SICK GM700 User manual

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MMMOPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS
GM700
TDLS Analyzer for NH3, HF or HCI
Cross-Duct Version
Installation, Operation, Maintenance

28011543/YU54/V4-1/2016-04 | SICKOPERATING INSTRUCTIONS | GM700
Subject to change without notice
Described Product
Product name: GM700
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Place of Manufacture
SICK AG
Nimburger Str. 11 · 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 modification, shortening 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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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 property damage.
Information symbols
IMMEDIATE HAZARD
of severe injuries or death
Hazard (general)
Please consult the documentation
Hazard by corrosive substances
Hazard by voltage
Hazard by unhealthy substances
Hazard by toxic substances
Hazard by laser radiation
Important technical information for this
product
Important information on electric or
electronic functions
Nice to know
Supplementary information
Link to information at another place

CONTENTS
48011543/YU54/V4-1/2016-04 | SICKOPERATING INSTRUCTIONS | GM700
Subject to change without notice
1 Safety Information..................................................................................... 8
1.1 Main hazards .................................................................................................. 8
1.1.1 Electrical safety .............................................................................. 9
1.1.2 Grounding the device ..................................................................... 9
1.1.3 Protection against hazards through gases ................................ 10
1.1.4 Protection against laser radiation ............................................... 11
1.1.5 Behavior during purge air failure................................................. 13
1.2 Intended use ................................................................................................. 13
1.2.1 Purpose of the device .................................................................. 13
1.3 Responsibility of user ................................................................................... 13
1.3.1 Disposing of device parts harmful to the environment ............. 14
2 Product Overview..................................................................................... 15
2.1 Product identification .................................................................................. 15
2.2 GM700 system, Cross-Duct version, layout ................................................ 15
2.3 GM700 options and accessories ................................................................. 17
2.4 Measuring principle...................................................................................... 18
2.4.1 Reference cuvette for wavelength stabilization.......................... 18
2.4.2 Signal evaluation.......................................................................... 18
3 Project planning....................................................................................... 19
3.1 Work steps from system selection to start-up............................................. 19
3.2 Project Planning Checklist............................................................................ 20
3.3 Initial onsite installation............................................................................... 22
3.3.1 Installation preparation at the measuring point ......................... 22
3.3.2 Uncovering the duct ..................................................................... 22
3.3.3 Installing the flanges with tube ................................................... 23
3.3.3.1 Performing installation ............................................. 24
3.3.4 Installation preparation for the purge air units........................... 26
3.3.5 Duct insulation ............................................................................. 26
3.3.6 Installation preparation for the evaluation unit .......................... 26
3.4 Preparations for electrical installation ........................................................ 27
3.4.1 Signal and power supply cables .................................................. 27
3.4.2 CAN bus wiring ............................................................................. 29
4 Installation................................................................................................ 30
4.1 Preparations ................................................................................................. 30
4.1.1 Checking the scope of delivery.................................................... 30
4.1.2 Installation prerequisites ............................................................. 30
4.2 Fitting system components .......................................................................... 31
4.2.1 Information on installing the SR-unit and reflector .................... 31
4.3 Installing the purge air units ........................................................................ 31
4.3.1 Terminal box with 24 V power supply unit (option)..................... 31
Contents

