SICK GM35 User manual

OPERATING INSTRUCTIONS
GM35
In-situ IR Gas Analyzer,
Cross-Duct Version

Described product
GM35
Cross-Duct 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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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
3.4.1 Pressure and temperature sensor.......................................... 14
3.5 Options...................................................................................................... 15
3.6 Check cycle............................................................................................... 15
4 Transport and storage....................................................................... 16
4.1 Storage...................................................................................................... 16
5 Mounting............................................................................................. 17
5.1 Safety......................................................................................................... 17
5.2 Tools required............................................................................................ 17
5.3 Material required...................................................................................... 17
5.4 Preparing the measuring point................................................................ 17
5.5 Checking the scope of delivery................................................................ 18
5.6 Installation sequence............................................................................... 18
5.6.1 Installation steps..................................................................... 18
5.6.2 Installing the flange with tube................................................. 18
5.6.3 Fitting the purge air attachments........................................... 22
5.6.4 Fitting the flange fixture on the purge air attachment.......... 22
5.6.5 Fitting the control unit............................................................. 24
5.6.5.1 Fitting the control unit at a greater distance
(option).................................................................... 25
5.6.6 Installing the purge air unit..................................................... 26
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6 Electrical installation........................................................................ 27
6.1 Safety......................................................................................................... 27
6.2 Tools required............................................................................................ 28
6.3 Overview of electrical connection steps.................................................. 28
6.4 Connection overview................................................................................ 29
6.4.1 Lines overview.......................................................................... 30
6.4.2 Laying lines.............................................................................. 30
6.5 Electrical connection of the control unit................................................. 31
6.5.1 Correct connection of the CAN bus line................................. 31
6.5.2 Connecting the control unit electrically.................................. 31
6.5.3 Connecting the grounding conductor on the control unit..... 33
6.6 Connecting the purge air unit electrically............................................... 34
6.7 Putting the purge air unit into operation................................................. 34
6.8 Connecting the connection unit (option)................................................. 35
7 Commissioning.................................................................................. 37
7.1 Safety......................................................................................................... 37
7.2 Requirements............................................................................................ 37
7.3 Tools required............................................................................................ 37
7.4 Material required...................................................................................... 37
7.5 Commissioning steps overview................................................................ 37
7.6 Removing the transport safety device..................................................... 38
7.7 Carrying out coarse optical alignment.................................................... 39
7.7.1 Optical alignment tool............................................................. 39
7.7.2 Fitting the alignment tool on the sender/receiver unit......... 39
7.7.3 Fitting the alignment tool on the reflector unit...................... 40
7.7.4 Carrying out coarse optical alignment of the reflector unit.. 40
7.7.5 Carrying out coarse optical alignment of the sender/
receiver unit............................................................................. 41
7.7.6 Checking coarse optical alignment........................................ 41
7.8 Fitting the sender/receiver unit and reflector unit on the flange fix‐
tures........................................................................................................... 42
7.9 Connecting the sender/receiver unit...................................................... 43
7.10 Connecting the reflector unit................................................................... 44
7.11 Fine optical alignment.............................................................................. 44
7.12 Fitting the weather hood (option)............................................................ 46
7.13 Starting measuring operation.................................................................. 47
7.13.1 Operating states...................................................................... 47
8 Operation............................................................................................ 48
8.1 Operating and display elements.............................................................. 48
8.2 Control unit menu tree............................................................................. 49
8.2.1 Menu tree Measuring.............................................................. 49
8.2.2 Menu tree, Diagnosis.............................................................. 49
8.2.3 Menu tree, Parameters........................................................... 49
8.2.4 Menu tree, Calibration............................................................. 51
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8.2.5 Menu tree, Maintenance......................................................... 51
