SICK GM35 User manual

OPERATING INSTRUCTIONS
GM35
In-situ IR Gas Analyzer,
Probe Version

Described product
GM35
Probe version
GM35-1, GM35-2, GM35-3, GM35-4, GM35-5, GM35-6, GM35-7, GM35-10
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Production location
SICK AG
Gisela-Sick-Str. 1 · D-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 modi‐
fication, abridgment or translation of this document is prohibited without the express
written 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............................................................................................ 7
1.4 Further information................................................................................... 7
1.5 Symbols and document conventions...................................................... 7
1.5.1 Warning symbols...................................................................... 7
1.5.2 Warning levels / Signal words................................................. 8
1.5.3 Information symbols................................................................ 8
1.6 Data integrity............................................................................................. 8
2 Safety information............................................................................ 9
2.1 Main operating information..................................................................... 9
2.2 Warning information on the device.......................................................... 10
2.3 Intended use............................................................................................. 10
2.4 Responsibility of user............................................................................... 10
3 Product description........................................................................... 12
3.1 Product identification............................................................................... 12
3.2 Product characteristics............................................................................ 12
3.3 Device variants......................................................................................... 12
3.4 Layout and function.................................................................................. 13
3.5 Options...................................................................................................... 15
3.6 Check cycle............................................................................................... 15
3.7 Measuring probes .................................................................................... 15
3.7.1 Open GMP measuring probe in detail.................................... 16
3.7.2 Gas-testable GPP measuring probe in detail......................... 17
4 Transport and storage....................................................................... 18
4.1 Storage...................................................................................................... 18
5 Mounting............................................................................................. 19
5.1 Safety......................................................................................................... 19
5.2 Tools required............................................................................................ 19
5.3 Material required...................................................................................... 19
5.4 Preparing the measuring point................................................................ 19
5.5 Checking the scope of delivery................................................................ 20
5.6 Installation sequence............................................................................... 20
5.6.1 Installation steps..................................................................... 20
5.6.2 Installing the flange with tube................................................. 21
5.6.3 Installing the purge air unit..................................................... 23
5.6.4 Connecting the purge air unit electrically.............................. 23
5.6.5 Removing the transport safety devices of the measuring
probe........................................................................................ 23
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5.6.5.1 Removing the transport safety device of the
GMP measuring probe............................................ 23
5.6.5.2 Removing the transport safety device of the GPP
measuring probe..................................................... 24
5.6.6 Fitting the measuring probe on the flange with tube............ 24
5.6.7 Putting the purge air unit into operation................................ 25
5.6.8 Fitting the flange fixture on the measuring probe................. 26
5.6.9 Fitting the control unit............................................................. 27
5.6.9.1 Fitting the control unit at a greater distance
(option).................................................................... 29
6 Electrical installation........................................................................ 31
6.1 Safety......................................................................................................... 31
6.2 Tools required............................................................................................ 32
6.3 Overview of electrical connection steps.................................................. 32
6.4 Connection overview................................................................................ 33
6.4.1 Lines overview.......................................................................... 34
6.4.2 Laying lines.............................................................................. 34
6.5 Electrical connection of the control unit................................................. 34
6.5.1 Correct connection of the CAN bus line................................. 35
6.5.2 Connecting the control unit electrically.................................. 35
6.5.3 Connecting the grounding conductor on the control unit..... 37
6.6 Connecting the connection unit (option)................................................. 38
7 Commissioning.................................................................................. 40
7.1 Safety......................................................................................................... 40
7.2 Requirements............................................................................................ 40
7.3 Tools required............................................................................................ 40
7.4 Material required...................................................................................... 40
7.5 Commissioning steps overview................................................................ 40
7.6 Removing the transport safety device of the sender/receiver unit....... 41
7.7 Fitting the sender/receiver unit on the flange fixture............................ 41
7.8 Connecting the sender/receiver unit with measuring probe................. 42
7.9 Fine optical alignment.............................................................................. 43
7.10 Fitting the weather hood (option)............................................................ 45
7.11 Starting measuring operation.................................................................. 46
7.11.1 Operating states...................................................................... 46
8 Operation............................................................................................ 47
8.1 Operating and display elements.............................................................. 47
8.2 Control unit menu tree............................................................................. 48
8.2.1 Menu tree, Measuring............................................................. 48
8.2.2 Menu tree, Diagnosis.............................................................. 48
8.2.3 Menu tree, Parameters........................................................... 48
8.2.4 Menu tree, Calibration............................................................. 50
8.2.5 Menu tree, Maintenance......................................................... 50
CONTENTS
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9 Maintenance...................................................................................... 51
9.1 Safety......................................................................................................... 51
9.2 Maintenance plan..................................................................................... 52
9.2.1 Maintenance protocol.............................................................. 52
9.2.2 Expendable, wearing and spare parts.................................... 53
9.3 Preparatory work....................................................................................... 53
9.4 Visual check.............................................................................................. 53
9.5 Removing the sender/receiver unit......................................................... 54
9.6 Cleaning optical surfaces......................................................................... 54
9.6.1 Cleaning the optical surface of the sender/receiver unit..... 55
9.6.2 Cleaning the optical surface of the GMP measuring probe.. 55
9.6.3 Cleaning the optical surface of the GPP measuring probe... 56
9.7 Cleaning the control unit.......................................................................... 58
9.8 Cleaning the purge air unit....................................................................... 58
9.9 Checking the function of the IR source................................................... 58
10 Troubleshooting................................................................................. 59
10.1 Safety......................................................................................................... 59
10.2 Monitoring and diagnostic system........................................................... 60
10.3 Device not functioning.............................................................................. 60
10.4 Clearing malfunctions on the control unit............................................... 61
10.4.1 Communication error between control unit and receiver..... 61
10.5 Malfunction messages............................................................................. 62
10.6 Warning messages................................................................................... 63
10.7 Repairing inadequate purge air supply................................................... 64
10.8 Corrosion on flange.................................................................................. 65
11 Decommissioning............................................................................. 66
11.1 Safety......................................................................................................... 66
11.2 Removing the device................................................................................ 67
11.3 Preparing the device ready for shipping.................................................. 68
11.4 Environmentally compatible disposal ..................................................... 68
12 Technical data.................................................................................... 70
12.1 GM35 system............................................................................................ 70
12.2 Sender/receiver unit................................................................................ 70
12.3 Open GMP measuring probe.................................................................... 71
12.4 Gas-testable GPP measuring probe........................................................ 71
12.5 Control unit, AWE, sheet steel enclosure................................................ 72
12.6 Control unit, AWE, cast metal enclosure................................................. 72
12.7 Connection unit......................................................................................... 73
12.8 Dimension drawing, sender/receiver unit .............................................. 74
12.9 Dimension drawing, open GMP measuring probe.................................. 75
12.10 Dimension drawing, gas-testable GPP measuring probe....................... 76
12.11 Dimension drawing, control units............................................................ 77
12.12 Dimension drawing, flange with tube, DN125........................................ 78
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12.13 Dimension drawing, connection unit....................................................... 78
12.14 Dimension drawing, purge air unit, SLV4-2............................................. 79
12.15 Dimension drawing, weather hoods........................................................ 80
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 only applicable for the measuring device described in
the product identification.
They are not applicable for other SICK measuring devices.
The standards referred to in these Operating Instructions are to be observed in the
respective valid version.
1.3 Target groups
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
Installation and maintenance may only be carried out by trained specialists familiar
with the installation conditions.
Please observe the information at the beginning of the respective Sections.
1.4 Further information
•Purge air unit Operating Instructions
•Final inspection record
NOTE
bObserve all documents provided.
1.5 Symbols and document conventions
1.5.1 Warning symbols
Table 1: Warning symbols
Symbol Significance
Hazard (general)
Hazard by electrical voltage
ABOUT THIS DOCUMENT 1
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Symbol Significance
Hazard by toxic substances
Hazard by unhealthy substances
Hazard through pressure/temperature
Hazard for environment and organisms
1.5.2 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
1.5.3 Information symbols
Table 2: Information symbols
Symbol Significance
Important technical information for this product
Important information on electric or electronic functions
1.6 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 ABOUT THIS DOCUMENT
8O P E R A T I N G I N S T R U C T I O N S | GM35 8009389/147I/V4-0/2021-03 | SICK
Subject to change without notice