CONTENTS
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4.4 Installing the evaluation unit ........................................................................32
4.4.1 Installing the evaluation unit – sheet metal enclosure version .32
4.4.2 Installing the evaluation unit – cast-metal enclosure version....33
4.5 Electrical connection of system components ..............................................34
4.5.1 CAN bus wiring options.................................................................34
4.5.2 Electrical connection in the evaluation unit EvU.........................35
5 Operation ..................................................................................................38
5.1 User qualifications ........................................................................................38
5.2 Operating elements.......................................................................................38
5.2.1 Menu overview..............................................................................39
6 Start-up......................................................................................................42
6.1 Preparations ..................................................................................................42
6.1.1 Required qualifications and further prerequisites ......................42
6.1.2 Prerequisites for successful start-up: ..........................................42
6.1.3 Tools and equipment....................................................................43
6.1.4 Start-up steps overview ................................................................43
6.1.5 Checking the scope of delivery ....................................................44
6.1.6 Removing the transport safety devices .......................................44
6.2 Measuring path free from sample gas - zero path ......................................45
6.2.1 Preparing a zero path ...................................................................45
6.2.2 Fitting the GM700 system components ......................................46
6.2.3 Electrical connections ..................................................................50
6.2.4 Optical alignment..........................................................................51
6.2.4.1 Optical alignment (for device version for NH3and
HF measurement) .....................................................51
6.2.4.2 Optical alignment of device version for HCl
measurement ...........................................................53
6.2.5 Zero adjust ....................................................................................53
6.2.6 Preparing the system for zero adjust...........................................53
6.2.7 Performing zero adjust .................................................................53
6.2.8 Installing the purge air fixtures ....................................................54
6.2.9 Purge air units start-up.................................................................55
6.2.10 Sender/receiver unit and reflector start-up ................................56
6.3 Installing weatherproof covers (option) .......................................................58
6.3.1 Evaluation unit start-up ................................................................60
6.3.2 Operating states ...........................................................................61
6.3.3 Starting operating mode...............................................................61
7 Maintenance.............................................................................................63
7.1 Safety.............................................................................................................63
7.2 Maintenance intervals ..................................................................................63
7.2.1 Maintenance protocol...................................................................63
7.3 Preparation and general preparatory work..................................................63

CONTENTS
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7.4 Maintenance work on SR-unit and reflector................................................ 64
7.4.1 Visual inspection and enclosure cleaning................................... 64
7.4.2 Cleaning the front windows on the SR-unit and on the
reflector ....................................................................................... 64
7.5 Evaluation unit (EvU) .................................................................................... 66
7.5.1 Selecting the ambient temperature range ................................. 66
7.5.2 Filter box measurement to check the measuring channels for
NH3, HF or HCl.............................................................................. 67
7.5.3 Determining the necessary test gas concentration .................... 68
7.5.4 Installing the filter box ................................................................. 68
7.5.5 Carry out filter box measurement................................................ 70
7.6 Checking the gas analyzer with test cell GMK10........................................ 71
7.6.1 Installation of the GM700 components with the test cell
GMK10.......................................................................................... 72
7.6.2 Carrying out measurement .......................................................... 73
8 Troubleshooting and Clearing Malfunctions........................................ 76
8.1 Malfunction categories/possible effects..................................................... 76
8.2 Purge air failure ............................................................................................ 76
8.3 Integrated monitoring and diagnosis system .............................................. 76
8.3.1 Display and retrieval of messages on the evaluation unit ......... 77
8.3.2 Troubleshooting and clearing malfunctions, evaluation unit..... 78
8.3.3 Error messages ............................................................................ 79
8.3.4 Warning messages ....................................................................... 81
8.3.5 Further tips on troubleshooting ................................................... 82
9 Technical Data, Expendable and Spare Parts ..................................... 83
9.1 Technical Data GM700 Cross-Duct system................................................. 83
9.2 Dimension drawing....................................................................................... 87
9.2.1 GM700 receiver unit dimensions ................................................ 87
9.2.2 GM700 reflector unit dimensions ............................................... 88
9.2.3 Purge air fixtures dimensions ...................................................... 88
9.2.4 Flanges with tube dimensions ..................................................... 89
9.2.5 Evaluation unit dimensions ......................................................... 89
9.2.6 Connection unit dimensions ........................................................ 90
9.2.7 Weatherproof cover dimensions.................................................. 90
9.3 Accessories, expendable and spare parts................................................... 92
9.3.1 Consumable parts for 2-years operation..................................... 92
9.3.2 Spare parts for the sender/receiver unit .................................... 92
9.3.3 Spare parts for the reflector unit................................................. 93
9.3.4 Spare parts for the purge air fixture (sender/receiver unit)....... 93
9.3.5 Spare parts for the purge air fixture (reflector side)................... 93
9.3.6 Spare parts for the evaluation unit ............................................. 94
9.3.7 Fixing accessories ........................................................................ 94
9.3.8 Spare parts assignment for sender/receiver unit ...................... 95