9 Maintenance...................................................................................... 52
9.1 Safety......................................................................................................... 52
9.2 Maintenance plan..................................................................................... 53
9.2.1 Maintenance protocol.............................................................. 53
9.2.2 Expendable, wearing and spare parts.................................... 54
9.3 Preparatory work....................................................................................... 54
9.4 Visual check.............................................................................................. 54
9.5 Removing the sender/receiver unit and reflector unit........................... 55
9.6 Cleaning optical surfaces......................................................................... 55
9.7 Cleaning the control unit.......................................................................... 56
9.8 Cleaning the purge air unit....................................................................... 57
9.9 Checking the function of the IR source................................................... 57
10 Troubleshooting................................................................................. 58
10.1 Safety......................................................................................................... 58
10.2 Monitoring and diagnostic system........................................................... 58
10.3 Device not functioning.............................................................................. 59
10.4 Clearing malfunctions on the control unit............................................... 59
10.4.1 Communication error between control unit and receiver..... 59
10.5 Malfunction messages............................................................................. 60
10.6 Warning messages................................................................................... 61
10.7 Repairing inadequate purge air supply................................................... 63
10.8 Corrosion on flange.................................................................................. 63
11 Decommissioning............................................................................. 64
11.1 Safety......................................................................................................... 64
11.2 Removing the device................................................................................ 64
11.3 Preparing the device ready for shipping.................................................. 65
11.4 Environmentally compatible disposal ..................................................... 66
12 Technical data.................................................................................... 67
12.1 GM35 system............................................................................................ 67
12.2 Sender/receiver unit................................................................................ 67
12.3 Reflector unit............................................................................................. 68
12.4 Control unit, AWE, sheet steel enclosure................................................ 68
12.5 Control unit, AWE, cast metal enclosure................................................. 69
12.6 Connection unit......................................................................................... 69
12.7 Purge air attachment................................................................................ 70
12.8 Dimension drawing, sender/receiver unit .............................................. 71
12.9 Dimension drawing, reflector unit........................................................... 72
12.10 Dimension drawing, control units............................................................ 73
12.11 Dimension drawing, flange with tube, DN125........................................ 74
12.12 Dimension drawing, purge air attachment.............................................. 74
12.13 Dimension drawing, connection unit....................................................... 75
CONTENTS
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12.14 Dimension drawing, purge air unit, SLV4-2............................................. 75
12.15 Dimension drawing, weather hoods........................................................ 76
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
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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
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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.
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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
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Document retention
bMust be kept for reference.
bMust be passed on to new owners.
SAFETY INFORMATION 2
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3 Product description
3.1 Product identification
Product name GM35
Device version Cross-Duct version
Manufacturer SICK AG
Erwin-Sick-Str. 1 · D-79183 Waldkirch · Germany
Type plates •Sender/receiver unit: On right side
•On purge air attachment: On tube
•On reflector unit: On right side
•Control unit: On right side
3.2 Product characteristics
•The device serves for continuous measurement of the gas concentrations in indus‐
trial plants..
•The device is an in-situ measuring device which means measuring is done directly
in the gas carrying duct.
•Measuring components:CO2, H2O, CO, N2O
•Measuring principle:
°Gas filter correlation
°Interference filter correlation
3.3 Device variants
The following device variants are available depending on the measuring task and
application:
Variant Measured components
GM35-1 CO
GM35-2 CO, H2O
GM35-3 CO, H2O, CO2
GM35-4 CO, CO2
GM35-5 H2O, CO2
GM35-6 H2O
GM35-7 CO2
GM35-10 N2O, H2O, CO2
3 PRODUCT DESCRIPTION
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3.4 Layout and function
maintcalpardiag
GM
Evaluation Unit
CO
CO 2
H2O
mg/
m3
236
Ref. conditions
Hum: wet
Measuring
Operation
Service
Warnin
Malfunction
Figure 2: Layout, GM35, cross-duct version
Connection lines
Purge air hose
1Sender/receiver unit
2Purge air attachment
3Flange with tube
4Reflector unit
5Connection unit (option)
6Control unit
7Purge air unit
The measuring device comprises the following components:
PRODUCT DESCRIPTION 3
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Sender/receiver unit
The sender/receiver unit contains the optical-electronic assemblies and determines the
measured values of the concentration of the measuring component(s) of the measuring
device.
