SICK GM32 Series User manual

OPERATING INSTRUCTIONS
Installation
Start-up
Maintenance
GM32
In-situ Gas Analyzer
Measuring Probe Version

2 GM32 Operating Instructions V1.3 8012707 © SICK MAIHAK GmbH
Document Information
Described Product
Product name: GM32
Variants: GM32 Probe (measuring probe)
Document Identification
Title: Operating Instructions GM32
Part No.: 8012707
Version: 1.3
Release: 2009-03
Publisher
SICK MAIHAK GmbH
Nimburger Str. 11 · D-79276 Reute · Germany
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Guarantee Information
Specified product characteristics and technical data do not serve
as guarantee declarations.
© SICK MAIHAK GmbH. All rights reserved.
Glossary
CAN-Bus: Control Area Network. A field bus.
CompactFlash®-Disc: Memory card.
CUSUM board: Quality control chart (Data Sheet).
Ethernet: Computer networking technology. Basis for network pro-
tocols, e.g. TCP/IP.
Check point: Test point at approx. 70% of the upper measuring
range value.
Check cycle: Test cycle with check of the zero and check point.
OPC: Openness, Productivity, Collaboration. Standardized data
interface (OPC FoundationTM).
QAL3: Quality monitoring according to DIN EN 14181.
Reference cycle: Test cycle with correction of internal drifts.
SCU: Operating unit for the control of several analyzers with SCU
capability.
SOPAS (SICK Open Portal for Applications and Systems):SICK
Parameter Setting and Data Calculation Software.
SOPAS ET: SOPAS PC Engineering Tool. Configuration protocol.

GM32 Operating Instructions V1.3 8012707 © SICK MAIHAK GmbH 3
Warning Symbols
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 personal injury or
property damage.
NOTICE
Hazard which could result in material damage.
Information Symbols
Hazard (general)
Hazard by voltage
Hazard in potentially explosive atmospheres
Hazard by unhealthy substances
Hazard by high temperature or hot surface
Important technical information for this product
Important information on electrical or electronic func-
tions
Nice to know
Supplementary information
Link to information at another place

Operating Instructions
4 GM32 Operating Instructions V1.3 8012707 © SICK MAIHAK GmbH
1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Main instructions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.1 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Responsibility of user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Additional documentation/information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Product identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2 Product description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.1 Device variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 SOPAS ET (PC program). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Reference cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.5 Check cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Design of GM32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.1 Measuring probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.7 Purge air unit (for GMP measuring probe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Preparation on the Gas Duct Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 Preparation of sampling point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.1.1 Checking the scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Overview of the installation steps (duct-side work). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.1 Work steps (overview) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2.2 Installing the “flange with tube” on the gas duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Installing the connection unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4 Installing the purge air unit (for GMP probe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5 Laying the electrical connection lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.2 Connecting I/O interfaces (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.3 Laying the electrical connection lines to the SR-unit. . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5.4 Preparing the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Inhaltsverzeichnis

Operating Instructions
GM32 Operating Instructions V1.3 8012707 © SICK MAIHAK GmbH 5
4Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Necessary technical knowledge for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Required material (not included in the scope of delivery) . . . . . . . . . . . . . . . . . . . . . . . . 26
4.3 Overview of assembly steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.4 Transport safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.5 Installing the device flange on the purge air fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.6 Aligning the measuring probe in flow direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.6.1 When the probe alignment has to be set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.7 For the GPP probe: Electric connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.8 SR-unit electric connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.9 Switching on the power supply of the GM32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.10 For GMP probe: Start-up of the purge air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.11 Installing the measuring probe in the gas duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
4.12 Installing the SR-unit on the device flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.13 Optical fine alignment of the SR-unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Recognition of an unsafe operational state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2 Operator panel (for the “Pro” variant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2.1 Status indicators (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2.2 Assignment of buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2.3 Contrast setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2.4 Language setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2.5 Menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
5.2.5.1 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2.5.2 Alignment check (automatic optical alignment) (option). . . . . . . . . . . . . . . . . . . . 41
5.2.5.3 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2.5.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6 Putting Out of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.1 Putting out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.1.1 Putting out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.1.2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.2 Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.3 Environmentally compatible disposal/recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.1 Maintenance plan (operator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
7.1.1 Recommended expendable and wearing parts for 2 years operation . . . . . . . . . . . 50
7.2 Preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.2.1 Swiveling out and removing the SR-unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.3 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.4 Cleaning the window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.5 Replacing the sender lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.6 Checking and replacing the drying agent cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.7 Cleaning the purge air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Operating Instructions
6 GM32 Operating Instructions V1.3 8012707 © SICK MAIHAK GmbH
8 Clearing Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.1 General hazard caused by electrical voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.2 Measured value blinks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.3 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.3.1 Example of an error message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.3.2 Error messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.4 Inadequate purge air supply (for GMP probe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8.5 Malfunctions on the connection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1 Conformities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.1.1 Electrical protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Important Information
GM32 Operating Instructions V1.3 8012707 © SICK MAIHAK GmbH 7
GM32
1Important Information
Main safety information
Main instructions for operation
Intended use
Own responsibility

8 GM32 Operating Instructions V1.3 8012707 © SICK MAIHAK GmbH
Important Information
1.1 Main instructions for operation
1.2 Intended use
1.2.1 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).
1.3 Responsibility of user
Designated users
The GM32 may be operated by competent persons only who, based on their device-specific
training and knowledge of the device as well as knowledge of the relevant regulations, can
assess the tasks given and recognize the dangers involved.
Correct use
b Use the device only as described in these Operating Instructions.
The manufacturer bears no responsibility for any other use.
b Perform the specified maintenance work.
⊗Do not remove, add or modify any components to or on the device unless described and
specified in the official manufacturer information.
Otherwise:
– Any warranty by the manufacturer becomes void.
– The device could become dangerous.
Special local conditions
b Follow all local laws, regulations and company-internal operating directives applicable
at the respective installation location of the equipment.
Retention of documents
These Operating Instructions:
b Must be available for reference.
b Must be passed on to new owners.
WARNING: Danger resulting from escaping gas when the SR-unit is swiveled
out
Excess pressure 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 safety measures.
CAUTION: If the hinge pin has not been correctly inserted ( → p. 35, Figure 15),
the SR-unit can drop when swiveled out.
b Check whether the hinge pin is completely pressed down before the SR-unit
is swiveled out.
CAUTION: Danger of contamination caused by purge air failure (for GM32
with GMP probe)
b If a failure of the purge air supply occurs, take immediate measures to pro-
tect the measuring system (
→ p. 59, §8.3)

Important Information
GM32 Operating Instructions V1.3 8012707 © SICK MAIHAK GmbH 9
1.4 Additional documentation/information
b Pay attention to the supplied documents.
Additional instructions
The following documents are applicable in addition to these Operating Instructions:
●Technical Information GM32 (option)
●Operating Instructions for purge air supply (for GMP probe)
●Technical Information “Modular I/O System” (option)
●Final inspection record
●CD-Rom with SOPAS ET PC operating program

10 GM32 Operating Instructions V1.3 8012707 © SICK MAIHAK GmbH
Important Information