CONTENTS
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10 Annex.........................................................................................................98
10.1 User information “Laser safety” ...................................................................98
11 Index ....................................................................................................... 100

88011543/YU54/V4-1/2016-04 | SICKOPERATING INSTRUCTIONS | GM700
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1SAFETY INFORMATION
1 Safety Information
1.1 Main hazards
Operational safety
DANGER: Hazards through defective device
The safety of the GM700 is endangered when it:
●Has been penetrated by moisture.
●Has been stored or operated under irregular conditions.
When safe operation is no longer possible:
▸Put the GM700 out of operation, separate all connections from the power supply
and secure against unauthorized start-up.
WARNING: Hot surfaces when enclosure open
Pay attention to hot surfaces of the measuring cell when opening the GM700
enclosure.

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SAFETY INFORMATION 1
1.1.1 Electrical safety
1.1.2 Grounding the device
WARNING: Hazard by voltage
▸Pay careful attention to power supply connections.
▸Do not interrupt protective conductor connections.
WARNING: Endangerment of electrical safety by not switching the power
supply off during installation and maintenance work.
An electrical accident can occur during installation and maintenance work
when the power supply to the device and/or lines is not switched off using a
disconnector switch/circuit breaker.
▸Before starting the work, ensure the power supply can be switched off
using a power isolating switch/circuit breaker in accordance with
DINEN61010.
▸Make sure the disconnector switch is easily accessible.
▸An additional disconnecting device is mandatory when the power isolating
switch is difficult to access or cannot be accessed when connecting the
equipment after installation.
▸The power supply may only be activated again after the work or for test
purposes by personnel carrying out the work under consideration of valid
safety regulations.
WARNING: Endangerment of electrical safety through power cable with
incorrect rating
When a removable power cable is used, electrical accidents can occur when
the specifications are not fully observed.
▸Always observe the exact specifications in the Operating Instructions
(Technical Data Section) when replacing a removable power cable.
CAUTION: Equipment damage through erroneous 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.

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1SAFETY INFORMATION
1.1.3 Protection against hazards through gases
WARNING: Hot and/or aggressive sample gases
▸Wear suitable protective clothing and mask when using hot and/or aggressive
sample gases and/or with high dust loads.
▸Never open the enclosure or switch off the purge air feed without taking appropriate
protective measures when the duct is pressurized.
WARNING: Toxic and caustic substances in parts in contact with sample gas
●Depending on the sample gas composition, parts of the GM700 in contact with
sample gas can contain toxic or caustic substances.
●When fitted in the measuring device, the reference cuvette contains the respective
gases to be measured. These gases must not escape.
Special care must be taken with the GME700-2 (HF). This cell not only contains
gaseous HF but also a certain amount of liquid (max. 0.1 g HF for 8 cm cell). HF /
hydrofluoric acid is extremely toxic and caustic. It is imperative to avoid inhaling or
skin contact at all times. Particularly when there are indications of leaks or defects,
wear protective clothing (protective goggles, latex gloves) and carry out work in a well
ventilated room/area. Never open the cuvette under any circumstances. Check
replacement cuvettes for any possible transport damage.
●Handle with care when test gases are used:
▸When handling HF, keep an HF emergency set (including calcium gluconate gel)
available.
▸Before working on the gas path, ask the operator which gases have been applied to
the GM700.
▸Ask the operator whether, and how, the gas path of the GM700 has been cleaned.
▸If necessary, clean the gas path with a suitable method.
▸In case of doubt, take appropriate protective measures before working on the gas
path: Ensure adequate ventilation at the workplace or work under a vent. Wear
protective goggles or a safety mask, protective gloves and acid-proof protective
clothes.
WARNING: 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 plants with overpressure as well as gas temperatures over 200°C:
▸Ensure reverse flow is prevented by fitting a valve.
▸Regularly check the functionality of the reverse flow safeguard.