Reflector unit
The reflector unit contains the triple reflector assembly and reflects the measuring
beam back to the sender/receiver unit.
Purge air attachments
The purge air attachments serve to attach the sender/receiver unit and reflector unit to
the flanges with tube. They contain the purge air nozzles for connecting the purge air
hoses of the purge air units and the connections for external sensors e.g., temperature
or pressure sensors as well as the connections for purge air monitoring.
Control unit
The control unit serves as user interface, and prepares and outputs the measured
values and performs control and monitoring functions.
These functions include the following:
•Output of measured values, computed data and operating states
•Communication with peripheral equipment
•Output of error messages and other status signals
•Control of automatic test functions and access during service work (diagnosis)
Flanges with tube
The flanges with tube are attached directly to the gas duct of the measuring point and
serves to fit the purge air attachments of the sender/receiver unit and reflector unit.
ANSI or DIN flanges can be used alternatively to the flanges supplied.
Purge air unit
The purge air unit supplies filtered ambient air to the purge air attachments and
protects the optical surfaces of the sender/receiver unit and reflector unit from con‐
tamination and high gas temperatures.
NOTE
As standard, SICK recommends a separate purge air unit for the sender/receiver unit
and reflector unit to ensure an optimal purge air supply.
If the supply of purge air is insufficient, hot and corrosive gases can destroy the
measuring device within a few minutes.
Further information on the purge air unit, see Operating Instructions of the purge air
unit.
3.4.1 Pressure and temperature sensor
NOTE
It is necessary to install and use a pressure and temperature sensor (available as
accessory) to calculate the concentrations at standard conditions.
3 PRODUCT DESCRIPTION
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3.5 Options
Connection unit
If the distance between the sender/receiver unit and and control unit is > 4 m, the
connection can be established via the connection unit and a CAN bus line provided by
the customer.
Total length of all CAN bus lines: max. 300 m.
Weather hoods
For the components sender/receiver unit, reflector unit and purge air unit when instal‐
ling the measuring device outdoors.
Air heater for purge air supply
To avoid condensation in the purge air. An air heater is required when the difference
between gas temperature and dew point temperature is too small.
The following formula serves as a guideline:
•Gas temperature [°C] – dew point temperature [°C] < abs. humidity [Vol.-%].
•Values are compared without considering the units of measure.
3.6 Check cycle
The check cycle serves to check the zero point and a reference point without feeding
test gases. Here, a measuring sequence is run through to determine the zero and check
point (usually 70 % of the measuring range end value).
“Function check” is signaled per digital output during output of the zero and reference
point.
The output for each takes 90 s for the zero point, followed by the reference point.
•Unit and scaling for the current zero point according to the setting.
•Reference point is displayed as percentage scaled to 70 % of the measuring
range.
PRODUCT DESCRIPTION 3
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4 Transport and storage
4.1 Storage
bClean all components of the measuring device (not the optical surfaces) with
slightly moistened cleaning cloths. Use a mild cleaning agent here.
bProtect the openings of the sender/receiver unit from atmospheric influences,
preferably with the original transport safety devices.
bPack all components for storage or transport. Preferably use the original packing.
bStore all components of the measuring device in a dry, clean area.
4 TRANSPORT AND STORAGE
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5 Mounting
5.1 Safety
WARNING
Risk of injury through improper assembly work
All assembly work must be carried out only by authorized persons who, based on their
training and knowledge as well as knowledge of the relevant regulations, can assess
the tasks given and recognize the hazards involved.
CAUTION
Accident risk through inadequate fastening of the device
bConsider the device weight specifications when planning the fitting supports.
bCheck the load capacity/condition of the duct on which the device is to be instal‐
led.
NOTICE
Damage to device and plant through unsecured parts during installation
During installation, parts of the device or flange can fall into the duct and cause
damage.
bSecure all parts with wire.
