The check
cycle creates the QAL3 values (quality assurance of automated measuring sys‐
tems). The QAL3 values can be displayed with SOPAS ET.
•Operator 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).
•SCU: Operating unit to control several analyzers with SCU capability (see SCU
Operating Instructions).
•Super calibration: Several applications/calibrations, e.g., for spare devices.
•Measuring range switch-over (analog outputs). The valid measuring range is sig‐
naled via a digital output (configured).
•Weatherproof cover.
3.3 SOPAS ET (PC program)
SOPAS ET enables:
•Additional configuration
•Access to logbook GM32
SOPAS ET runs on an external PC connected via the Ethernet, see "Connection over‐
view", page 37, to the GM32.
NOTE
Further information on SOPAS ET:
•Technical Information GM32
•SOPAS ET Help menu
PRODUCT DESCRIPTION 3
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3.4 Reference cycle
Internal drifts correction in an adjustable interval (standard: 1 hour, setting: SOPAS ET)
or per command (with SOPAS ET).
Measured value output during the reference cycle: Last valid measured value.
3.5 Check cycle
Check cycle = reference cycle + following check and output of the zero and check point
(70% of full scale value).
Start a check cycle via
•Set interval (SOPAS ET).
•Command via SOPAS ET.
•External signal (optional).
Purpose of check cycle
■Check of the zero point and a reference point for each component without feeding
test gases.
■Meets the requirements of EN14181.
■Replaces drift monitoring with test gases according to QAL3.
Zero point
An internal 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 the calibration function and thus the zero points of all ducts
measured and output.
Signaling of maintenance request: Deviation from zero> ±2% of the FS.
Check cycle
An internal swivel element with two reference filters and an NO-filled cell is swiveled in
during the check cycle in addition to the zero point reflector and the reference value or
concentration value measured. These control values are scaled to 70% of the selected
measuring range.
Signaling of maintenance request: Deviation from setpoint value > ±2% of the FS.
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1
2
3
4
7
8
5
6
1Measuring
2Zero point
3Check
4Data recorder
5Swivel element
6Zero point reflector
7Zero point
8Check point (70% fsc)
Table 3: Measuring principle of check cycle
Output of measured values during the check cycle Last valid measured value
Signal output during the check cycle (optional digital output or
OPC interface)
Not_measuring
Output of determined zero and reference values on analog
outputs
•Directly after the check cycle
•On request via a digital 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 and reference values of the last check cycle as
well as QAL3 values in SOPAS ET
Menu: Diagnosis/check values
Display when check of NO cell failed •All interfaces: Results of NO cell.
•All interfaces: "0" is output instead of zero and reference
values.
•Analog output: "Live Zero".
•Results of zero and reference measurement are irrele‐
vant.
PRODUCT DESCRIPTION 3
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3.6 Layout and function
1
8
7
65432
9
ßà
Figure 3: GM32 Ex probe version category 2G and 3G
1Connection unit
2SR-unit
3Operator panel (for the “Pro” variant)
4Purge air fixture (without electronics)
5GMP measuring probe (without electron‐
ics)
6Measuring gap (active measuring path)
7Ex purge air unit
8Ex valve for protective gas supply
9Hose (suitable for overpressure)
ßFor version 3G: No connection cable to
connection unit
àEx control unit FS850S of pressurized
enclosure
The 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 spectroscope principle.
•GMP measuring probe with flange or purge air fixture: see "Intrinsically safe meas‐
uring probe (GMP probe)", page 24.
•Purge air unit: see "Ex purge air unit", page 24.
•Connection unit: see "Installing the connection unit", page 32, see "Connection
diagram for version 2G", page 37 and see "Connection diagram for version 3G",
page 38.
3 PRODUCT DESCRIPTION
20 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 without notice