2 Safety information
2.1 Main operating information
NOTICE
Risk for system safety through work on the device not described in these Operating
Instructions
Work on the device not described in these Operating Instructions or associated docu‐
ments can lead to unsafe operation of the measuring system and therefore endanger
plant safety.
bOnly carry out the work described in these Operating Instructions or the corre‐
sponding documents on the device.
WARNING
Danger of ineffectiveness of the protective device
In case of nonobservance, persons or parts of the body to be protected are not
detected.
bPay special attention to all safety information in these Operating Instructions.
CAUTION
Hazard for persons and plant through unsafe operation of the measuring device
If the device is or could be in an unsafe state:
bPut the device out of operation.
bDisconnect the device from the main supply voltage and signal voltage.
bSecure the device against unallowed or unintentional start-up.
CAUTION
Risk of injury through incorrect lifting and carrying the device
Injuries can occur due to the weight and projecting enclosure parts when the equip‐
ment tips over or drops.
bConsider the device weight before lifting.
bObserve the regulations for protective clothing (e.g., safety shoes, non-slip gloves).
bGrip underneath the equipment when possible to carry it safely.
bDo not use projecting parts on the device to carry the device.
bCall in further personnel for assistance as required.
bUse a hoist or transport equipment as an option.
bPay attention to the transport safety device.
bClear obstacles that could cause falls and collisions out of the way.
SAFETY INFORMATION 2
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2.2 Warning information on the device
Sender/receiver unit
 
Figure 1: Sender/receiver unit from the front and right side
1Warning sign: Disconnect the power plug before opening the device.
2Do not disconnect under voltage.
2.3 Intended use
The device serves exclusively for emission and process monitoring of gases in industrial
plants.
The device measures continuously directly in the gas duct (in-situ).
2.4 Responsibility of user
Intended users
see "Target groups", 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 (see delivered System Documentation).
bIf you are not sure whether the device corresponds to the state defined
during project planning or to the delivered system documentation: Please
contact SICK Customer Service.
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
bRead and observe these Operating Instructions.
bObserve all safety instructions.
bIf anything is not clear: Please contact SICK Customer Service.
2 SAFETY INFORMATION
10 O P E R A T I N G I N S T R U C T I O N S | GM35 8009389/147I/V4-0/2021-03 | SICK
Subject to change without notice