NOTICE
Damage to the measuring device due to premature installation on the stack
Unsuitable ambient conditions in the measuring duct can damage the measuring
device and make commissioning impossible.
bFirst install the measuring device on the stack after commissioning.
5.2 Tools required
•Fork or ring spanner set
•Insulated screwdriver set
•Allen key set, metric
•Flange alignment tool (not included in standard scope of delivery)
5.3 Material required
•Optics cleaning wipes without detergent
•Personal protective equipment
5.4 Preparing the measuring point
Responsibility of the operator
•Determining the measuring point (e.g. determining a representative sampling
point)
•Preparing the measuring point (e.g. load capacity of welded-on flange)
MOUNTING 5
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NOTICE
Basis for determining the measuring point:
•Preceding project planning
•Final inspection specifications for device
•Regulations of local authorities
5.5 Checking the scope of delivery
bCheck the scope of delivery according to the order confirmation/delivery note.
bEnsure the supply voltages indicated on the type plates correspond to the system
conditions.
bCheck all components for externally perfect delivery condition.
5.6 Installation sequence
5.6.1 Installation steps
Installation comprises two main steps:
1 Installing the required device components at the measuring point before commis‐
sioning.
2 Installing the measuring device at the measuring point (carried out by SICK Serv‐
ice during commissioning).
Table 3: Overview of installation steps before commissioning
Step Procedure Reference
1 Install the flanges with tube. see "Installing the flange with tube",
page 18.
2 Install the purge air attachments. see "Fitting the purge air attachments",
page 22.
3 Install the flange fixtures on the purge air
attachments.
see "Fitting the flange fixture on the
purge air attachment", page 22.
4 Fit control unit. see "Fitting the control unit", page 24.
5 Install one or two purge air units (according
to project planning).
see Purge air unit Operating Instructions
NOTICE
Sender/receiver unit and reflector unit may only be installed in the specified sequence
during commissioning. Otherwise the device may be damaged.
5.6.2 Installing the flange with tube
Prerequisite
•Installation location was determined during the project planning.
•Stability of the duct wall has been checked.
5 MOUNTING
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DANGER
Health risk through hot or toxic gases/dusts in the measuring channel
The measuring duct can contain hot or toxic gases or dust deposits which can escape
when opening the duct-side flange. Even if the measuring duct is out of operation
during the installation, escaping gases can lead to severe damage to health.
bAlways put the measuring duct out of operation for the duration of the installation.
bIf required, purge the measuring duct with ambient air before starting installation
work.
bAlways wear suitable or company-specified protective clothing during installation
work.
NOTICE
Device damage through incorrect/missing insulation of the duct when the measuring
channel is hot
bWhen the measuring channel is hot, plan the duct and flange insulation so that
the device is protected against high temperatures.
NOTE
•Flange with tube dimensions: see "Dimension drawing, flange with tube, DN125",
page 74
Arrangement of the flanges with tube on the gas duct
bDetermine flange - flange distance and measuring distance.
1
2
≤ 1°
Figure 3: Flanges with tube — determining the measuring distance
1Measuring distance
2Flange - flange distance
NOTE
The installation steps for the flanges with tube are identical for the sender/receiver unit
and reflector unit.
MOUNTING 5
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Installing the flange with tube
ø 240
ø 178
240/500
min. 30
≤ 1°
ø 133
45°
TOP
TOP
Figure 4: Flange with tube incl. orientation “TOP”
Steps
1. Cut openings on the gas duct for the flange with tube.
2. Position the flange with tube. Make sure:
°Marking “TOP” must point vertically upwards independent of the gas duct
angle.
°The tube must project at least 30 mm into the gas duct.
°Tube axis deviations between sender/receiver unit and reflector unit: Max. 1°
3. Attach the flange with tube.
NOTE
Other devices or fittings must not cut or interrupt the measuring device beam path.
5 MOUNTING
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